Nit CHP Silo PDF

NOTICE INVITING TENDER
FOR
COAL HANDLING PLANT WITH SILO LOADING
ARRANGEMENT AT LINGARAJ OCP
OF
LINGARAJ AREA
MAHANADI COALFIELDS LIMITED
VOL – I (PART-I)
A Subsidiary of Coal India Limited

A Mini Ratna Company
Office of The General Manager(E&M)

Ancillary & Talcher Coalfields
P.O. – JagrIti Vihar, Burla, Dist – Sambalpur – 768020
(Orissa ) Gram : SAMBCOAL, FAX : (0663) 2542797
Tel. : (0663) 2542973
E-mail : gm-enm.mcl@nic.in
(Under Jurisdiction of Sambalpur Court only)
Mahanadi Coalfields Limited
(A Subsidiary of Coal India Limited)
Office of The General Manager(E&M)
P.O. – Jagruti Vihar, Burla, Dist – Sambalpur – 768020
(A Subsidiary of Coal India Limited) (Orissa ) Gram : SAMBCOAL,
A Mini Ratna Company Tel.:(0663) 2542973 FAX : (0663) 2542797
E-MAIL : gm-enm.mcl@nic.in
NOTICE FOR PRE-NIT MEETING
REF NO.: E&M/2011-12/PRE-NIT/97 Dt. 16 / 12 /2011
Name of the job : : Planning, Design, Engineering, Construction, Fabrication, Supply,

Erection, Commissioning & Trial Run of Coal Handling Plant with SILO Loading
Arrangement at Lingaraj OCP, Lingaraj Area complete with Civil, Structural, Electrical
& Mechanical works of Conveyor System & SILO having Rapid Wagon Loading System
along with allied auxiliary facilities such as Dust Suppression System, Passenger Lift, Fire
fighting System, Plant Cleaning System , Illumination & Communication System, etc. as
per requirement on Turn-key basis.
Value of Work : Rs. 25680.00 Lakh
The Pre-NIT Meeting for the aforesaid work is for exchanging views and to firm up the
NIT’s specifications & other conditions etc. considering the views of prospective bidders if
required. The interested prospective firms may attend the Pre-NIT Meeting scheduled to
be held on 05.01.2012 at 11.30 AM at Main Conference Hall of MCL HQ, Jagruti Vihar,
Burla, Sambalpur – 768020, Orissa (India). The interested firms are requested to go
through the Draft NIT of the above mentioned job as hoisted in the website
( http://tenders.gov.in / www.mcl.gov.in )
Sd/
General Manager(E&M)
A Subsidiary of Coal India Ltd
A Mini Ratna Company
TENDER DOCUMENT
VOL – I (Part-I)
NAME OF WORK : Planning, Design, Engineering, Construction, Fabrication, Supply,

Erection, Commissioning & Trial Run of Coal Handling Plant with SILO Loading
Arrangement at Lingaraj OCP, Lingaraj Area complete with Civil, Structural,
Electrical & Mechanical works of Conveyor System & SILO having Rapid Wagon
Loading System along with allied auxiliary facilities such as Dust Suppression System,
Passenger Lift, Fire fighting System, Plant Cleaning System , Illumination &
Communication System, etc. as per requirement on Turn-key basis.
ELCTRICAL & MECHANICAL DEPARTMENT

MAHANADI COALFIELDS LIMITED
JAGRITI VIHAR,BURLA
SAMBALPUR-768020
PHONE : 0663 – 2542973
FAX : O663 – 2542797
EMAIL : gm-enm.mcl@nic.in
LINGARAJ CHP & SILO 1

CONTENTS
Section Contents Page Ref.
PART - I
Section - 1 Notice Inviting Tender 3 - 6
Section - 2 Instruction to Bidders 7 - 23
Section - 3 Forms of Bid and Qualification 24 - 31
Information
Section - 4 Conditions of Contract 32 - 87
General Terms and Conditions of 33 - 56
Contract
Additional Terms and Conditions 57 - 61
of Contract
General Technical Conditions 62 - 71
Erection Conditions of Contract 72 - 87

Section - 5 Forms of Bank Guarantees, Form 88 - 115
of Article of Agreement &
Annexure

SECTION -1
NOTICE INVITING TENDER

DRAFT TENDER NOTICE
COMPANY : MAHANADI COALFIELDS LIMITED

PROJECT / AREA: LINGARAJ OCP, LINGARAJ AREA
TENDER NOTICE NO: E&M/2011-12/PRE-NIT/ DT. / / 2011
1. Sealed turn-key tenders are invited from reputed and experienced bidders for the
following work :
Name and description of work Location Estimated Expected date of Period of

Value (Rs.) Commencement completion
Planning, Design, Engineering, Lingaraj OCP, 25680.00 The work shall 2 (Two )
Construction, Fabrication, Lingaraj Area Lakh commence from Years
Supply, Erection, of Talcher the 30th day of
Commissioning & Trial Run Coalfields issue of LOA or
of Coal Handling Plant with handing over of
SILO Loading Arrangement at site whichever
Lingaraj OCP, Lingaraj Area is later
complete with Civil,
Structural, Electrical &
Mechanical works of
Conveyor System & SILO
having Rapid Wagon Loading
System along with allied
auxiliary facilities such as Dust
Suppression System, Passenger
Lift, Fire fighting System,
Plant Cleaning System ,
Illumination &
Communication System, etc.
as per requirement on Turn-
key basis
2. 0 Earnest Money:
Rs. 1,00,00,000.00 (Rupees One Hundred Lakhs) only Earnest Money / Bid Security
is to be deposited in the form of irrevocable Bank Guarantee ( from Banks listed at
Annexure-X) with validity 28 days beyond the validity of the Bid in the format given
in the Bid document. Certified Cheques and Demand Drafts will also be acceptable as
Earnest Money / Bid Security drawn in favour of MAHANADI COALFIELDS
LIMITED on any scheduled Bank payable at its branch at Sambalpur. Earnest Money
/ Bid Security of the unsuccessful bidder shall be refundable as promptly as possible
after opening of Price Bid and finalisation of the tender and shall bear no interest.
3.0 Application fee for Tender Documents:
The price of the tender document shall be Rs. 5000.00 (Rupees Five thousand) only
payable either in cash or by bank draft drawn in favour of Mahanadi Coalfields Ltd.,
on any bank as per Annexure-X payable at its branch at Sambalpur.

4.0 Availability of tender documents:
The tender documents including terms and conditions of work, shall be available, on
payment, from the Office of General Manager (E&M), Electrical and Mechanical
Department, Mahanadi Coalfields Limited , Corporate Office, At/PO- Jagriti Vihar,
Burla, Dist :Sambalpur, Pin :768020 from ……….. to …………… (Excluding
Holiday) during office hours.
4.1 Complete tender documents are also available on website http://tenders.gov.in /

www.mcl.gov.in / www.mahanadicoal.nic.in which can be down loaded from the
website for submitting the tender. However, Bidders using downloaded tender
document has also to pay the cost of tender document in the form of D.D. in favour of
Mahanadi Coalfields Limited payable at Sambalpur to be submitted in Part –I
envelope of the tender. The Bidder has to submit an undertaking (Annexure-III) duly
filled up as required in this connection.
5.0 General Instructions for Submission of Tender:
A Bidder should strictly comply with the following instructions:
5.1 A Bidder is required to submit his offers in sealed covers giving reference to this
Tender Notice No. and date, containing offers in three parts prominently superscribed
as Part I, Part II and Part III respectively.
5.2 Three parts should contain the details of the offer as follows:
Part I- Full details of the firm, information on the supplies of equipment to

different parties in the country, details of project handled, testimonials and
documentary evidence in support of satisfactory performance, financial
capabilities and any other relevant information , the Earnest Money
Deposit and cost of tender documents.
Part II – Technical offer along with technical specifications of equipment / know-

how offered, drawings, pamphlets etc. strictly in terms of tender enquiry
Part III - Prices only in the format as indicated in the tender documents.
6.0 Part II and III of the offer shall be opened only in respect of such tenders as are
found valid after scrutiny of Part I.
7.0 Validity period of Offer:

The rates offered in Part III should be valid for a period not less than one hundred and
eighty days after the deadline for bid submission.
8.0 Receipt of tenders:

Tenders are to be received in Sealed covers up to ……. on …….. at the following
offices:
(a) Office of General Manager (E&M),

Electrical and Mechanical Department,
Mahanadi Coalfields Limited ,Corporate Office.
At/PO- Jagriti Vihar, Burla, Dist :Sambalpur, Pin :768020

(b) Office of the General Manager
Plot # G-3, Gadakana, Near Omfed Chowk,
Chandrasekharpur, Bhubaneswar - 751017
(c) Office of the General Manager

MCL, Lingaraj Area,
P.O. : Dera Colliery
Dist : Angul ( Orissa )
9.0 Opening of Tenders:

Tenders will be opened at ………… on ……….. at the Office of the General Manager
(E&M), Electrical and Mechanical Department, Mahanadi Coalfieids Ltd, Corporate
Office, At/PO- Jagriti Vihar, Burla, Dist :Sambalpur, Pin :768020.
10.0 Deputation of representatives for negotiation:

After opening of the tender, if the company decides to negotiate, the Bidders should
be in a position to depute their representatives at short notice with full authority for
negotiating on technical as well as commercial terms and conditions of the contract.
11.0 The company is not under any obligation to accept the lowest tender / tenders and
reserves the right to reject any or all the tenders without assigning any reason
whatsoever and also to distribute the work and allot the work / works to more than
one Bidder, at its sole discretion.
12.0 The bidders are required to sign the integrity pact as per format given in Part-I
(Annexure-IX) of Tender Document. Name and address of Independent External
Monitor is as under: -
Shri S.K. Chatterjee,IPS (Retd.),

Plot No.C-1377 / 3, Sector-6,
C.D.A. Bidanasi, Cuttack – 753014
(Orissa)
General Manager(E&M)
Distribution :
1. D.T.( P&P), MCL for kind information

2. D.T.( Operation), MCL for kind information
3. D(P), MCL for kind information
4. CVO, MCL for kind information
5. GM(F)A&T, MCL for kind information
6. Regional Director, RI-VII, CMPDIL, Bhubaneswar
7. TS to CMD, MCL
8. CGM/GM, Jagannath/Lakhanpur/Orient/Ib Valley/B-G Area/ Hingula/ Lingaraj/
Bharatpur/Talcher Area / Bhubaneswar for display the NIT in the Notice Board
9. CGM/GM(E&M), SECL/WCL/CCL/BCCL/NCL/NEC/ECL/CMPDIL/SCCL for
wide publicity.
10. FM(Cash), MCL HQ
11. All Notice Board, MCL Hq.

SECTION 2
INSTRUCTIONS TO BIDDERS

INSTRUCTIONS TO BIDDERS
.0 SCOPE OF TENDER:
.1 The MAHANADI COALFIELDS LTD (referred to as employer in these
documents) invites bids for the construction on turn key basis for the works ( as
defined in these documents and referred to as “the works”) detailed in the table
given in the Notice Inviting Tenders (NIT).
.2 The successful Bidder will be expected to complete the Works by the Intended
Completion Date specified in the Contract.
2.0 ELIGIBLE BIDDERS:
2.1 The Invitation for Bids is open to all bidders eligible to participate as per
qualifying criteria laid down separately hereinafter.
2.2 All bidders shall provide in Part I, Forms of Bid and Qualification Information, a
statement that the Bidder (including all members of a joint venture / consortium
and subcontractors) is not associated, nor has been associated in the past, directly
or indirectly, with the consultant or any other entity that has prepared the design,
specifications, and other documents for the Project or being proposed as Engineer
for the Contract. A firm that has been engaged by the Employer to provide
consulting services for the preparation or supervision of the Works shall not be
eligible to Bid.
2.3 (i) Joint Venture: Two or three companies may jointly undertake contract / contracts.
Each entity will be jointly responsible for completing the task as per the contract.
(ii) Consortium Route: A Lead Member in Consortium limited to four members /
associates is also a bidder to eligible to participate as per qualifying criteria.
2.4 The company reserves its right to allow Public Enterprises preference facility as
admissible under prevailing policy.
3.0 QUALIFICATION OF THE BIDDER:
3.1 All bidders shall provide in Part I, Forms of bid and qualification information, a
preliminary description of the proposed work method and schedule, including
drawings and charts, as necessary.
3.2 In the event that pre-qualification of potential bidders has been undertaken, only
Bids from pre qualified bidders will be considered for award of contract. These
qualified bidders should submit with their bids any information updating their
original prequalification applications or, alternatively, confirm in their Bids that
the originally submitted pre-qualification information remains essentially correct
as of the date of bid submission. The up date or confirmation should be provided
in Part I
3.3 If the Employer has not undertaken pre-qualification for potential bidders, all
bidders shall include the following information and documents with their Bids
(copies of all documentary evidences are to be duly authenticated by the Bidders /
constituted attorney of the Bidder with full signature in indelible ink and seal. All
signed declarations are to be made in the Bidder’s letter head.)
a) copies of original documents defining the constitution of legal status, place of

registration and principal place of business; written power of attorney of
signatory of the Bid to commit the Bidder;

b) i) total monetary value of contractual work performed for each of the last five
years;
ii) experience of having successfully executed similar works during last fifteen
years;
c) experience in works of similar nature and size for each of the last five years,
and details of work under way or contractually committed; and the name and
address of clients who may be contacted for further information on those
contracts with performance certificate for the works executed in last five years
from the respective owners;
d) major items of construction equipment proposed to carry out the Contract;
e) qualifications and experience of key site management and technical personnel
proposed for the contract;
f) reports on financial standing of Bidder, such as profit and loss statement and
auditor’s reports for the past five years;
g) evidence of adequacy of working capital for this contract ( access to lines of
credit and availability of other financial resources);
h) authority to seek references from the Bidder’s Bankers;
i) information regarding any litigation, current or during the last five years, in
which the Bidder is involved, the parties concerned, and disputed amount
including status of final settlement of contracts including claims / counter
claims, liquidated damages, bonus etc. if any;
j) Proposals for subcontracting components of the Works amounting to more
than 10 percent of the Contract price
k) Permanent Income Tax Account No. (PAN)
l) The bidders would give a declaration that they have not been banned or delisted
by any Govt or Quasi-Govt. Agencies or PSUs. If a bidder has been banned
by any Govt or Quasi Govt Agencies or PSU’s that fact must be clearly stated
and it may not necessarily be a cause for disqualifying him. If this declaration
is not given the bid will be rejected as non- responsive.
m) Two or three companies participating in the bid as Joint Venture should
submit Firm-Wise participation details, Banker’s name, execution of work
with details of contribution of each and all other relevant details.
n) Lead Member in the Consortium Route should submit Firm-Wise participation
details, execution of work with details of contribution of each and all other
relevant details. (Memorandum of understanding duly signed by all corporate
entity as per Annexure –XI)
[ Note : The intending Bidder will have to submit a declaration in support of the
authenticity of the credential submitted by them alongwith the tender in the
form an affidavit as per the format provided in the bid document.]
3.4 To qualify for award of the contract :

a. The intending tenderer must have in its name as prime contractor experience
having successfully completed “Design, Supply, Construction &
Commissioning of Integrated Bulk Material Handling System / CHP / RLS /
UTLS with Conveyor System for Coal or other minerals and its allied works
on Turn-Key basis during last 15 (Fifteen) years ending last day of month
previous to the one in which bid application are invited ( i.e eligibility period)
which should be either of the following:
(i) Three similar completed works each costing not less than less than
Rs. 6163.200 Lakh

OR
ii) Two similar completed works each costing not less than Rs.7704.000 Lakh
OR
iii) One similar completed work costing not less than Rs.12326.400 Lakh
In case the bidder is not a Prime Contractor but a Sub-Contractor, the bidder’s
experience as subcontractor will be taken into account if the contract in support of
qualification is a sub-contract in compliance with the provision of such sub-
contract in the original contract awarded to prime contractor.
b.(i) The intending tenderer must have in its name as prime contractor having experience
of successfully completed either a SILO of minimum capacity of 2400 Tonnes or
RCC Bunker of minimum capacity of 15,000 Tonnes for Coal or any other
Minerals irrespective of value and period and the same is in successful operation.
(ii) The Conveyor execution job will be considered irrespective of the Size of the
Conveyors.
(iii) Different work orders issued for supply & erection etc. separately against the
same job will be considered as one job for qualifying in eligibility criteria.
(iv) The intending Bidder must submit documentary evidence in support of 3.4a and
3.4 b(i) above in the form of certified copy of work order(s) & completion
certificate(s) / Affidavit for completion of work and satisfactory performance from
the bidder / associated member both from inside and outside India shall be
verified by a suitable mode. In case of consortium /associate route of participation,
consortium partners must collectively meet the technical and financial qualifying
requirements. In this route, individual associate may or may not possess any of the
technical and financial qualification requirement. In such a case the bidder :
A) shall furnish a MOU with Associates/ Consortium partners as per format given
in the Annexure-XI of bid document and Power of Attorney for signing of
MOU from Lead Partner and Associates / Consortium Partners. Bidders will
be required to submit the Memorandum of understanding ( MOU) entered
with the associates along with the bid in Part-I &
B) shall furnish a JDU ( Joint deed of undertaking ) prior to signing of the
contract ( provided the bidder has got LOA on the basis of bid valuation ) as
per format given in bid documents .
c. The average annual financial turnover of contract work during the last (3) three
years ending 31st march of previous financial year should be at least 30% of the
estimated cost. The bidders must submit Audited Balance Sheet, Profit & Loss
A/C for last 3 (Three) years ending 31st March of the previous financial year.
d. Evidence of possessing adequate working capital, at least 20% of the value of this
work inclusive of access to lines of credit and availability of other financial
resources to meet the requirement to be furnished by the Bidder (For working
capital as per latest Accounts refer Annexure-II and for others evidence
documents to be submitted).

e. Evidence of possessing infrastructural support with respect to design,
construction, manufacturing / supply of major equipment inclusive of legally
bound back-up MOU / Agreement with other agencies in the respective field of
specialization as joint venture partners / associates members or sub-contractors
(To be specified by the bidder both for Lead Partner as well as Associate
Partners).
f. In case, bidder is coming through a consortium route then the Lead Member shall
have to submit MoU (Annexure-XI) along with the bid in Part-I and in case of
successful bidder, a JDU (Annexure-XII) prior to signing of contract.
Note : Financial turn over and cost of completed works of previous works shall be
given a weightage of 5% per year (average annual rate of inflation) to bring them at
current price level.
3.5 Bidders who meet the minimum qualification criteria will be qualified only if their
available bid capacity is more than the total bid value. The available bid capacity
will be calculated as under:
Assessed available bid capacity = (A x N x 2 – B)
Where, A: Maximum value of contract works executed in any one year during
the last five years (Updated to current level given a weightage of
5% per year) taking into account the completed as well as works
in progress)
N: Number of years prescribed for completion of the works for which
bids are invited.
B: Value at present price level of existence commitments and on-going
works to be completed during the next 24 months.
Note: (i) The statements showing the value of existing commitments and on going
works as well as the stipulated period of completion remaining for each of the
works listed should be countersigned by the Engineer – in – Charge not below
the rank of Executive Engineer / Site Engineer.
(ii) In case of Consortium Route, their collective qualifications/eligibility -

technical and financial as well as Bid capacity in the consortium shall be
collectively taken /aggregated for evaluation of their bid.
3.6 Even though the bidders meet the above qualifying criteria, they are subject to be
disqualified if they have:
a) made misleading or false representations in the forms, statements and attachments

submitted in proof of the qualification requirements; and /or
b) record of poor performance such as abandoning the works, not properly
completing the contract, inordinate delays in completion, litigation history, or
financial failures etc.

4.0 ONE BID PER BIDDER
4.1 Each bidder shall submit only one Bid, either by self or in a partnership firm or a
partner in a joint venture or a public limited firm. A Bidder who submits or
participates updated estimated value in more than one Bid (other than as a
subcontractor or in cases of alternatives that have been permitted or requested)
will cause all the proposals with the Bidder’s participation to be disqualified.
5.0 COST OF BIDDING

5.1 The bidder shall bear all costs associated with the preparation and submission of
his bid, and the Employer will in no case be responsible or liable for those costs.
6.0 SITE VISIT:

6.1 The Bidder, at the bidder’s own responsibility, cost and risk, is encouraged to visit
and examine the Site of Works and its surroundings and obtain all information
that may be necessary for preparing the Bid and entering into a contract for
construction of the works. The costs of visiting the Site shall be at the Bidder’s
own expense.
6.2 It shall be deemed that the Bidder has visited the site / area and got fully
acquainted with the working conditions and other prevalent conditions and
fluctuations thereto whether he actually visits the site / area or not and has taken
all the factors into account while quoting his rates and prices.
6.3 Site Investigation Reports: The Contractor, in preparing the bid, shall rely on the
Site Investigation Report referred to in the contract data, supplemented by any
information available to the Bidder.
7.0 CONTENT OF BIDDING DOCUMENTS:

7.1 The set of bidding documents comprises the documents listed in the table below
and addenda issued in accordance with Clause 9:
PART-I ( VOL – I ) :
Section 1 Notice inviting tender;
Section 2 Instructions to bidders ;
Section 3 Forms of Bid and Qualification Information;
Section 4 Conditions of Contract;
Section 5 Forms of Securities, Forms of Bank Guarantees and form of Article of
Agreement & Annexure etc.
PART-II : Scope of work, Text & Specifications etc. (VOL-II ) & Drawings
(VOL-II A) ;
PART-III : Bill of Quantities / Price Bid in Pricing Format(VOL-III);
8.0 CLARIFICATION OF BIDDING DOCUMENTS

8.1 A prospective Bidder requiring any clarification of the bidding documents may
notify the Employer in writing or by cable (cable includes telex and facsimile) at
the Employer’s address indicated in the Notice Inviting Tender. The Employer
will respond to any request for clarification received earlier than 15 days prior to
the dead line for the submission of Bids. Copies of Employer’s response will be
forwarded to all purchasers of the bidding documents, including a description of
the inquiry but without identifying its source.
8.2 Pre-bid meeting : A Pre-Bid meeting will be held on ………… at ……. hrs at the
Main Conference Hall, MCL HQ, Jagruti Vihar, Burla – 768020( Orissa) to

clarify the issues and to answer questions on any matter that may be raised at that
stage.
9.0 AMENDMENT OF BIDDING DOCUMENTS
9.1 Before the dead line for submission of Bids, the Employer may modify the
bidding documents by issuing addenda.
9.2 Any addendum thus issued shall be part of the bidding documents and shall be
communicated in writing or by cable to all purchasers of the bidding documents.
Prospective bidders shall acknowledge receipt of each addendum by cable to the
Employer.
9.3 To give prospective Bidders reasonable time in which to take an addendum into
account in preparing their bids, the Employer shall extend, as necessary, the
deadline for submission of Bids, in accordance with Sub-clause 19.2 below. And
the same is also to be communicated simultaneously to all the purchasers of the
bidding document.
10.0 LANGUAGE OF BID

10.1 All documents relating to the Bid shall be in English language.
11.0 DOCUMENTS COMPRISING THE BID

11.1 The Bid comprising of three parts, will be submitted by the bidder in the
following manner:
a. Part I of the bid to be submitted in 1st inner sealed envelope comprising of –
(i) bid security / earnest money deposit
(ii) letter of the bidder submitting the bid in the form as stipulated in
Contractor’s bid of the bid document and
(iii) qualification information as indicated in bid document and Documents
as required in accordance with stipulations of bid document and any
other materials required to be completed and submitted by bidder in
accordance with these instructions.
b. Part II of the bid to be submitted in the 2nd inner sealed envelope comprising of -
(i) Technical offer along with technical specifications of equipments /
know-how offered, drawings, pamphlets etc. strictly in terms of tender
enquiry.
(ii) Alternative offers of the bidder, if any, fulfilling the requirements in
terms of tender inquiry with specifications and details.
c. Part III of the bid, to be submitted in 3rd inner sealed envelope, shall comprise of
Price Bid only in the format as indicated in the tender documents.
d. All the inner sealed envelopes will then be placed in one outer envelope, sealed
and marked properly as per Clause 18 and submitted to the employer at its address
before the deadline for submission of the bid as described in Clause 19.
12.0 BID PRICES
12.1 The contract shall be for the whole Works as described in Sub-Clause 1.1, based
on the scope of work as detailed in the bidding document.
12.2 The bidder shall submit rates and prices for all items of the Works described in the
scope of works, corrections, if any, shall be made by crossing out, initialing dating
and rewriting. The bidders may quote their bid either Item-Wise or Broad
Head-Wise.
12.3 All duties, taxes and other levies payable by the Contractor under the contract, or
for any other cause as applicable on the last date of submission of tender/bid ,
shall be included in the rate, prices and the total Bid Price submitted by the bidder.

All incidentals, Overheads, etc. as may be attendant upon execution and
completion of works shall also be included in the rates, prices and total Bid price
submitted by the bidder.
However, such duties, taxes, levis etc. which is notified after the last date of
submission of tender and/or any increase over the rate existing on the last date of
submission of tender shall be reimbursed by the company on production of
documentary evidence in support of payment actually made to the concerned
authorities.
NB : (i) Incase of decrease in duties, taxes, levis etc., the same shall be refunded
by the bidder or to be deducted by the owner.
(ii) Provision relating to Tax is given below:
A. Orissa Value Added Tax Act (OVAT Act) / Central Sales Tax Act (CST
Act)
(a) The bidder shall furnish Tax Clearance Certificate in Form VAT-612 from the
Sales Tax Authorities of Orissa at the time of submission of bid (Section 99 of
OVAT Act 2004).
(b) If the bidder is not a registered dealer in the State of Orissa, he shall have to
furnish an affidavit declaring that he has no Sales Tax liability in the State of
Orissa. However, before entering into agreement, the successful bidder shall
have to furnish the Tax Clearance Certificate in Form VAT-612. For obtaining
such Tax Clearance Certificate, the bidder has to necessarily register himself
with Sales Tax Authorities of Orissa.
c(1) The Company(MCL) shall not deduct any tax on the value of any
property in goods transferred in the course of Inter-State Sales, Sales
outside the State or Sales in the course of import as per Explanation to sub-
section 6 of Sec 54 of OVAT Act.
(2) In other cases i.e. (i) the value of the property in goods transferred by other
means (e.g., purchase within Orissa) and (ii) other portions of the value of
work (e.g., labour, service) at the time of payment to the contractor, the
Company (Mahanadi Coalfields Ltd.) shall deduct TDS (OVAT) at the
prevalent rate of 4% from the gross amount of the bill {Section 54 (1) of
OVAT Act}. However, if the contractor produces a certificate from the
Competent Sales Tax Authority for no deduction of tax / deduction at reduced
rate, the same shall be complied with by the Company {Section 54(5) of
OVAT Act}. In the absence of such a certificate, TDS (VAT) @ 4% shall be
recovered by the Company.
(d) For execution of works contract, if the Contractor desires, then Company can
issue statutory Way bill (in the name of the approved vendor of the Company
(MCL) on whom the Contractor has placed Order for purchase of goods) and
declaration form ‘C’ (in the name of the Contractor) to enable him to procure
the goods from outside Orissa and transfer them in the name of the Company
(MCL) by subsequent sale i.e. E-1 Sale. For this purpose, the contractor shall
have registration under CST Act in the State of Orissa.
B. Orissa Entry Tax (OET)
If the contractor issues his own Way Bill, the liability to pay Orissa Entry Tax lies
with him. However if the Contractor desires the Company to issue the statutory
forms such as Way bill and ‘C’ form to the Contractor and if the Company so
issues them as described in para 1(d) above, then Company shall initially deposit
the Entry tax on the invoice value of the Contractor and then recover the same
from the Contractor.
C. Income Tax
The Company shall deduct 2% from the gross amount of the bill payable to the
contractor. However, if the contractor produces a certificate from the Income Tax
authorities for no deduction of tax / deduction of tax at reduced rate, the same
shall be complied with by the Company.
D. Service Tax
As per Section 65(105) (zzzza) of the Finance Act, the turnkey contract falls under
“works contract” and is a taxable service. The liability to pay Service Tax lies
with the Contractor. However, the Contractor shall show the Service Tax claim
separately in his bill and mention his Service Tax Registration number.
12.4 The rates and prices quoted by the Bidder shall be fixed for the duration of the
contract and shall not be subject to variations on any account except to the extent
variations allowed as per the conditions of the contract indicated in the bidding
document.
13.0 CURRENCIES OF BID AND PAYMENT

13.1 The unit rates and prices shall be quoted by the Bidder entirely in Indian Rupees.
14.0 BID VALIDITY:

14.1 Bid shall remain valid for a period not less than one hundred and eighty days after
the deadline for bid submission specified in Clause 19. A bid validity for a shorter
period shall be rejected by the Employer.
14.2 In exceptional circumstances, prior to expiry of the original time limit, the
employer may request that the bidders may extend the period of validity for
specified additional period. The request and the bidder’s responses shall be made
in writing or by cable. A bidder may refuse the request without forfeiting his bid
security. A bidder agreeing to the request will not be required or permitted to
modify his bid but will be required to extend the validity of his bid security for a
period of the extension, and in compliance with Clause 15 in all respects.
15.0 BID SECURITY / EARNEST MONEY DEPOSIT

15.1 The bidder shall furnish, as a part of his bid a Bid Security/ Earnest Money in the
amount as shown in NIT for this particular work. Bid Security / EMD will be
required to be deposited in the form of irrevocable Bank Guarantee ( from Banks
listed at Annexure-X) with a validity 28 days beyond the validity of the Bid in the
format given in the Bid document. Certified Cheques and Demand Drafts will also
be acceptable as Bid Security/ Earnest Money drawn in favour of MAHANADI
COALFIELDS LIMITED on any scheduled Bank payable at its branch at
Sambalpur.
15.2 Any Bid not accompanied by an acceptable Bid security / EMD shall be rejected
by the Employer as non-responsive.
15.3 The Bid Security/ EMD of the unsuccessful bidder shall be refundable as
promptly as possible after opening of Price Bid and finalisation of the tender.

15.4 The Bid Security/ EMD of the successful Bidder will be discharged when the
Bider has signed the Agreement and furnished the required Performance Security/
Security Deposit.
15.5 The Bid Security/ Earnest Money may be forfeited :

(a) If the Bidder withdraws the Bid after Bid opening during the period of Bid
validity ; or
(b) in the case of a successful Bidder, if the Bidder fails within the specific
time limit to
(i) sign the Agreement or
(ii) furnish the required Performance Security / Security Deposit.
(c) if the bidder does not accept the correction of the bid price pursuant to
clause 26 of ITB.
15.6 The Bid Security / EMD deposited with the Employer will not carry any interest.
16.0 ALTERNATIVE PROPOSALS BY BIDDERS
16.1 Bidders shall submit offers that comply with the requirements of the Bidding
documents, including the basic technical design as indicated in the drawings and
specifications. Alternatives will not be considered, unless specifically allowed in
the Bidding Data. If so allowed, Sub-Clause 16.2 shall govern.
16.2 If so allowed in the bid document, Bidders wishing to offer technical alternatives
to the requirements of the bidding documents must also submit a Bid that
complies with the requirements of the Bidding documents, including the basic
technical design as indicated in the drawings and specifications. In addition to
submitting the basic Bid, the Bidder shall provide all information necessary for a
complete evaluation of the alternative by the Employer, including design
calculations, technical specifications, breakdown of prices proposed construction
methods and other relevant details. Only the technical alternatives, if any, of the
lowest evaluated Bidder conforming to the basic technical requirements stipulated
in the bidding document shall be considered by the Employer.
17. 0 FORMAT AND SIGNING OF BID
17.1 The bidder shall prepare the bidding documents comprising the Bid as described in
Clause 11 of these instruction to Bidders.
17.2 All documents of the bid shall be typed or written in indelible ink and shall be
signed by a person / persons duly authorized to sign on behalf of the Bidder,
pursuant to Sub-Clauses 3.3(a). The person or persons signing the Bid shall initial
in indelible ink in all pages of the Bid document. In case of associate / consortium
route , proposal for qualification shall be signed by all the consortium partners or
through their respective legally authorized signatories , at all the places as per
requirement or by the Lead Member through legal authorisation / Power of
Attorney from all the associate(s).
17.3 The Bid shall contain no alterations, or additions, except those to comply with
instructions issued by the Employer or as necessary to correct errors made by the
Bidder, in which case such corrections shall be initialed by the person or persons
signing the Bid. Erasing or overwriting in the bid document may disqualify the
bidder.

18.0 SEALING, MARKING AND SUBMISSION OF BIDS
18.1 The Bidder shall seal the Bid in three inner sealed envelopes and one outer sealed
envelope, duly marking the inner envelopes in the following manner:
a) 1st inner sealed envelope will be marked “Part I-Bid for “ …………….”
comprising of Bid security / EMD with qualification information.”
b) 2nd inner sealed envelope will be marked as “Part II – Technical and
Commercial part for “ ……………………..”.
c) 3rd inner sealed envelope will be marked “Part III – Price Bid for “
…………….”.
d) Outer Sealed envelope will be marked as “Bidding Documents for “
………….”
18.2 The inner envelopes placed in the outer envelopes shall:
a) be addressed to the Employer at the following address and submitted

accordingly before the deadline for submission of bid as indicated in Clause
19:
i. General Manager (E&M),

Electrical and Mechanical Department,
Mahanadi Coalfields Limited ,Corporate Office.
At/PO- Jagriti Vihar, Burla, Dist :Sambalpur, Pin :768020
ii. Office of the General Manager

Plot # G-3, Gadakana, Near Omfed Chowk,
Chandrasekharpur, Bhubaneswar - 751017
iii. Office of the General Manager

MCL, Lingaraj Area,
P.O. : Dera Colliery
Dist : Angul ( Orissa )
b) inner and outer envelopes will bear the following additional identification:
- Bid for “ ………………………………”

- Bid reference No……………………….
-- DO NOT OPEN BEFORE ---------------HRS IST ON -------------
18.3 In addition to the identification required in Sub-Clause 18.2 the inner and outer
envelopes shall indicate the name and address of the Bidder.
18.4 If the outer envelope is not sealed and marked as above, the Employer will assume no
responsibility for the misplacement or premature opening of the Bid.
19.0 DEADLINE FOR SUBMISSION OF BIDS
19.1 Bids shall be delivered to the employer at the address specified above not later than
……… upto ………... In the event of the specified date for the submission of bids
being declared a holiday for the Employer, the Bids will be received up to the
appointed time on the next working day.
19.2 The Employer may extend the dead line for submission of Bids by issuing an
amendment in accordance with Clause 9, in which case all rights and obligations of

the Employer and the Bidders previously subject to the original deadline will then be
subject to the new deadline.
20.0 LATE BIDS
20.1 Any Bid received by the Employer after the deadline prescribed in Clause 19 due to
any reason whatsoever will not be accepted.
21.0 MODIFICATION AND WITHDRAWAL OF BIDS
21.1 Bidders may modify or withdraw their Bids by giving notice in writing before the
deadline prescribed in Clause 19 in case the bidder has submitted the bid well before
the deadline or extended deadline.
21.2 Each Bidder’s modification or withdrawal notice shall be prepared, sealed, marked
and delivered in accordance with the provisions of Clause 11, 17,18 and 19 with the
outer and inner envelopes additionally marked “MODIFICATION” or
“WITHDRAWAL” as appropriate.
21.3 No Bid may be modified after the deadline for submission of Bids
21.4 Withdrawal of a Bid between the deadline for submission of Bids and the expiration
of the period of Bid validity specified in the bid document or as extended pursuant to
Sub-Clause 14.2 may result in the forfeiture of the Bid Security pursuant to Clause 15.
22.0 BID OPENING
22.1 The Employer will open Part I of the bids first, including modifications made
pursuant to Clause 21 in the presence of the bidders, or their representatives who
choose to attend at the time and in the place specified in clause 19. In the event of the
specified date of Bid opening being declared a holiday for the Employer, the Bids will
be opened at the appointed time and location on the next working day.
22.2 After examination and evaluation of Part I of the bids in accordance with Clause 25 of
these instructions, Part II of the bids which are substantially responsive and fulfill the
requisite eligibility criteria laid down under these instructions shall be opened.
22.3 Part III of the bids which are technically and commercially at par and substantially
responsive in accordance with specifications, scope, terms and conditions and
fulfilling the requirements of the instructions to the bidders, shall be opened.
22.4 Envelopes marked “WITHDRAWAL” shall be opened and read out first. Bids for
which an acceptable notice of withdrawal has been submitted pursuant to Clause 21
shall not be opened.
22.5 The Bidders’ names, the Bid Prices, the total amount of each Bid and of any
alternative Bid (if alternatives have been requested or permitted), any discounts, Bid
modifications and withdrawals , the presence or absence of Bid Security, and such
other details as the Employer may consider appropriate, will be announced by the
Employer at the opening.
23.0 PROCESS TO BE CONFIDENTIAL
23.1 Information relating to the examination, clarification, evaluation and comparison of

Bids and recommendations for the award of a contract shall not be disclosed to
Bidders or any other persons not officially concerned with such process until the
award to the successful Bidder has been announced . Any effort by a Bidder to
influence the Employer’s processing of Bids or award decisions may result in
rejection of his bid.

24. 0 CLARIFICATION OF BIDS
24.1 No document presented by the Bidder after closing date and time of the bid will be
taken into account by the Evaluation Committee unless otherwise called for during
technical scrutiny by the tender committee as clarification. This However will have
no bearing with the price quoted in the price bid.
25.0 EXAMINATION OF BIDS AND DETERMINATION OF RESPONSIVENESS
25.1 Prior to the detailed evaluation of Bids, the Employer will determine whether each
Bid :
a. meets the eligibility criteria defined in Clause 3 ;
b. has been properly signed ;
c. is accompanied by the required securities ; and
d. is substantially responsive to the requirements of the Bidding documents.
25.2 A substantially responsive Bid is one which conforms to all the terms, conditions &
specifications of the Bidding documents without material deviation or reservation. A
material deviation or reservation is one:
a. which affects in any substantial way the scope, quality, or performance of the
works ;
b. which limits in any substantial way, inconsistent with the Bidding documents,
the Employer’s rights or the Bidder’s obligations under the Contract ; or
c. whose rectification would affect unfairly the competitive position of other
Bidders presenting substantially responsive Bids.
25.3 If a Bid is not substantially responsive, it may be rejected by the Employer at its sole
discretion.
26.0 CORRECTION OF ERRORS
26.1 Bids determined to be substantially responsive will be checked by the Employer for
any arithmetical errors. Errors will be corrected by the Employer as follows:
a. where there is a discrepancy between the amounts in figures and in words, the
amounts in words will govern ; and
b. where there is a discrepancy between the unit rate and the line item total
resulting from multiplying the unit rate by the quantity, the unit rate as quoted
will govern ;
c. discrepancy in totaling or carry forward in the amount quoted by the
contractor shall be corrected.
The tendered sum so corrected and altered shall be substituted for the sum originally
tendered and considered for acceptance instead of the original sum quoted by the
tendered along with other tender / tenders. Rounding off to the nearest rupee should
be done in the final summary of the amount instead of in totals of various sections of
the offer.
26.2 The amount stated in the Bid will be adjusted by the Employer in accordance with the
above procedure for the corrections of errors and, shall be considered as binding upon
the Bidder.
27.0 EVALUATION AND COMPARISON OF BIDS
27.1 The Employer will evaluate and compare only the Bids determined to be substantially
responsive in accordance with Clause 25.

27.2 In evaluating the Bids, the Employer will determine for each Bid the evaluated Bid
Price by adjusting the Bid price as follows:
a. making any correction for errors pursuant to Clause 26 ;
b. making an appropriate adjustment for any other quantifiable acceptable
variations, deviations or alternative offers submitted in accordance with Clause
16 ; and
c. making appropriate adjustments to reflect discounts or other price modifications
offered in accordance with Clause 21.
27.3 The Employer reserves the right to accept or reject any variation, deviation or
alternative offer and other factors that are in excess of the requirements of the Bidding
documents or otherwise result in unsolicited benefits for the employer shall not be
taken into account in Bid evaluation.
27.4 If the Bid of the successful Bidder is seriously unbalanced in relation to the
Engineer’s Estimate of the cost of work to be performed under the contract, the
Employer may require the Bidder to produce detailed price analysis for any or all
items of the work to demonstrate the internal consistency of those prices with the
construction methods and schedule proposed.
28.0 AWARD CRITERIA
28.1 Subject to Clause 29, the Employer will award the Contract to the best qualified
Bidder whose Bid has been determined to be substantially responsive to the Bidding
documents and who has offered the lowest evaluated Bid Price. Employer shall be the
sole judge in this regard.
29.0 EMPLOYER’S RIGHT TO ACCEPT ANY BID AND TO REJECT ANY OR

ALL BIDS
29.1 Notwithstanding Clause 28, the Employer reserves the right to accept or reject any
Bid and to cancel the bidding process and reject all Bids, at any time prior to the
award of Contract, without thereby incurring any liability to the affected Bidder or
Bidders or any obligation to inform the affected Bidder or Bidders of the grounds for
the Employer’s action.
30.0 NOTIFICATION OF AWARD AND SIGNING OF AGREEMENT

30.1 The Bidder, whose Bid has been accepted will be notified of the award by the
Employer prior to expiration of the Bid validity period by cable, telex or facsimile
confirmed by registered letter. This letter ( hereinafter and in the Conditions of
Contract called the “Letter of Acceptance”) will state the sum that the Employer will
pay the Contractor in consideration of the execution, completion and maintenance of
the Works by the Contractor as prescribed by the Contract (hereinafter and in the
Contract called “the Contract Price”).
30.2 The notification of award will constitute the formation of the Contract, subject only to
the furnishing of a Performance Security / Security Deposit in accordance with Clause
31.
30.3 The Agreement will incorporate all agreements between the Employer and the
successful Bidder within 28 days following the notification of award along with the
letter of Acceptance.
30.4 Upon the furnishing by the successful Bidder of the Performance Security / Security
Deposit, the Employer will promptly notify the other Bidder that their Bids have been
unsuccessful and refund the Bid Security / Earnest Money Deposit.

31.0 PERFORMANCE SECURITY / SECURITY DEPOSIT / PERFORMANCE
GUARANTEE
31.1 Security Deposit shall consist of two parts :

a) Performance Security to be submitted at award of work and
b) Retention Money to be recovered from running bills.
The Security deposit shall bear no interest.
31.1.1 Performance Security should be 5% of contract amount and should be submitted

within 28 days of receipt of LOA by the successful bidders in any of the form given
below after which bid security / earnest money will be refunded to the contractor.
a Bank Guarantee in the form given in the bid document
Govt. Securities, FDR or any other form of deposit stipulated by the owner
Demand Draft drawn in favour of Mahanadi Coalfields Ltd on any
Scheduled Bank payable at its Branch at Sambalpur.
31.1.2 If performance security is provided by the successful bidders in the form of bank
guarantee it shall be issued either
(a) at Bidder’s option from Banks listed at Annexure-X or

(b) by a foreign bank located in India and acceptable to the employer.
31.1.3 Retention Money should be deducted at 5% from running bills. Total of performance
security and Retention Money should not exceed 10% of contract amount.
31.2 The Guarantee amount shall be payable to the Employer without any condition
whatsoever.
31.3 The Performance Guarantee shall cover additionally the following guarantees to the
Employer :
(a) The successful bidder guarantees the successful and satisfactory operation of
the equipment furnished and erected under the contract, as per the
specifications and documents,
(b) The successful Bidder further guarantees that the equipment provided and
installed by him shall be free from all defects in design, material and
workmanship and shall upon written notice from the employer fully remedy
free of expenses to the Employer such defects as developed under the normal
use of the said equipment within the period of guarantee specified in the
relevant clause of the Conditions of the Contract.
31.4 The Contract Performance Guarantee is intended to secure the performance of the
entire Contract. However, it is not construed as limiting the damages under clause
entitled “ Equipment Performance Guarantee” in section Technical Conditions of
Contract and damages stipulated in the other clauses in the bidding documents
31.5 Bank Guarantee is to be submitted in the format prescribed by the company in the bid
document. Bank Guarantee shall be irrevocable and it shall be from any Bank listed
at Annexure-X.
31.6 The Company shall be at liberty to deduct / appropriate from the Contract
Performance Guarantee / Security Deposit such sums as are due and payable by the

Contractor to the company as may be determined in terms of the contract, and the
amount appropriated from the Contract Performance Guarantee / Security Deposit
shall have to be restored by the Contractor subsequently.
31.7 The Contract Performance Guarantee will be returned to the Contractor without any
interest at the end of the Guarantee period.
31.8 Failure of the successful Bidder to comply with the requirements of Sub-Clause 31.1
shall constitute sufficient grounds for cancellation of the award and forfeiture of the
Bid Security.
31.9 Performance Security & Security Deposit shall be converted into Performance
Guarantee on successful completion of work in accordance with contract and upon
satisfactory trial operations and shall be valid for 90 days after the end of Guarantee
period.
32.0 EMPLOYMENT OF LOCAL LABOUR
32.1 “Contractors are to employ, to the extent possible, only local project affected people
and pay wages not less than the minimum wages fixed by the local Government”.
33.0 LEGAL JURISDICTION
33.1 Matter relating to any dispute or difference arising out of this tender and subsequent
contract awarded based on the bid shall be subject to the jurisdiction of Sambalpur
Court, Orissa and High Court of Orissa, Cuttack only.
34.0 DEEMED EXPORTS
34.1 If the bidder has quoted any item / items under the deemed exports then it will be the
responsibility of the Bidder to get all the benefits under deemed exports from the
Government. The Company’s responsibility shall only be limited to the issuance of
required certificates. The Project consessional Duty (PCD) is applicable. The
quotation of the bidder will be unconditional and phrases like “ Subject to availability
of Deemed Exports benefit” will not find place in it.
35.0 CONSULTANTS NOT TO BID & VICE-VERSA
35.1 A firm which has been engaged by the Company to provide Goods or Works for a
project or any of its affiliates will be barred from providing consultancy services for
the same project. Conversely, a firm hired to provide consultancy services for the
preparation or implementation of a project and any of its affiliates will be barred from
subsequently providing Goods or Works or services related to the initial assignment
for the same project.
36.0 SUB-CONTRACTOR / SUB-VENDOR :
36.1 The Contract agreement will specify major items of supply of services for which the
contractor proposes to engage Sub-Contractor / Sub-Vendor. The contractor may
from time to time propose any addition or deletion from any such list and will submit
the proposals in this regard to the Engineer in Charge / Designated Officer in Charge
for approval well in advance so as not to impede the progress of work. Such approval

of the Engineer in Charge / Designated Officer will not relieve the contractor from
any of his obligation, duties and responsibilities under the contract.
36.2 If a contractor submits his bid, qualifies and does not get the contract because of his
not being the lowest, he will be prohibited from working as a sub-contractor for the
contractor who is executing the work.

SECTION 3
FORMS AND BID AND
QUALIFIACTION INFORMATION
( PART – I )

FORMS OF BID AND QUALIFICATION INFORMATION
CONTRACTOR’S BID
Sub: BID for the work--------------------------------------------
To
--------------------------------------
--------------------------------------
--------------------------------------
Dear Sir,
We offer to execute the works described above in accordance with the Conditions of
Contract accompanying the Bidding Document issued to us. The Bid Security / Earnest
Money in accordance with the NIT and instructions to Bidders amounting to Rs. ---------------
------------- (in figures) ---------------------------------------- (in words) in the form as stipulated
in Clause 15 of the Instructions to Bidders is enclosed herewith (to be filled in by the
Bidder)
This Bid and your written acceptance of it shall constitute a binding contract between
us . We understand that you are not bound to accept the lowest or any Bid you receive.
We hereby confirm that this bid complies with the Bid validity and Bid security
required by the Bidding documents. We also confirm that EMD and other required
documentary evidences related to this part of the Bid are enclosed (As listed below) herewith
either in original/copies attested by Gazetted Officer / copies duly authenticated by us with
signature and seal alongwith affidavit as per the format provided in the bid document.
Yours faithfully,
Authorised Signature: ------------------------

Name and Title of the Signatory: ----------------------
Name of the Bidder (the Contractor) ----------------------
Address ---------------------
Date: ------------------------
(To be filled in by the Bidder)
Encl :
i) EMD of Rs……………….. vide ………. Dt. …………
ii)
iii)
iv)

QUALIFICATION INFORMATION
(The information to be submitted by all the Bidders)
1.0 Individual Bidders or Individual Members of Joint Ventures or Consortium

Members : -----------------------
1.1 Constitution or Legal Status of Bidder (attach copy)
Place of registration : --------------------------------

Principal place of business --------------------------------
Power of Attorney of signatory Bid (attach): --------------------------------
1.2 Details of the turnover:
Annual Turnover Data - Contract Work (During last three years)

Year Turnover in Rupees Remarks
1.3 Joint Venture / Consortium Route Details:

Name of all Partners of Joint Venture / Consortium Route
1. Lead Partner
2. Partner
3. Partner
Notes:
Joint ventures must comply the following requirements:

(i) The qualifying criteria parameter e.g. experience, financial resources etc. of the
individual partners of the Joint Venture will be added together and the total
criteria should not be less than as spelt out in para 3.0 of ITB as Qualification
Criteria.
ii) The formation of joint venture or change in the character of joint venture after
submission of the bid and any change in the bidding regarding joint venture will
not be permitted.
iii) Any bid shall be signed so as to legally bind all partners jointly and severally and
any bid shall be submitted with a copy of the Joint Venture Agreement ( JV
Agreement) providing the joint and several liabilities with respect to the contract.
iv) The pre-qualification of a joint venture does not necessarily pre-qualify any of its
partners individually or as a partner in any other joint venture or association. In
case of dissolution of a joint venture, each one of the constituent firms may pre-
qualify if they meet all the pre-qualification requirements, subject to written
approval of the employer.
v) The bid submission must include documentary evidence to the relationship
between joint venture partners in the form of JV Agreement to legally bind all
partners jointly and severally for the proposed agreement which should set out the
principles for the constitution, operation, responsibilities regarding work and
financial arrangements, participation (percentage share in the total) and liabilities
(joint and several) in respect of each and all of the firms in the joint venture /

consortium. Such JV Agreement must evidence the commitment of the parties to
bid for the facilities applied for (if pre-qualified) and to execute the contract for
the facilities if their bid is successful.
vi) One of the partners responsible for performing a key component of the contract
shall be designated as Lead Partner. This authorization shall be evidenced by
submitting with the bid a Power of Attorney signed by legally authorized
signatories of all the partners.
vii) The JV Agreement must provide that the Lead Partner shall be authorized to incur
liabilities and receive instructions for and on behalf of any and all partners of the
Joint Venture and the entire execution of the contract shall be done with active
participation of the Lead Partner.
viii) The contract agreement should be signed jointly by each Joint Venture Partners.
ix) An entity can be a partner in only one Joint Venture. Bid submitted by Joint
Ventures including the same entity as partner will be rejected.
x) The JV agreement may specify the share of each individual partner for the
purpose of execution of this contract. This is required only for the sole purpose
of apportioning the value of the contract to that extent to individual partner for
subsequent submission in other bids if he intends to do so for the purpose of the
qualification in that tender.
1.4 Details of experience for similar nature and complexity of work in last 15(fifteen)
years: Use a separate sheet for each contract;
1. Number of Contract:
Name of Contract:
2. Name of the employer
3. Employer’s address
4. Nature of work and special
features if any:
5. Contract role (Check out)
1. Sole Contractor 2. Sub Contractor 3. Partner in joint venture
6. Value of the total Contract:
7. Date of award:
8. Date of completion with original
schedule and slippage if any
9. Specified requirements:
(a) concrete : (b) Structural steelworks : (c ) equipment:
NB : Performance Certificate shall be submitted by bidder after obtaining the same from
the customer for the completed job(s). However if required Concerned Technical
Department may also seek/verify the Performance Certificate from the issuing authority of
the work order(s) or a committee may visit the site of the customer to verify and certify
about the satisfactory performance after approval of competent authority. In case of
unsatisfactory performance received from the customer in which the bidder is qualifying in
eligibility criteria, the offer of the bidder shall be rejected.

1.5 Subcontractors / Consultants and firms proposed to be involved:
(Attach performance credentials including Bio-data of design personnel of
Consultants)
Section of Approximate value of Sub-contractor Experience in
Work subcontract (Name and address) similar work
1.6 Information on Bid Capacity (Works for which bids have been submitted and work
which are yet to be completed) as on the date of this bid:
a) Total value of contract work executed in last five years (year wise):
Year
Executed
contract Value
(Rs.in Lakh)
b) Details of existing commitments and ongoing works during the next 24

months :
Description Place Contract Name and Value of Stipulated Value of works Anticipated
of work & No.& address of Contract period of remaining to be date of
State Date Employer (Rs. in completion completed completion
lakhs)
(1) (2) (3) (4) (5) (6) (7) (8)
c) Details of Works for which bids already submitted:
Description Place & Estimated Stipulated Date when Remarks if

of work State value of works period of decision is any
(Rs. In lakhs) completion expected
(1) (2) (3) (4) (5) (6)

1.7 Financial reports of the last five years: Balance sheets, profit and loss statement,
auditors report etc. (Copies to be submitted and the following format be filled up)
Financial Actual : Previous five years Projected next
information in two years
Indian Rupees. 1 2 3 4 5 6 7
1. Total assets
2. Current assets
3.Total Liabilities
4. Current liabilities
5. Profits Before Tax
6. Profits after Tax
1.8 Evidence of access to financial resources to meet the qualification requirements: Cash
in hand, lines of credit and other financial means etc. sufficient to meet the
construction cash flow copies to be submitted and the following format to be filled
up).
Source of financing Amount in Indian Rupees
1.
2.
1.9 Details of bankers:
A.
Banker Name of the banker
Address of the banker
Account No. (Required to receive payment)
Type : Branch Code :
Telephone Contact name & title
Fax Telex
B. The Bank mandate in duplicate in the prescribed format for e-Payment
through Electronic Fund Transfer / Internet Banking (SBI-Net / RTGS
Transfer) is needed before issue of LOA ( Annexure -IV )
1.10 Information about litigations, if any, in which bidder is involved:
Year Award FOR or Name of the client, Clause of Disputed
AGAINST litigation and matter of dispute amount in
applicant Rupees
1.11 Details of major construction equipment to be used for the work :

Sl.No Equipment type and Make and model Minimum number
capacity
1
1.12 Details of additional construction equipment to be purchased new for the project,
indicating delivery times required in the form given below:
Equipment to be Make and Delivery Number
purchased new-type model Period
and capacity

1.13 Personnel capabilities:
The applicant must have suitably qualified personnel to fill the following key
positions for the project. The applicant will supply information on a prime candidate
and an alternate for each positions both of whom, wherever possible meet the
experience requirements as specified in format below:
Position Name Total post In similar As Manager or
qualification works Section Leader of
experience (years) Similar Works
(years) (Years)
Project Manager
Alternative Name
Site engineers of
resp. disc.
Alternative Names
Cost Controller
Alternative name
Quality Assurance
Engineer
Alternative Name
Site Supervisors of
resp.disc.
Alternative Names
1.14 The bidder should list transport available for personnel, construction, plant, stores and
machinery where transport is to be subcontracted the proposed arrangements should
be clearly demonstrated…………………………
1.15 The bidder should provide full details of his plant and maintenance facilities together
with the full details of laboratory personnel, workshop personnel including fitters,
mechanics, machinists etc……………………..
1.16 Permanent Income Tax Account No. (PAN) ………………………..
1.17 DETAILS OF EARNEST MONEY / BID SECURITY
Deposit of Earnest Money by :

Draft No :
Drawn on :
Amount (Rs.) :
or
Bank Guarantee Details
Name of the Bank :
Amount of B.G. :
Bank Guarantee valid upto :
1.18 OTHER DETAILS

(a) Details of registration/ enlistment with the Government
Organization /PSUs /Subsidiaries of Coal India : ……………………..
(b) Certificate of registration as per statutory requirements under Sales Tax, Service
Tax and Contract Labour Laws etc. as may be applicable

1.19 Acceptance by the Bidder of conditions of contract as per Tender Documents
( attach signed & sealed copies of the bid document issued to them / downloaded from
website along with the offer as proof of acceptance) as under :
a) Vol-I of Tender document in Part-I
b) Vol-II & Vol-II A of Tender document in Part-II
c) Price Bid (Vol-III) in Part-III
Signature of Bidder with name & Seal
Note : Separate sheets may be attached to furnish details, if necessary.

SECTION 4
CONDITIONS OF CONTRACT

GENERAL TERMS AND CONDITIONS OF CONTRACT
1. DEFINATIONS
i) The word “Company” or “Employer” or “Owner” wherever occurs in the

conditions, means the Mahanadi Coalfields Limited, represented at the head
quarters of the Company by the General Manager (E&M) or his authorised
representative or any other officer specially deputed for the purpose.
ii) The Word “Principal Employer” or “Engineer” wherever occurs, means the
authorised representative or any other officer specially deputed by the company
for the purpose of contact.
iii) (a) The word 'Contractor'/Contractors' or “Manufacturer” wherever occurs means
the successful Bidder/Bidders who has/have deposited the necessary Earnest
Money and has/have given written intimation about the acceptance of tender and
shall include legal representative of such individual or persons composing a firm
or a company or the successors and permitted assignees of such individual, firm or
company, as the case may be.
(b) The word ‘Bidder(s)/ tenderer ’ shall mean a proprietary firm/ registered
partnership firm/ a body corporate / joint stock company or joint venture .
Bidding may be done either as a sole bidder or with associate ( Consortium
Partner) as a Lead Member. In case of associate / consortium route, lead member
of consortium shall be termed as bidder.
iv) “The Site" shall mean the site of the contract work including land and any
building and erections thereon and any other land allotted by the company for
Contractor's use in the performance of the contract.
v) The term “sub-contractor” as employed herein, include those having a direct
contract with contractor either on piece rate, items rate, time rate or on any other
basis and it includes one who furnishes work to a special design according to the
plans or specifications of this work but does not include one who merely supplied
materials.
vi) “Consulting Engineer”/”Consultant” shall mean any firm or person duly appointed
as such from time to time by the owner.
vii) ‘Accepting authority’ shall mean the management of the company and includes an
authorised representative of the company or any other person or body of persons
empowered in this behalf by the company.
viii) A 'Day' shall mean a day of 24 hours from midnight to midnight.
ix) Engineer-in-charge/Designated Officer-in-charge who is of an appropriate

seniority will be responsible for supervising and administering the contract,
certifying payment due to the contractor, valuing variations to the contract,
awarding extension of time and valuing compensation events. Engineer-in-
charge/Designated Officer-in-charge may further appoint his representatives i.e.
another person/Project Manager or any other competent person and notify to the
contractor who is directly responsible for supervising the work being executed at
the site, on his behalf under the Delegation of Powers of the company. However,
overall responsibility, as far as contract is concerned will be that of the Engineer-
in-charge/Designated Officer-in-charge
x) The 'Contract' shall mean the notice inviting tender, the tender as accepted by the
company and the formal agreement executed between the company and the
contractor together with the documents referred to therein including conditions of

contract, special conditions, if any, specifications, designs and drawings including
those to be submitted during progress of work, scope of work, billing
schedule/schedule of quantities with rates and amounts.
xi) The 'Works' shall mean and include the furnishing of equipment, labour and the
services in accordance with the contract or parts thereof as the case may be and
shall also include all extra or additional, altered or substituted works or any work
of emergent nature, which in the opinion of the Engineer-in-charge, become
necessary during the progress of the works to obviate any risk or accident or
failure or become necessary for security.
xii) “Specification” shall mean the technical specifications forming a part of the
contract and such other schedules and drawings as may be mutually agreed upon.
xiii) “Contract price” shall mean the total sum for which tender is accepted by the
company.
xiv) “'Written notice” shall mean a notice or communication in writing and shall
deemed to have been duly served if delivered in person to the individual or to a
member of the firm or to an office of the corporation/company for whom it is
intended, or if delivered at or sent by registered mail to the last business address
known to him who gives the notice.
xv) “Letter of Acceptance” of the tender shall mean the official notice issued by the
company notifying the contractor that his tender has been accepted.
xvi) “Date of Contract” shall mean the date on which both the parties have signed
the contract agreement.
xvii) “Manufacturer’s Works or Contractor’s Works” shall mean the place of work used
by the Manufacturer, the Contractor, their collaborators or sub-contractors for the
performance of the works.
xviii) “Inspector” shall mean the Owner or any person nominated by the Owner from time
to time to inspect the equipment stores or works under the contract and/or the duly
authorised representative of the owner.
xix) When the words “Approved”, “Subject to Approval”, “Satisfactory”, “Equal to”,
”Proper”, “Requested”, “As Directed”, “Where Directed”, “ When Directed”,
“Determined by”, “Accepted”, “Permitted”, or words and phrases of like import are
used, the approval, judgment, direction etc. is understood to be a function of the
Owner/Engineer/Engineer-in-charge.
xx) “Test of Completion” shall mean such tests as prescribed in the contract to be
performed by the contractor before the Works is taken over by the Owner.
xxi) ”Start-up” shall mean the time period required to bring the equipment covered under
the Contract from an inactive condition, when construction is essentially complete,
to the state ready for trial operation. The start-up period shall include preliminary
inspection and check out of equipment and Supporting sub-systems; initial
operation of the complete equipment covered under the Contract to obtain necessary
pre-trial operation data, perform calibration and corrective action; shut down
inspection and adjustment prior to the trial operation period.
xxii) “Initial operation” shall mean the first integral operation of the complete equipment
covered under the contract with sub-systems and supporting equipment in service.
xxiii) “Trial Operation”, “Reliability Test”, “Trial Run”, “Complete Test” shall mean the
extended period of time after the “Start-up” period. During this trial operation period
the unit shall be operated over the full load range. The length of trial operation shall
be as determined by the Engineer, unless otherwise specified elsewhere in the
Contract.
xxiv) “Performance and Guarantee Tests” shall mean all operation checks and tests required
to determine and demonstrate capacity, efficiency, and operating characteristics as
specified in the contract document.

xxv) “Commercial Operation” shall mean the condition of operation in which the complete
equipment covered under the contract is officially declared by the owner to be
available for continuous operation at different loads up to and including rated
capacity. Such declaration by the owner however, shall not relieve or prejudice any of
the contractor’s obligation under this contract.
xxvi) “Final Acceptance” shall mean the owner’s written acceptance of the works performed
under contract, after successful completion of performance and guarantee tests.
xxvii) “Guarantee Period/Maintenance Period” shall mean the period during which the
contractor shall remain liable for repair or replacement of any defective part of the
works performed under the contract.
xxviii) “Drawing”/ “Plans” shall mean all:
a) drawing furnished by the owner/consultant as a basis for proposals,
b) supplementary drawings furnished by the owner/ consultant to clarify and
to define in greater detail the intent of the contract,
c) drawings submitted by the contractor with his proposal provided such
drawings are acceptable to the owner/consultant,
d) drawing furnished by the Owner/Consultant to the contractor during the
progress of the work, and
e) engineering data and drawings submitted by the Contractor during the
progress of the work provided such drawings are acceptable to the
Engineer,
xxix) “Codes” shall mean the following, including the latest amendments, and /or
replacements, if any :
a) Standards of Bureau of Indian Standards relevant to the
works under the contract and their specifications.
b) Other Internationally approved Standards and/or rules and regulations
touching the subject matter of the contract.
i) A.S.M.E Test Code
ii) A.I.E.E Test code
iii) American Society of Materials Testing code
iv) Indian Electricity Act and Rules and Regulations made there under
v) Indian Explosive Act and Rules and regulations made there under
vi) Indian Petroleum Act and Rules and Regulations made there under
vii) Indian Mines Act and Rules and Regulations made there under
c) Any other laws, rules, regulations and Acts applicable in the country with
respect to labour, safety, compensation, insurance etc.
xxx) Words importing singular only shall also include the plural and vice-versa where the
context so requires.
xxxi) Words importing “Person” shall include firms, companies, corporations, and
associations or bodies of individuals, whether incorporated or not.
xxxii) Terms and expressions, not defined herein, shall have the same meaning as are
assigned to them in the Indian Sale of Goods Act, failing that in the Indian Contract
Act, and failing that in the General clauses Act.
xxxiii) “Commissioning” the plant/project shall mean completion in all respect of
construction rendering the plant/project ready for performance test and commercial
operation as per xxv.
xxxiv) “Government Approvals” shall mean all permits, license, authorisations, consents,
clearances, decrees, waivers, privileges, approvals from and filing with government
instrumentalities necessary for the development, construction and operation of the
plant/project.
xxxv) “Month” shall mean a calendar month according to the Gregorian calendar

xxxvi) “Bank Guarantee” shall mean the Bank Guarantee to be provided by the Bidder to
Mahanadi Coalfields Limited, Sambalpur
xxxvii) Bid/ offer/ proposal shall mean the proposal of the bidder submitted in response to
the bid document issued by the company i.e. MCL.
xxxviii) “Revised Price Bid” shall mean the one which refers to alternative offer invited from
the bidders based on the agreed finalized specification and terms & conditions
before opening of Price Bids. In case of such revised price bid, the base date for
working out price escalation shall be 30 days prior to the date set for opening of the
revised price bids.
xxxix) “Negotiated Rate” shall mean the one which refers to the price offered by the lowest
bidder after price negotiation with the owner. In case of such negotiated rate, the
base date for working out price escalation shall be 30 days prior to the date set for
opening of the bids.
2.0 CONTRACT DOCUMENTS:
The following documents shall constitute the contract documents:
i) Article of agreement
ii) Notice Inviting Tender
iii) Letter of acceptance of Tender indicating deviation, if any, from the
conditions of contract incorporated in the Tender document issued to the
bidder and/or the bid submitted by the bidder.
iv) Conditions of contract, including general terms and conditions, additional
terms and conditions, technical terms and conditions, erection terms and
conditions, special conditions, if any etc. forming part of the agreement.
v) Specification, where it is part of Tender Documents
vi) Scope of works/Bills of quantities/schedule of works/quantities and
vii) Contract Drawings/finalised work programme
2.1 After acceptance of the tender the Contractor shall be deemed to have carefully
examined all Contract Documents to his satisfaction. If he shall have any doubt as to
the meaning of any portion of the Contact Documents, he shall have any doubt as to
the meaning of any portion of the contract Documents, he shall before signing the
Contract, set forth the particulars thereof, and submit them to the Owner in writing in
order that such doubt may be removed. The Owner will provide such clarifications as
may be necessary in writing to the Contractor. Any information otherwise obtained
from the Owner or the engineer shall not in any way relieve the Contractor of his
responsibility to fulfill his obligations under the Contract.
2.2 The Contractor shall enter into a Contract Agreement with the Owner within 60
(sixty) days from the date of ‘Acceptance of Tender’ or within such extended time as
may be granted by the owner. The performance Bank Guarantee for the proper
fulfillment of the contract shall be furnished by the contractor in the prescribed form
within thirty (30) days of ‘Acceptance of Tender’. The performance Guarantee shall
be as per terms prescribed in clause31 of Instructions to Bidders of this tender.
2.3 The owner, after the issue of the letter of Acceptance of Tender, will send one copy of
the final agreement to the contractor for his scrutiny and approval.
2.4 The agreement, unless otherwise agreed to shall be signed with in 60 days of issue of
the letter of Acceptance of Tender, at the office of the owner on a date and time to be
mutually agreed. The contractor shall provide for signing of the contract, performance
guarantee in copies as required, appropriate power of attorney and other requisite
materials. In case it is agreed mutually that the contract is to be signed beyond the

stipulated time, the bid guarantee submitted with the tender will have to be extended
accordingly.
2.5 The agreement will be signed in six originals and the contractor shall be provided
with one signed original and the rest will be retained by the owner. None of these
documents shall be used by the contractor for any purpose other than this contract and
the contractor shall ensure that all persons employed for this contract strictly adhered
to this and maintain secrecy, as required of such documents.
2.6 The contractor shall provide free of cost to the owner all the engineering data,
drawings and descriptive materials submitted with the bid, in at least (6) six copies to
form a part of the contract immediately after issue of Letter of acceptance .
2.7 Subsequent to signing of this contract, the contractor at his own cost shall provide the
owner with at least 6 (six) true copies of agreement with in 30 (thirty) days after the
signing of the contract.
2.8 The contract shall be considered as having come into force from the date of the letter
of acceptance of tender issued by the owner.
2.9 The laws applicable to this contract shall be the laws in force in India. The Courts of
Sambalpur, Orissa and High Court of Orissa, Cuttack shall have exclusive jurisdiction
in all matters arising under this contract.
3.0 CONTRACT PERFORMANCE GUARANTEE / SECURITY DEPOSIT:

3.1 Security Deposit shall consist of two parts :
a) Performance Security to be submitted at award of work and
b) Retention Money to be recovered from running bills.
The Security deposit shall bear no interest.
3.1.1 Performance Security should be 5% of contract amount and should be submitted
within 28 days of receipt of LOA by the successful bidders in any of the form given
below after which bid security / earnest money will be refunded to the contractor.
a Bank Guarantee in the form given in the bid document
Govt. Securities, FDR or any other form of deposit stipulated by the owner
Demand Draft drawn in favour of Mahanadi Coalfields Ltd on any
Scheduled Bank payable at its Branch at Sambalpur.
3.1.2 If performance security is provided by the successful bidders in the form of bank
guarantee it shall be issued either
(a) at Bidder’s option from a Bank listed at Annexure-X or
(b) by a foreign bank located in India and acceptable to the employer.
3.1.3 Retention Money should be deducted at 5% from running bills. Total of performance
security and Retention Money should not exceed 10% of contract amount.
3.2 Bank Guarantee shall be valid up to ninety (90) days after the end of Guarantee
Period.
3.3 The Guarantee amount shall be payable to the Employer without any condition
whatsoever.
3.4 The Performance Guarantee shall cover additionally the following guarantees to the
Employer:
a. The successful bidder guarantees the successful and satisfactory operation of
the equipment furnished and erected under the contract, as per the
specifications and documents,
b. The successful bidder further guarantees that the equipment provided and
installed by him shall be free from all defects in design, material and
workmanship and shall upon written notice from the employer fully remedy
free of expenses to the Employer such defects as developed under the normal

use of the said equipment within the period of guarantee specified in the
relevant clause of the Conditions of Contract.
3.5 The Contract Performance Guarantee is intended to secure the performance of the
entire Contract. However, it is not construed as limiting the damages under the clause
entitled “Equipment Performance Guarantee” in section Technical Conditions of
Contract and damages stipulated in other clauses in the bidding documents.
3.6 Bank guarantee is to be submitted in the format prescribed by the company in the bid
document. Bank Guarantee shall be irrevocable and it shall be from any Bank listed
at Annexure-X.
3.7 The company shall be at liberty to deduct / appropriate from the Contract
Performance Guarantee / Security Deposit such sums as are due and payable by the
contractor to the company as may be determined in terms of the contract, and the
amount appropriated from the Contract Performance Guarantee / Security Deposit
shall have to be restored by the Contractor subsequently.
3.8 The Contract Performance Guarantee will be returned to the Contractor without any
interest at the end of the Guarantee Period.
4.0 ASSIGNMENT AND SUBLETTING OF CONTRACT:

4.1 The Contractor may, after informing the engineer and getting his written approval,
assign or sublet the contract or any part thereof other than for raw materials, for minor
detail or any part of the plant for which makes are identified in the contract. Suppliers
of the equipment not identified in the contract or any change in the identified supplier
shall be subject to approval by the engineer. The experience list of the equipment
vendors under consideration by the contractor for this contract shall be furnished to
the engineer for approval prior to the procurement of all such items / equipments.
Such assignment sub-letting shall not relieve the contractor from any obligation , duty
or responsibility under the contract. Any assignment as above without prior written
approval of engineer shall be void.
4.2 For components / equipments procured by the contractors for the purposes of the
contract, after obtaining the written approval of the owner, the contractor’s purchase
specifications and enquiries shall call for quality plans to be submitted by the
suppliers alongwith their proposals. The quality plans called for from the vendors
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
documentation raised, etc. Such quality plans of the successful vendor shall be
discussed and finalized in consultation with the engineer and shall form a part of the
purchase order/contract between the contractor and the vendor. Within 3 weeks of the
release of the same purchase order/contracts for such bought out items/components, a
copy of the same without price details but together with detailed purchase
specifications, quality plans and delivery conditions shall be furnished to the engineer
by the contractor.
5.0 PATENT RIGHTS AND ROYALTIES

5.1 Royalties and fees for patent covering materials, articles, apparatus, devices,
equipment or processes used in the works shall be deemed to have been included in
the contract price. The contractor shall satisfy all demands that may be made at any
time for such royalties or fees and he alone shall be liable for any damages or claims
for patent infringements and shall keep the owner indemnified in that regard. The
contractor shall, at his own cost and expense, defend all suits or proceedings that may
be instituted for alleged infringement of any patent involved in the works, and , incase
of an award of damages, the contractor shall pay for such award. In the event of any

suit or other proceedings instituted against the owner, the same shall be defended at
the cost and expense of the contractor who shall also satisfy/comply and decree,
order or award made against the owner. But it shall be under stood that no such
machine, plant, work, material or thing has been used by the owner for any purpose or
any manner other than that for which they have been furnished and installed by the
contractor and specified under these specifications. Final payment to the contractor by
the owner will not be made while any such suit or claim remains unsettled. In the
event any apparatus or equipment , or any matter thereof furnished by the
contractor, is in such suit or proceedings held to constitute infringement, and its use is
enjoined, the contractor shall, at his option and at his own expense, either procure for
the owner, the right to continue use of said apparatus, equipment or part thereof,
replace it with non-infringing apparatus or equipment or modify it, so it becomes non-
infringing.
6.0 TIME - THE ESSENCE OF CONTRACT

6.1 The time and the date of completion of the works as stipulated in the contractor’s
proposal and accepted by the owner without or with modifications, if any and so
incorporated in the award letter shall be deemed to be the essence of the contract. The
contractor shall so organize his resources and perform his work as to complete it not
later than the date agreed to.
6.2 The contractor shall submit a detailed PERT network within the time frame agreed
above consisting of adequate number of activities covering various key phases of the
works such as design, procurement, manufacturing, shipment and field erection
activities within fifteen (15) days after the date of acceptance of tender. This network
shall also indicate the interface facilities to be provided by the owner and the dates by
which such facilities are needed. Contractor shall discuss the network so submitted
with the owner and the agreed network which may be in the form as submitted or in
revised form in line with the outcome of discussions and shall form part of the
contract to be signed within sixty(60) days from the date of letter of acceptance of
notice of award of contract. During the performance of contract, if in the opinion of
the engineer proper progress is not maintained suitable changes shall be made in the
contractor’s operations to ensure proper progress.
6.3 The above PERT network shall be reviewed and periodic review reports shall be
submitted by the contractor as directed by the engineer.
6.4 Subsequent to the award of the contract, the contractor shall make available to the
engineer, a detailed manufacturing programme, in line with the agreed contract
network. Such manufacturing programme shall be reviewed, updated and submitted to
the Engineer, once every two month thereafter.
7.0 CONTRACT PRICE

7.1 The lump sum prices quoted by the contractor in his bid with additions and deletions
and as may be agreed before signing of the contract, for the entire scope of the work
including furnishing and erection of equipment covered under the specifications and
documents and shall be treated as the contract price.
8.0 CHANGED QUANTITY

8.1 The owner reserves the right to vary the quantities of items or groups of items to be
ordered as specified in the accompanying technical specifications, as may be
necessary, during the execution of contract, but such variations unless otherwise
specified in the accompanying technical specifications shall be limited to plus or
minus twenty percent (20%) of the original quantity ordered.

9.0 DEDUCTION FROM CONTRACT PRICE
All costs, damages or expenses which the owner may have paid, for which under the
contract the contractor is liable, will be claimed by the owner. All such claims shall be
billed by the owner to the contractor regularly as and when they fall due. Such bills
shall be supported by appropriate and certified vouchers or explanations, to enable
the contractor to properly identify such claims. Such claims shall be paid by the
contractor within fifteen (15) days of the receipt of the corresponding bills and if not
paid by the contractor within the said period, the owner may then deduct the amount,
from any moneys due or becoming due by him to the contractor under the contract or
may be recovered by actions of law or otherwise, if the contractor fails to satisfy the
owner of such claims.
10.0 CONTRACT PRICE ADJUSTMENT

10.1 All adjustments in the contract price shall be computed in accordance with the
conditions and formulae prescribed in the relevant clauses of ‘Additional Terms and
Conditions of contract’, the accompanying technical specifications and further
satisfying the requirements specified herein.
10.2 The contract price stated in the contract agreement is the base price. A certain fixed
percentage of the base price as indicated in the technical specifications shall not be
subject to any price adjustment. The balance percentage viz. the cost portion shall
only be subject to price adjustment.
10.3 Price adjustment shall be applicable to the cost portion, only if changes in the cost of
labour and materials (either increases or decreases) occur during the contract period,
directly affecting the cost portion.
10.4 Variation in the cost of materials shall be determined by comparing published
material indices as of thirty (30) days prior to the date set for opening of bids or the
revised price bid, whichever is later, with the same indices published during the
manufacture at the respective cut off periods for material as specified in clause 2.0 of
additional Terms and Conditions of Contract. Variations in the cost of labour shall be
determined by comparing the wages as per the Minimum Wages Act/Rules of the
State or Central Government, whichever is more, applicable to the place of work as of
thirty (30) days prior to the date set for opening of bids or the revised price bid,
whichever is later, with the same wages as per the Minimum Wages Act/Rules of the
state or Central Government, whichever is more, during the work/manufacture
applicable to the place of work/manufacture at the respective cut off periods for
labour as specified in clause 2.0 of Additional Terms and conditions of contract of
this volume.
10.5 The total computed variation in the contract price shall be restricted to limiting
percentage as specified in clause 2.5 of Additional Terms and Conditions of Contract
of this volume.
10.6 The price adjustment for the erection shall be made on the value of erection work
done as indicated in each billing.
10.7 Every three months after the award of contract, and a month prior to shipment of
equipment (in the case of Ex-factory price component of contract price), and every
month after establishing his site office (in the case of erection), the contractor shall
submit to the engineer a written notice of the changes, if any, that have occurred in the
specified material and labour indices during the previous reporting period containing
the effective date of such change, the amount of change, the amount of contract price
adjustment and documentary evidence to substantiate the price adjustment.
10.8 The contract price adjustment provisions detailed above, shall only be applicable if so
specified in the Additional Terms and Conditions of Contract.

11.0 PACKING, FORWARDING AND SHIPMENT
11. 1 The contract, wherever applicable, shall after proper painting, pack and crate all
equipment in such a manner as to protect them from deterioration and damage during
rail and road transportation to the site and storage at the site till the time of erection.
The contractor shall be held responsible for all damages due to improper packing.
11.2 The contractor shall notify the owner of the date of each shipment from his works,
and the expected date of arrival at the site for the information of the owner.
11.3 The contractor shall also give all shipping information concerning the weight, size
and content of each packing including any other information the owner may require.
11.4 The following documents shall be sent by registered post to the owner within 3 days
from the date of shipment, to enable the owner to make progressive payments to the
contractor. The payment shall be made only after receipt and acceptance of materials
at site in good condition:
Application for payment in the standard format of the owner (3 copies)

Invoice (6copies)
Packing list (6 copies)
Pre-despatch clearance certificate, if any (3 copies)
Test certificate, wherever applicable (3 copies)
11.5 The contractor shall prepare detailed packing list of all packages and containers,
bundles and loose material forming each consignment dispatched to site. The
contractor shall further be responsible for making all necessary arrangements for
loading, unloading and other handling right from his works up to the site and also till
the equipment is erected, tested and commissioned. He shall be solely responsible for
proper storage and safe custody of all equipment.
12.0 DEMURRAGE, WHARFAGE, ETC.

12.1 All demurrage, wharfage and other expenses incurred due to delayed clearance of the
material or any other reason shall be to the account of the contractor.
13.0 INSURANCE
13.1 The contractor shall arrange, secure and maintain insurance as may be necessary and
for all such amounts to protect his interests and the interests of the owner, against all
risks as detailed herein in the joint names of the Owner and the Contractor with the
condition that payments against all claims shall be payable by insurers to the owner as
elaborated at clause 13.5. All premiums and other charges of the said insurance
policies shall be paid by the contractor. The form and the limit of such insurance as
defined herein together with the under –writer thereof in each case shall be acceptable
to the owner. However, irrespective of such acceptance, the responsibility to maintain
adequate insurance coverage on comprehensive all risks basis at all time during the
period of contract shall be that of the contractor alone. The contractor’s failure in this
regard shall not relieve him of any of his contractual responsibilities and obligations.
13.2 Any loss of damage to the equipment, during handling, transporting, storage and
erection, till such time the plant is taken over by the owner, shall be to the account of
the contractor. The contractor shall be responsible for preferring of all claims and
make good for the damage or loss by way of repairs and /or replacement of the
portion of the works damaged or lost. The transfer of title shall not in any way relieve
the contractor of the above responsibilities during the period of the contract. The
contractor shall provide the owner with a copy of all insurance policies and
documents taken out by him in pursuance of the contract. Such copies of document

shall be submitted to the owner immediately after such insurance coverage. The
contractor shall also inform the owner in writing at least sixty (60) days in advance,
regarding the expiry, cancellation and/or change in any of such documents and ensure
revalidation/renewal, etc. as may be necessary well in time.
13.3 the risk that are to be covered under the insurance shall include, but not be limited to,
the loss or damage in transit, theft, pilferage, riot, civil commotion, weather
conditions, accidents of all kinds, fire, etc. The scope of such insurance shall cover the
entire value of the works from time to time.
13.4 All costs on account of insurance liabilities covered under the contract will be on
contract’s account and will be included in contract price. However, the owner may
from time to time, during the pendency of the contract, ask, the contractor in writing
to limit the insurance coverage risks and in such case, the parties to the contract will
agree for a mutual settlement for reduction in contract price to the extent of reduced
premium amounts.
13.5 All insurance claims, payable by the insurers, shall be paid to the Owner which shall
be released to the contractor in installments as may be certified by Engineer-in-charge
for the purpose of rebuilding or replacement of repair of the works and/or goods
destroyed or damaged for which payment was received from the insurers.
13.6 The clause entitled insurance under the section erection terms and conditions of
contract of this volume, covers the additional insurance requirements for the portion
of the works to be performed at the site of work.
14.0 LIABILITY FOR ACCIDENTS AND DAMAGES

14.1 Under the contract, the contractor shall be responsible for loss or damage to the plant
until the plant is taken over in accordance with clause entitled ‘Taking Over’ in
section technical terms and conditions of contract of this volume.
15.0 LIQUIDATED DAMAGES FOR DELAY IN COMPLETION

15.1 If the contractor fails to maintain the required progress in terms of the agreed time and
progress chart or to complete the work and clear the site on or before the date of
completion of contract or extended date of completion, he shall without prejudice to
any other right or remedy available under the law to the company on account of such
breach, pay as compensation/ Liquidated Damages @ one percent (1%) of the
contract price per week of delay. The aggregate of such compensation /
compensations shall not exceed 20(twenty) % of the total value as shown in the
contract.
This will also apply to items or group items for which separate period of completion
has been specified. The amount of compensation may be adjusted or setoff against
any sum payable to the contractor under this or any other contract with the company.
15.1.1 The company, if satisfied, that the works can be completed by the contractor within a
reasonable time after the specified time of completion, may allow further extension of
time at its discretion with or without the levy of L.D. In the event of extension granted
being with L.D., the company will be entitled without prejudice to any other right or
remedy available in that behalf, to recover from the contractor as agreed damages
equivalent to one percent of the contract value of the works for each week or part of
the week subject to a ceiling of 20% of the contract price.
15.1.2 The company, if not satisfied that the works can be completed by the contractor, and in
the event of failure on the part of the contractor to complete work within further
extension of time allowed as aforesaid, shall be entitled, without prejudice to any
other right, or remedy available in that behalf, to rescind the contract.

15.1.3 The company, if not satisfied with the progress of the contract and in the event of
failure of the contractor to recoup the delays in the mutually agreed time frame, shall
be entitled to terminate the contract.
15.1.4 In the event of such termination of the contract as described in clauses 15.1.2 or
15.1.3 or both, the company, shall be entitled to recover L.D. upto twenty percent
(20%) of the contract value and forfeit the security deposit made by the contractor
besides getting the work completed by other means at the risk and cost of the
contractor.
15.2 The company may waive the payment of compensation, depending upon merit of the
case, on request received from the contractor if the entire work is completed within
the date as specified in the contract or as validly extended without stipulating any
penalty.
16.0 CONTRACTOR’S DEFAULT

16.1 If the contractor shall neglect to execute the works with the diligence and expedition
or shall refuse or neglect to comply with any reasonable orders given to him, if
writing by the engineer in connection with the works or shall contravene the
provisions of the contract, the owner may give notice in writing to the contractor to
make good the failure, neglect or contravention complained of. Should the contractor
fail to comply with the notice within thirty (30) days from the date of service thereof,
then and in such case the owner shall be at liberty to employ other workmen and
forthwith execute such part of the works as the contractor may have neglected to do or
if the owner shall think fit, it shall be lawful for him, without prejudice to any other
right he may have under the contract, to take the works wholly or in part thereof and
in that event the owner shall have free use of all contractor’s equipment that may
have been at the time on the site in connection with the works without being
responsible to the contractor for fair wear and tear thereof and to the exclusion of any
right of the contractor over the same, and the owner shall be entitled to retain and
apply any balance which may otherwise be due on the contract by him to the
contractor, or such part thereof as may be necessary, the payment of the cost of
executing the said part of the works or of completing the works as the case may be. If
the cost of completing the works or executing a part thereof as aforesaid shall exceed
the balance due to the contractor, the contractor shall pay such excess . Such payment
of excess amount shall be independent of the liquidated damages for delay which the
contractor shall have to pay if the completion of work is delayed.
16.2 In addition, such action by the owner as aforesaid shall not relieve the contractor of
his liability to pay liquidated damages for delay in completion of works as defined in
clause 15.0 of this section
16.3 the termination of the contract under this clause shall not entitle the contractor to
reduce the value of the performance bank guarantee nor the time thereof. The
performance guarantee shall be valid for the full value and for the full period of the
contract including guarantee period.
16.4 The bidding documents will clearly state that, if the contractor fails to complete the
work and the order is cancelled, the amount due to him on account of work executed
by him, if payable, shall be paid to him only after due recoveries as per the provisions
of the contract and that too after alternative arrangements to complete the work has
been made.
17.0 FORCE MAJEURE

17.1 Force majeure is herein defined as any cause which is beyond the control of the
contractor or the owner as the case may be which they could not foresee or with a

reasonable amount diligence could not have foreseen and which substantially affect
the performance of the contract, such as:
(a) natural phenomena, including but not limited to floods, drought, earthquakes,
and epidemics:
(b) acts of any government, including but not limited to war, declared or undeclared,
priorities, quarantines, embargoes,
Provided either party shall within fifteen (15) days from the occurrence of such a
cause notify the other in writing of such causes.
17.2 a) The successful bidder / contractor will advise, in the event of his having resort to
this clause by registered letter duly certified by the local chamber of commerce or
statutory authorities, the beginning and end of the clause of delay, within fifteen
days of the occurrence and cessation of such Force Majeure condition. In the
event of delay lasting over two months, if arising out of Force Majeure, the
contract may be terminated at the discretion of the company.
b) For delays arising out of Force Majeure, the bidder / contractor will not claim
extension in completion date for a period exceeding the period of delay
attributable to the causes of Force Majeure and neither company nor the bidder
shall be liable to pay extra costs ( like increase in rates, remobilisation advance,
idle charges for labour and machinery etc.) Provided it is mutually established that
the Force Majeure conditions did actually exist.
c) If any of the Force Majeure conditions exists in the place of operation of the bidder
even at the time of submission of bid he will categorically specify them in his bid
and state whether they have been taken into consideration in their quotations.
17.3 The contractor or the owner shall not be liable for delays in performing his obligations
resulting from any force majeure cause as referred to and/or defined above. The date
of completion will, subject to hereinafter provided, be extended by a reasonable time
even though such cause may occur after contractor’s performance of his obligations
has been delayed for other causes.
18.0 DELAYS BY OWNER OR HIS AUTHORISED AGENT

18.1 In case the contractor’s performance is delayed due to any act of omission on the part
of the owner or his authorized agents, the contractor shall be given due extension of
time for the completion of the works, to the extent such omission on the part of the
owner has caused delay in the contractor’s performance of his work. Regarding
reasonableness or otherwise of the extension of time, the decision of the engineer
shall be final.
18.2 In addition, the contractor shall be entitled to claim demonstrable and reasonable
compensation if such delays have resulted in any increase in the cost of work. The
owner shall examine the justification for such a request for claim, and if satisfied, the
extent of compensation shall be mutually agreed depending upon the circumstances at
the time of such an occurrence.
18.3 Any delay in finalisation of mutual agreement in regard to any of the contractor’s
claim/compensation against any act of omission on the part of the owners or his
authorised agents should not result in any work stoppage/further delay on the part of
the contractor.
19.0 EXTENSION OF DATE OF COMPLETION

19.1 On happening of any events causing delay as stated hereinafter, the contractor shall
intimate immediately in writing the Engineer-in-charge:
a) due to any reason defined as Force Majeure .

b) non-availability of stores which are the responsibilities of the owner to supply
c) non-availability or breakdown of tools and plant to be made available or made
available by the owner
d) delay on the part of the contractors or tradesmen engaged by the owner not
forming part of the contract, holding up further progress of the work
e) non-availability of working drawings/work programme in time, which are to be
made available by the company during progress of the work
f) any other causes which, at the sole discretion of the company is beyond the
control of the contractor.
19.2 A “Hindrance Register” shall be maintained by both the Company and the Contractor
at site to record various hindrances, as mentioned above, encountered during the
course of execution.
19.3 The contractor may request the company in writing for extension of time within 14
days of happening of such event causing delay stating also, if practicable, the period
of which extension is desired. The company may, considering the eligibility of the
request, give a fair and reasonable extension of time for completion of the work. Such
extension shall be communicated to the contractor in writing by the company through
the engineer-in-charge within 1 month of the date of receipt of such request. The
contractor shall however use his best efforts to prevent or make good the delay by
putting his endeavors constantly as may be reasonably required of him to the
satisfaction of the Engineer-in-charge.
19.4 Provisional extension of time may also be granted by the Engineer-in-charge during
the course of execution, on written request for extension of time within 15 (Fifteen)
days of happening of such events as stated above, reserving the company’s right to
impose/waive liquidated damages at the time of granting final extension of time as per
contract agreement.
19.5 When the period fixed for the completion of the contract is about to expire, the
question of extension of the contract may be considered at the instance of the
Contractor of or the Company or the both. The extension will have to be by party’s
agreement, expressed or implied.
19.6 In case the contractor does not apply for grant of extension of time within 15 (fifteen)
days of hindrance occurring in execution of the work and the Company wants to
continue with the work beyond the stipulated date of completion for reason of the
work having been hindered, the Engineer-in-charge at his sole discretion can grant
provisional extension of time even in the absence of application from the Contractor.
Such extension of time granted by the Engineer-in-charge is valid provided the
Contractor accepts the same either expressly or implied by his actions before and
subsequent to the date of completion. Such extension of time shall be without
prejudice to Company’s right to levy compensation under the relevant clause of
contract.
20.0 TERMINATION, SUSPENSION, CANCELLATION & FORECLOSURE OF

CONTRACT
20.1 The owner shall, in addition to other remedial steps to be taken as provided in the
conditions of contract, be entitled to cancel the contract in full or in part, if the
contractor
a) makes default in proceeding with the works with due diligence and continues to do so
even after a notice in writing from the Engineer-in-charge, then on the expiry of the
period as specified in the notice OR
b) commits default/breach in complying with any of the terms and conditions of the
contract and does not remedy it or fails to take effective steps for the remedy to the

satisfaction of the Engineer-in-charge, then on the expiry of the period as may be
specified by the Engineer-in-charge in a notice in writing
OR
c) fails to complete the work or items of work with individual dates of completion, on
or before the date/dates of completion or as extended by the company, then on the
expiry of the period as may be specified by the Engineer-in-charge in a notice in
writing
OR
d) shall offer or give or agree to give any person in the service of the company or to any
other person on his behalf any gift or consideration of any kind as an inducement or
reward for act/acts of favour in relation to the obtaining or execution of this or any
other contract for the company. OR
e) shall try to obtain a contract with the company by way of ring tendering or other
non-bonafide method of competitive tendering
OR
f) transfers, sublets, assigns the entire work or any person there of without the prior
approval in writing from the engineer- in- charge. The engineer- in -charge may by
giving a written notice, cancel the whole contract or portion of it in default.
20.2 The owner shall in such an event give 15 (fifteen) days notice in writing to the
contractor of his decision to do so.
20.3 The contractor upon receipt of such notice shall discontinue the work on the date and
to the extent specified in the notice, make all reasonable efforts to obtain cancellation
of all orders and contracts to the extent they are related to the work terminated and to
the terms satisfactory to the owner, stop all further sub-contracting or purchasing
activity related to the work terminated, and assist the owner in maintenance,
protection, and disposition of the works acquired under the contract by the owner.
20.4 The contract shall stand terminated under the following circumstances unless the
owner is satisfied that the legal representatives of the individual contractor or of the
proprietor of the proprietary concern and in the case of partnership, the surviving
partners, are capable of carrying out and completing the contract and the owner shall
in any way not be liable to payment of any compensation to the estate of deceased
contractor and/or to the surviving partners of the contractor’s firm on account of the
termination of contract:
a) If the contractor being an individual in the case of proprietary concern or in

the case of a partnership firm any of its partners is declared insolvent under the
provisions of insolvency act for the time being in force, or makes any
conveyance or assignment of his effects or composition or arrangement for the
benefit of his creditors amounting to proceedings for liquidation or
composition under any insolvency act.
b) In case of the contractor being a company, its affairs are under liquidation
either by a resolution passed by the company or by an order of court, not being
a voluntary liquidation proceedings for the purpose of amalgamation or re-
organization, or a receiver or manager is appointed by the court on the
application by the debenture holders of the company, if any.
c) If the contractor shall suffer an execution being levied on his/their goods,
estates and allow it to be continued for a period of 21 days.
d) On the death of the contractor being a proprietary concern or any of the
partners in the case of a partnership concern and the company is not satisfied
that the legal representative of the deceased proprietor or the other surviving
partners of the partnership concern are capable of carrying out and completing
the contract. The decision of the company in this respect shall be final and

binding which is to be intimated in writing to the legal representative or to the
partnership concerned.
20.5 If the contractor is an individual or a proprietary concern and the individual or the
proprietor dies and if the contractor is a partnership concern and one of the partners
dies, then unless the owner is satisfied that the legal representatives of the individual
contractor or of the proprietor of the proprietary concern and in the case of partnership
the surviving partners, are capable of carrying out an completing the contract the
owner shall be entitled to cancel the contract as to its incomplete part without being in
any away liable to payment of any compensation to the estate of deceased contractor
and / or to the surviving partners of the contractor’s firm on account of the
cancellation of the contract.
The decision o f the owner that the legal representatives of the deceased contractor or
surviving partners of the contractor’s firm cannot carry out and complete the contract
shall be final and binding on the parties. In the event of such cancellation, the owner
shall not hold the estate of the deceased contractor and / or the surviving partners of
the estate of the deceased contractor and / or the surviving partners of the contractor’s
firm liable to damages for not completing the contract.
20.6 On cancellation of the contract or on termination of the contract, the Engineer-in -
charge shall have powers
a) to take possession of the site and any materials, constructional plant, implements,
stores etc., thereon.
b) to carry out the incomplete work by any means at the risk of the contractor
c) to determine the amount to be recovered from the contractor for completing the
remaining work or in the event the remaining work is not to be completed the loss
/ damage suffered, if any, by the company after giving credit for the value of the
work executed by the contractor upto the time of termination / cancellation less on
a/c payments made till date and value of contractor’s materials, plant, equipment
etc., taken possession of after termination / cancellation.
d) to recover the amount determined as above, if any, from any moneys due to the
contractor or any account or under any other contract and in the event of any
shortfall, the contractor shall be called upon to pay the same on demand.
The need for the determination of amount of recovery of any extra cost /
expenditure or of any loss / damage suffered by the company shall not however
arise in the case of termination of the contract for death / demise of the contractor
as stated in 20.4(d)
20.7 Suspension of work- The company shall have power to suspend the progress of work
or any part there of and the Engineer-in-charge may direct the contractor in writing to
suspend the work, for such period and in such manner as may be specified therein, on
account of any default on the part of the contractor, or for proper execution of the
work for reasons other than any default on the part of the contractor , or on ground of
safety of the work or part there of. In the event of suspension for reason other than
any default on the part of the contractor, extension of time shall be allowed by the
company equal to the period of such suspension. Any necessary and demonstrable
cost incurred by the contractor as a result of such suspension of the works will be paid
by the owner, provided such costs are substantiated to the satisfaction of the engineer.
The owner shall not be responsible for any liabilities if suspension or delay is due to
some default on the part of the contractor or his sub contractor.
The work shall, throughout the stipulated period of contract, be carried out with all
due diligence on the part of the contractor. In the event of termination or suspension

of the contract, on account of default on the part of the contractor, as narrated
hereinbefore, the security deposit and other dues of this work or any other work done
under this company shall be forfeited and brought under the absolute disposal of the
company provided, that the amount so forfeited shall not exceed 20% of the contract
value.
20.8 Foreclosure of contract in full or in part – If at any time after acceptance of tender,
the company decides to abandon or reduce the scope of work for any reason
whatsoever the company through its Engineer-in-charge, shall give notice in writing
to that effect to the contractor. In the event of abandonment / reduction in the scope
of work, the company shall be liable:
a) to pay the contractor at the contract rates full amount for the works executed and
measured at site up to the date of such abandonment / reduction in the work.
b) to pay reasonable amount assessed and certified by the engineer in charge of the
expenditure incurred, if any, by the contractor on preliminary works at site e.g.
temporary access roads, temporary construction for labour and staff quarters,
office accommodation, storage of materials, water storage tanks, and supply for
the work including supply to labour / staff quarters, office etc.
c) to pay for the materials brought to site or to be delivered at site, which the
contractor is legally liable to pay, for the purpose of consumption in works carried
out or were to be carried out but for the foreclosure, including the cost of purchase
and transportation and cost of delivery of such materials. The materials to be
taken over by the company should be in good condition and the company may
allow at its discretion the contractor to retain the materials in full or part if so
desired by him and to be transported by the contractor from site to his place.
d) to take back the materials issued by the company but remaining unused, if any, in
the work on the date of abandonment / reduction in the work, at the original issued
price less allowance for any deterioration or damaged caused while in custody of
the contractor.
e) to pay for the transportation of tools and plants of the contractor from site to
contractor’s place or to any other destination , which ever is less.
The contractor shall if required by the Engineer-in-charge, furnish to him books of

accounts, papers, relevant documents as may be necessary to enable the engineer -
in -charge to assess the amount payable in terms of Para 20.8(b), (c ) and (e)
above, the contractor shall not have any claim for compensation whatsoever either
for abandonment or for reduction in the scope of work, other than those as
specified above.
21.0 NO WAIVER OF RIGHTS
Neither the inspection by the owner or the engineer or any of their officials,
employees or agents nor any order by the owner or the engineer for payment of
money or any payment for or acceptance of , the whole or any part of the works by
the owner or by the engineer , nor any extension of time, nor any possession taken by
the engineer shall operate as a waiver of any provision of the contract, or of any
power herein reserved to the owner, or any right to damages herein provided, nor shall
any waiver or any breach in the contract be held to be a waiver of any other
subsequent breach.

22.0 CERTIFICATE NOT TO AFFECT RIGHT OF OWNER AND LIABILITY OF
CONTRACTOR:
No interim payment certificate of the engineer, nor any sum paid on account, by the
owner, nor any extension of time for execution of the works granted by the engineer
shall affect or prejudice the rights of the owner against the contractor or relieve the
contractor of his obligations for the due performance of the contract, or be interrupted
as approval of the works done or of the equipment furnished and no certificate shall
create liability for the owner to pay for alterations, amendments, variations or
additional works not ordered, in writing, by the engineer or discharge the liability of
the contractor for the payment of damages whether due, ascertained, or certified or
not, for any sum against the payment of which he is bound to indemnify the owner,
nor shall any such certificate nor the acceptance by him of any sum paid on account or
otherwise affect of prejudice the rights of the contractor against the owner.
23.0 GRAFTS AND COMMISSIONS ETC.

Any graft, commission, gift or advantage given, promised or offered by or on behalf
of contractor or his partner, agent, officers, director, employee or servant or any one
of his or their behalf in relation to the obtaining or to the execution of this or any other
contract with the owner, shall in addition to any criminal liability which it may incur
subject the contractor to the cancellation of this and all other contracts and also to
payment of any loss or damage to the owner resulting from any cancellation. The
owner shall then be entitled to deduct the amount so payable from any moneys other
wise due to the contractor under the contract.
24.0 LANGUAGE AND MEASURES

All documents pertaining to the contract including specifications , schedules notices,
correspondence, operating and maintenance instructions, drawings or any other
writing shall be written in English language. The metric system of measurement shall
be used exclusively in the contract.
25.0 RELEASE OF INFORMATION

The contractor shall not communicate or use in advertising, publicity, sales releases or
any other medium photographs or other reproduction of the works under this contract,
or descriptions of the site, dimension, quantity, quality or other information,
concerning the works unless prior written permission has been obtain from the owner.
26.0 CONSTRUCTION OF THE CONTRACT

26.1 Not withstanding any thing stated elsewhere in the bid documents, the contract to be
entered into will be treated as divisible supply and erection contract. The supply
portion of the contract will relate to the supply of equipment and materials and the
erection portion will relate to the handling at the site, storage, erection, construction,
testing, commissioning etc. as defined in the bid documents. The contractor will pay
the sales tax for the supply of equipment and materials in accordance with law and
the same will be reimbursed by the owner as a part of the total contract price on
actuals. The Sales tax should be included in the total bid price in the proposal and
should also be indicated separately.
26.2 In case of divisible supply and erection contract, or where the owner hands over his
equipment to the contractor for executing, then the contractor shall at the time of
taking delivery of the equipment/despatch documents be required to execute an
indemnity bond in favour of the owner in the form acceptable to the owner for

keeping the equipment in safe custody and to utilise the same exclusively for the
purposes of the said contract.
26.3 The contract shall in all respects be construed and governed accordingly to Indian
Laws.
26.4 It is clearly understood that the total consideration for the contract(s) has been broken
up into various components only for the convenience of payment of advance under
the contract(s) and for the measurement of deviations or modifications under the
contracts(s).
27.0 COMPLETION OF CONTRACT

Unless otherwise terminated under the provisions of any other relevant clause, this
contract shall be deemed to have been completed at the expiration of the guarantee
period as provided for under the clause entitled ‘Guarantee’ in this section.
28.0 ENFORCEMENT OF TERMS

The failure of either party to enforce at any time of the provisions of this contract or
any rights in respect there to or to exercise any option herein provided, shall in no
way be construed to be a waiver of such provisions, rights or options or in any way to
affect the validity of contract. The exercise by either party of any of its rights herein
shall not preclude or prejudice either party from exercising the same or any other right
it may have hereunder.
29. 0 ENGINEER’S DECISION

29.1 In respect of all matters which are left to the decision of the engineer including the
granting or withholding of the certificates, the engineer shall , if required to do so by
the contractor give in writing a decision thereon.
29.2 If in the opinion of the contractor, a decision made by the engineer is not in
accordance with the meaning and intent of the contract, the contractor may file with
the engineer with in fifteen(15) days after receipt of the decision, a written objection
to the decision. Failure to file an objection with in the allotted time will be considered
as acceptance of the engineer’s decision and the decision shall become final and
binding.
29.3 The engineer’s decision and the filing of the written objection thereto shall be a
condition precedent to the right to any legal proceedings. It is the intent of the
agreement that there shall be no delay in the execution of the works and the decision
of the engineer as rendered shall be promptly observed.
30.0 CO-OPERATION WITH OTHER CONTRACTORS AND CONSULTING

ENGINEERS:
The contractor shall agree to co-operate with the owner’s other contractors and
consulting engineers and freely exchange with them such technical information as is
necessary to obtain the most efficient and economical design and to avoid
unnecessary duplication of efforts. The engineer shall be provided with three copies
of all correspondence addressed by the contractor to other sub-contractors and
consulting engineers in respect of such exchange of technical information.
31.0 TRAINING OF OWNER’S PERSONNEL :

31.1 The contractor shall undertake to train, engineering personnel selected and sent by the
owner at the works of the contractor unless otherwise specified in the technical
specifications. These engineering personnel shall be given special training in the
shops where the equipment will be manufactured and / or their collaborator’s works
and where possible, in any other plant where equipment manufactured by the

contractor or his collaborator is under installation or test, to enable those personnel to
become familiar with the equipment being furnished by the contractor.
31.2 All traveling and living expenses for the engineering personnel to be trained during
the total period of training will be borne by the owner. These engineering personnel
while undergoing training shall be responsible to the contractor for discipline
31.3 In the event of the owner, for any reason, failing to avail of the training facilities, he
shall not be entitled for any rebate whatsoever on this account.
32.0 POWER TO VARY OR OMIT WORK

32.1 No alterations, amendments, omissions, suspensions or variations of the works (herein
after referred to as ‘variation’) under the contract as detailed in the contract
documents, shall be made by the contractor except as directed in writing by the
engineer, but the engineer shall have full power subject to the provision hereinafter
contained from time to time during the execution of the contract, by notice in writing,
to instruct the contractor to make such variation without prejudice to the contract.
The contractor shall carry out such variation and be bound by the same conditions as
far as applicable as though the said variation occurred in the contract documents. If
any suggested variation would, in the opinion of the contractor, if carried out, prevent
him from fulfilling any of his obligations or guarantees under the contract, he shall
notify the engineer there of in writing and the engineer shall decide forthwith, whether
or not the same shall be carried out and if the engineer confirm his instructions,
contractor’s obligations and guarantees shall be modified to such an extent as may be
mutually agreed. Any agreed difference in cost occasioned by any such variation
shall be added to or deducted from the contract price as the case may be.
32.2 In the event of the engineer requiring any variation, such reasonable and proper notice
shall be given to the contractor to enable him to work his arrangements accordingly,
and in cases where goods or materials are already prepared or any design, drawings of
pattern made or work done requires to be altered, a reasonable and agreed sum in
respect there of shall be paid to the contractor.
32.3 In any case in which the contractor has received instructions from the engineer as to
the requirement of carrying out the altered or additional substituted work which either
then or later on, will in the opinion of the contractor, involve a claim for additional
payments, the contractor shall immediately and in no case later than thirty (30) days,
after receipt of the instructions aforesaid and before carrying out the instructions,
advise the engineer to that effect. But the engineer shall not become liable for the
payment of any charges in respect of any such variations, unless the instructions for
the performance of the same shall be confirmed in writing by the engineer.
32.4 If any variation in the works, results in reduction of contract price, the parties shall,
agree, in writing, so to the extent of any change in the price, before in contractor
proceeds with the change.
32.5 In all the above cases, in the event of a disagreement as to the reasonableness of the
said sum, the decision of the engineer shall prevail.
32.6 Notwithstanding anything stated above in this clause, the engineer shall have the full
power to instruct the contractor, in writing, during the execution of the contract, to
vary to quantities of the items or groups of items. The contractor shall carry out such
variations and be bound by the same conditions, as though the said variations
occurred in the contract documents. However, the contract price shall be adjusted at
the rates and prices provided for the original quantities in the contract.
33.0 GUARANTEE
33.1 The contractor shall warrant that the equipment will be new and in accordance with
the contract documents and be free from defects in material and workmanship for a

period of twelve(12) calendar months commencing immediately upon the satisfactory
completion of the trial operations. The contractor’s liability shall be limited to the
replacement of any defective parts in the equipment of his own manufacture of those
of his sub-contractors, under normal use and arising solely form faulty design,
materials, and / or workmanship provided always that such defective parts are
repairable at the site and are not in the meantime essential in the commercial use of
the plant. Such replaced defective parts shall be returned to the contractor unless
otherwise arranged. No repairs or replacements shall normally be carried out by the
engineer when the plant is under the supervision of the contractor’s supervisory
engineers.
34.0 REPLACEMENT OF DEFECTIVE PARTS AND MATERIALS:

34.1 If during the progress of the works the engineer shall decide and inform in writing to
the contractor, that the contractor has manufactured any plant or part of the plant
unsound or imperfect or has furnished any plant inferior than the quality specified, the
contractor on receiving details of such defects or deficiencies shall at his own expense
within seven (7) days of his receiving the notice, or otherwise, within such time as
may be reasonably necessary for making it good, proceed to alter, re-construct or
remove such work and furnish fresh equipment up to the standards of the
specifications. In case the contractor fails to do so, the engineer may on giving the
contractor seven (7) days notice in writing of his intentions to do so, proceed to
remove the portion of the works so complained of and , at the cost of the contractor,
perform all such work or furnish all such equipment provided that nothing in this
clause shall be deemed to deprive the owner of or affect any rights under the contract
which the owner may otherwise have in respect of such defects and deficiencies.
34.2 The contractor’s full and extreme liability under this clause shall be satisfied by the
payments to the owner of the extra cost, of such replacement procured, including
erection, as provided for in the contract, such extra cost being the ascertained
difference between the price paid by the owner for such replacements and the contract
price portion for such defective plant and repayments of any sum paid by the owner to
the contractor in respect of such defective plant. Should the owner not so replace the
defective plant, the contractor’s extreme liability under this clause shall be limited to
repayment of all sums paid by the owner under the contract for such defective plant.
35.0 DEFENCE OF SUITS

If any action in court is brought against the owner or engineer or an officer or agent
of the owner for the failure or neglect on the part of the contractor to perform any
acts, matters, covenants or things under the contract or for damage or injury caused by
the alleged omission or negligence on the part of the contractor, his agents,
representatives or his sub-contractors, workmen, suppliers or employees, the
contractor shall in all such cases indemnify and keep the owner, and the engineer and
/ or his representative, harmless from all losses, damages, expenses or decrees arising
of such action;
36.0 LIMITATIONS OF LIABILITIES

The final payment by the owner in pursuance of the contract shall mean, the release of
the contractor from all his liabilities under the contract. Such final payment shall be
made only at the end of the guarantee period as detailed in clause 33 above and till
such time as the contractual liabilities and responsibilities of the contractor, shall
prevail. All other payments made under the contract shall be treated as on account
payments.

37.0 MARGINAL NOTES
The marginal notes to any clause of the contract shall not affect or control the
construction of such clause.
38.0 TAXES, PERMITS & LICENCES

The contractor shall be liable and pay all-Indian taxes, duties, levies, lawfully
assessed against the owner or the contractor in pursuance of the contract. In addition
the contractor shall be responsible for payment of all Indian duties, levies and taxes
lawfully assessed against the contractor for his personal income and property only.
This clause shall be read in conjunction with clause 12.3 of section Instruction to
Bidders.
39.0 PROGRESS REPORTS AND PHOTOGRAPHS

During the various stages of the works in the pursuance of the contract, the contractor
shall at his own cost submit periodic progress reports as may be reasonably required
by the engineer with such materials as charts, net-works, photographs, test
certificates, etc. such progress report shall be in the form and size as may be required
by the engineer and shall be submitted in at least three (3) copies.
40.0 LONG TERM AVAILABILITY OF SPARES

40.1 The contractor shall guarantee the long term availability of spares to the owner for the
full life of the equipments covered under the contract. The contractor shall guarantee
that before going out of production of spare parts of the equipment covered under the
contract, he shall give the owner at least twelve (12) months advance notice so that
the latter may order his bulk requirement of spares, if he so desires. The same
provision will also be applicable to sub-contractor. Further, in case of discontinuance
of manufacture of any spares by the contractor or his sub-contractors the contractor
will provide the owner two years in advance, with full manufacturing drawings,
material specifications and technical information required by the owner for the
purpose of manufacture of such items.
40.2 Further, in case of discontinuance of supply of spares by the contractor or his sub-
contractors the contractor will provide the owner with full information for
replacement of such spares with other equivalent makes, if so required by the owner.
40.3 The contractor shall provide the owner with a “directory” of his sub-contractors
giving the addresses and other particulars of his sub-contractors. The owner, if he so
desires, shall have the right to procure the spares directly from sub-contractors.
40.4 Notwithstanding anything stated elsewhere in the bid documents, the prices of all
spares which may be procured to cover long term requirements beyond the 2 years
maintenance and operational requirements will be generally in accordance with the
mutually agreed prices.
40.5 The contractor will indicate in advance the delivery period of the items of spares,
which the owner may procure in accordance with the sub-clause 40.4. In case of
emergency requirements of spares, the contractor would make every effort to expedite
the manufacture and delivery of such spares on the basis of mutually agreed time
schedule.
40.6 The procedure specified in clause 40.4 and 40.5 shall apply for future procurement of
items included in stand by spare list, mandatory spares lists, optional spares list and
special tools, plants and equipment list, if any, specified in the bid documents.
40.7 The contractor shall indemnify the owner for the availability of long time spares as
per the terms and conditions laid down above in clause 40.1 to clause 40.6.

41.0 PAYMENT
41.1 The payment to the contractor for the performance of the work under the contract will
be made by the owner as per the guidelines and conditions specified herein. All
payment made during the contract shall be on account payments only. The final
payment will be made on completion of all the works and on fulfillment by the
contractor of all his liabilities under the contract.
41.2 CURRENCY OF PAYMENT
All payments under the contract shall be in Indian Rupees only.
41.3 DUE DATES FOR PAYMENT
Owner will make progressive payment as and when the payment is due as per the
terms of payment set forth in the accompanying technical specifications. Payment will
become due and payable by the owner within thirty (30) days from the date of receipt
of contractor’s bill/invoice/debit note by the owner, provided the documents
submitted are complete in all respects.
41.4 PAYMENT SCHEDULE
The contractor shall prepare and submit to the engineer for approval, a break-up of the
contract price. This contract price break-up shall be interlinked with the agreed
detailed PERT network of the contractor setting forth his starting and completion
dates for the various key phases of works prepared as per condition of the section.
Any payment under the contract shall be made only after the contractor’s price break-
up is approved by the engineer. The aggregate sum of the contractor’s price break-up
shall be equal to the lump sum contract price.
41.5 APPLICATION FOR PAYMENTS

41.5.1 The contractor shall submit application for the payment in the prescribed proforma of
the owner.
41.5.2 Each such application shall state the amount claimed and shall set forth in detail, in
the order of the payment schedule, particulars of the works including the works
executed at site and of the equipment brought on to the site pursuant to the contract
upto the date mentioned in the application and for the period covered since the last
preceding certificate, if any.
41.5.3 Every interim payment certificate shall certify the contract value of the works
executed upto the date mentioned in the application for the payment certificate,
provided that no sum shall be included in any interim payment certificate in respect of
the works that according to the decision of the engineer, does not comply with the
contract, or has been performed, at the date of certificate prematurely.
41.6 MODE OF PAYMENT

The payments due on receipt of equipment and materials, and those for the inland
transportation and the erection portion of the works shall be made direct to the
contractor by the owner.
41.7 TERMS OF PAYMENTS

41.7.1 The terms of payment for the price components of the equipment and its erection are
detailed herein for each equipment package. A certain percentage of the equipment

and erection costs, for each package shall be paid as initial advance on fulfillment of
the following by the contractor :
i) FOR THE PRICE-COMPONENT OF EQUIPMENT

a) Issue of letter of acceptance of tender
b) Submission of an unconditional Bank Guarantee covering the advance amount
which shall be initially kept valid till expiry of the month after the schedule
date for successful completion of trial operations. The proforma of Bank
Guarantee for advance is enclosed. The value of Bank Guarantee ( other
security ) for advance shall be allowed to be reduced every six months after
first running account bill / stage payment under the contract, if the value of
such B.G. (Security) is more than Rupees Five (5) lacs and validity is more
than one year. The cumulative amount of reduction at any point of time shall
not exceed 75% of the advance corresponding to cumulative value of supplies
/ work completed as per a certificate to be issued by the engineer-in-charge. It
should be clearly understood that the reduction in the value of advance bank
guarantee or other security as above shall not in any way dilute the
contractor’s responsibilities and liabilities under the contract including in
respect of supplies/ work for which the reduction in the value of bank
guarantee ( or other security) is allowed.
c) Submission of an unconditional bank guarantee towards contract performance
guarantee valid up to ninety (90) days after the end of the guarantee period, in
accordance with clause 33.0.
d) Submission of a detailed PERT network based on the work- schedule
stipulated in the letter of award and its approval by owner.
ii) FOR THE ERECTION PRICE COMPONENT

a) On establishment of his office at site preparatory to mobilization of his
erection establishment.
b) Submission of an unconditional bank guarantee for an equivalent amount,
which shall be initially kept valid till expiry of the month after schedule date
for successful completion of trial operations. The proforma of bank guarantee
for advance is enclosed.
c) Signing of contract agreement.
41.7.2 All payments under the contract shall be made as stipulated in the technical
specifications after signing the contract agreement. The payments linked with the
materials shall be made only after receipt and inspection of the materials including all
the documents as indicated at Clause No.11.4 of General Terms & Condition. In case
of erection, progress payments shall only be made after the issue certificates by the
engineer’s field quality surveillance representative for the successful completion of
quality check points involved in the quantum of work billed.
41.7.3 INLAND TRANSPORTATION AND INSURANCE

Inland transportation (including port handling) and inland insurance charges shall be
paid to the contractor on pro-rata to the value of the equipment received at site on
production of the invoices by the contractor. However, wherever equipment wise
inland transportation charges have been called for in the bid proposal sheets and have
been furnished by the contractor, the payment of inland transportation charges shall
be made after receipt of equipment at site based on charges thus identified by the
contractor in his proposal and incorporated in the contract. The aggregate of all such

pro-rata payments shall however, not exceeds the total amount quoted by the bidder in
his bid and incorporated in the contract.
42.0 SETTLEMENT OF DISPUTES

It is incumbent upon the contractor to avoid litigation and disputes during the course
of execution. However, if such disputes take place between the contractor and the
department, effort shall be made first to settle the disputes at the company level.
The contractor should make request in writing to the Engineer-in-charge for
settlement of such disputes/ claims within 30 ( thirty) days of arising of the cause of
dispute / claim failing which no disputes / claims of the contractor shall be entertained
by the company.
If differences still persist, the settlement of the dispute with Govt. Agencies shall be
dealt with as per the Guidelines issued by the Ministry of Finance, Govt. of India in
this regard. In case of parties other than Govt. Agencies, the redressal of the dispute
may be sought in the Court of Law.
43.0 SALES TAX ON WORKS CONTRACTS

All taxes, levies, cess, royalties, whether local, muncipal or central pertaining to the
contract are payable during the entire periods of contract, shall be to the contractor /
contractors account and shall be deemed to have been included in the contracted rate
for the work to be executed by the contractor. The Company shall not be liable for
any taxes or levies etc. whatsoever in connection with this contract.
The company reserves the right to deduct / withhold any amount towards taxes,
levies, etc. and to deal with such amount in terms of the provisions of the Statute or in
terms of the direction of any Statutory authority and the company shall only provide
with certificate towards such deduction and shall not be responsible for any reason
whatsoever.

ADDITIONAL TERMS & CONDITIONS OF CONTRACT
The following additional terms & conditions are also acceptable to the company. The Bidders
are requested not to quote any additional conditions in their tender.
1.0 MOBILISATION ADVANCE :
i) In the case of works whose estimated value is more than Rs 100.00 lakhs,
a maximum of 10% of the total contract value of work will be paid as
advance subject to submission of Bank Guarantee for equal amount.
ii) Mobilisation Advance against survey, soil investigation, design and
engineering will be paid in two equal installments – one after signing of
the agreement and the second after the system design drawings have been
completed and detailed design work is to be taken up by the contractor.
iii) Mobilisation Advance against supply of equipments shall be released only
after the contractor has finalised their vendors / suppliers for the specific
equipment and the amount of advance shall be proportionate to the value
of equipment for which vendors / suppliers have been finalised vis-à-vis
the total value of equipments offered in the contract limited to 10% of the
contract value.
iv) Mobiilisation Advance against works contract for site activities shall be
paid in two equal installment. First installment shall be paid after the
contractor has opened their site office and having finalised their
subcontractors. The second installment shall be paid for taking
procurement action of construction materials like reinforcing steel and
structural steel by the contractor.
v) The mobilisation advance shall be recovered from the bills of the
contractor from the second running on account bills onward @ 20% of the
advance amount paid.
vi) The value of Bank Guarantee may be reduced to the extent such advance is
recovered by the company subject to the conditions that the value of Bank
Guarantee amount at any time is more than the recoverable outstanding
advance. Bank Guarantee shall be irrevocable and from a Bank listed at
Annexure-X.
vii) Interest on mobilisation advance will be charged as per the rate of CIL’s
borrowing rate under cash credit arrangement as varying from time to
time.
viii) In case of “Machinery & Equipment Advance”, insurance & hypothecation
to be done by the contractor in the name of Mahanadi Coalfields Limited,
Sambalpur.
ix) Utilisation Certificate from the contractor for the mobilization Advance
shall be obtained. Mobilisation Advance shall be given to the Contractor in
installments as explained above and subsequent installments shall be
released after getting satisfactory utilization certificate from the contractor
for the earlier installment.
2.0 PRICE VARIATION CLAUSE :

2.1 The contract price shall remain firm without any price variation due to escalation for
the portions of survey geo-engineering investigations, design and engineering and
supply of equipments, plant and machineries as envisaged in the scope of work and

the price agreed thereon as per the contract except the statutory increase / decrease in
taxes and duties such as excise duty, sales tax, import duty etc.
2.2 If the contract is to be extended beyond the stipulated period for completion of the
work due to fault on the part of the contractor escalation on prices should not be
allowed further if not provided otherwise in the accepted contract.
2.2.0 For the portions of civil & structural works and erection and commissioning works of
the plant & machineries, the price variation due to escalation shall be allowed to the
extent as detailed hereinafter.
2.2.1 If the prices of materials ( not being materials supplied at fixed issue rates by the
company) and wages of labour, required for execution of the work, increase, the
contractor shall be compensated for such increase as per provisions detailed below :
a) The amount of the contract shall accordingly be varied, subject to the condition
that such compensation for variation in prices shall be available only for the
work done during the stipulated period of the contract as per the work
programme agreed including such period for which the contract is validly
extended under the provisions of the contract without any penal action.
b) The base date for working out such price variation shall be thirty (30) days prior
to the date set for opening of the bids or the revised price bid which ever is later.
c) The compensation of Price variation shall be worked out at quarterly intervals

and shall be with respect to the cost of work done during the previous three
months. The first such payment shall be made at the end of three months after
the month ( Excluding) in which the tender was accepted and thereafter at three
months interval.
2.2.1.1 PRICE VARIATION FOR LABOUR
The amount paid to the contractor for the work done shall be adjusted for increase or
decrease in the cost of labour and the cost shall be calculated quarterly in accordance
with the following formula :
A L - Lo
VL = W x ____ x _____
100 Lo
Where
VL = Variation in labour cost i.e. increase or decrease in the amount in rupees to be

paid or recovered.
W = Value of work done during the period under reckoning to which the price
variation relates as indicated in clause No.2.3 of the “ ADDITIONAL TERMS
& CONDITIONS OF CONTRACT”
A = Component of labour expressed as percentage of the total value of work adopted
from Table-1.
Lo = Minimum wages for unskilled workers payable as per the Minimum Wages Act
/ Rules of the State or Central Government., whichever is more applicable to
the place of work as on the last date stipulated for receipt of the Price bids or
Revised Price bids whichever is later.
L = Revised minimum wages of unskilled workers corresponding to Lo during the
period to which the escalation relates.

2.2.1.2 PRICE VARIATION ON MATERIALS :
The amount to be paid to the contractor for the work done shall be adjusted for
increase or decrease in the cost of materials and the cost shall be calculated
quarterly in accordance with the following formula :
B M - Mo
Vm = W x ____ x _______
100 Mo
Where :
Vm = Variation in material cost i.e. increase or decrease in the amount in rupees to be

paid or recovered.
B = Component of material expressed as percentage of the total value of work
adopted from Table-1.
M = Average All India Wholesale Price Index for all commodities for the period to
which price variation relates as published by the RBI Bulletin, Ministry of
Industry & Commerce, Govt. of India.
Mo = All India Wholesale Price Index for all commodities as published by the RBI
Bulletin Ministry of Industry & Commerce, Govt. of India, relating to the last
date on which the price bids or revised price bids whichever is later were
stipulated to be received.
2.2.1.3 PRICE VARIATION ON POL

The amount paid to the contractor for the work done shall be adjusted for increase or
decrease in the cost of POL and the cost shall be calculated quarterly in accordance
with the following formula :
C F - Fo
Vf = W x _____ x ______
100 Fo
Where
Vf = Variation in cost of fuel, oil & lubricants increase or decrease in the amount in
rupees to be paid or recovered.
C = Component of POL expressed as percentage of total value of work adopted
from Table-1.
F = Average Index Number for Wholesale Price for the group of fuel, power, light
and lubricants” as published by Economic Advisor, Ministry of Industry, Govt.
of India for the period to which escalation / de-escalation relates.
Fo = Index Number for Wholesale Price for the group of “Fuel, power, light and
lubricants” as published by Economic Advisor, Ministry of Industry, Govt. of
India prevalent on the last date of receipt of price bids or revised price bids
whichever is later.

2.3 WHILE CALCULATING THE VALUE OF “W” THE FOLLOWING MAY
BE NOTED :
The cost on which the escalation / price variation shall be payable shall be reckoned
as 85% of the cost of work as per the bills to which escalation relates, and from this
amount the value of materials supplied or services rendered at the prescribed charges
under the relevant provisions of the contract, and proposed to recovered in the
particular bill, shall be deducted before the amount of compensation for escalation /
price variation is worked out. Further the cost shall not include any work for which
payment is made at prevailing market rates.
2.4 In the event of the price materials and / or wages of labour required for execution of
the work decrease, there shall be downward adjustment of the work so that such price
of materials and / or wages of labour shall be deductible from the cost of work under
this contract and in this regard the formulae hereinbefore stated under this clause shall
mutatis / mutandis apply.
For all the other works not listed above, the component of labour, material and POL
of the total cost of work shall be as specifically indicated in the tender document.
The price variation clause as stated above will be applied for extended time frame of a
contract by following the principles as under :-
i) Normally, if and when it is understood that a contract is not going to be

completed within the scheduled time period, the contract is kept operative by
extending the time of completion provisionally . During this provisional
extended period the operation of the Price Variation Clause will remain
suspended.
ii) If and when it is decided at the end of the successful completion of the work
that the delay was due to causes not attributable to the contractor, then the
Price Variation Clause will be revived and applied as if the scheduled date of
completion has been shifted to the approved extended date.
iii) If it is decided at the end of successful completion of the work that the delay
was due to the fault of the contractor then the Price Variation Clause will not
be revived and no payment will be made to the contractor on this account.
Additionally the Clause related to Compensation for delay will be applied.
iv) In some cases the total delay may be partially due to causes not attributable
to the contractor and partially due to his fault. It may be difficult to exactly
quantify the total delay proportionately in such cases. The Price Variation
Clause under such condition will be made operative for the entire extended
time period by freezing the relevant indices on the date of the scheduled date
of completion as originally fixed in the contract / agreement. At the same
time the Clause related to the compensation for delay will be also be applied.

Table – 1
Value of A,B & C in the Price variation formula in the ‘Additional Terms and Conditions of
Contract’
Sl. Particulars A B C Remarks
No. (Labour (Material (POL
component) component) component)
1. For Building works 25 75 NIL
2. For Road works 15 80 05
3. For external sewerage, external
water supply and external
electrification 10 90 NIL
4. For external water supply,
external sanitary and external
electrification (Through labour
rate contract ) 75 25 NIL
5. For steel structural works 15 85 NIL
6. For steel structural works with
Department free supply of
rolled steel sections ( Through
labour rate contract ) 75 25 NIL
7. For Coal Handling Plant Civil
works 25 75 NIL
8. For underground civil works
such as Incline Drivage, Shaft
Sinking etc. 35 65 NIL
9. For erection and
Commissioning of P&M 65 35 NIL
2.5 CEILING ON PRICE VARIATION DUE TO ESCALATION

There shall be a ceiling on price variation due to escalation covered under clauses
mentioned hereinbefore on the whole contract, limited to 10% of the ‘contract price’
only.
2.6 VARIATION IN THE TAXES, DUTIES, LEVIES ETC.

Other statutory variation due to increase in taxes, duties, levies etc. by Govt. (Central
or State or Local ) which is notified after the last date of submission of tender and/or
any increase over the rate existing on the last date of submission of tender shall be
reimbursed by the company on production of documentary evidence in support of
payment actually made to the concerned authorities. Similarly decrease in taxes,
duties, levies etc. shall be returned / deducted to/by the owner.

GENERAL TECHNICAL CONDITIONS
1.0 GENERAL
This part covers technical conditions pursuant to the contract and will form an integral
part of the contract. The following provisions shall supplement all the detailed
technical specifications and requirements brought out in the accompanying technical
specifications. The contractor’s proposal shall be based on the use of equipment and
materials complying fully with the requirements, specified herein. It is recognised
that the contractor may have standardised on the use of certain components,
materials, processes or procedures different that those specified herein. Alternate
proposals offering similar equipment based on the manufacturer’s standard practice
will also be considered provided such proposals meet the specified designs, standard
and performance requirements and are acceptable to the owner.
2.0 LIMIT OF CONTRACT

Equipment furnished shall be complete in every respect with all mountings, fittings,
fixtures and standard accessories normally provided with such equipment and/or
needed for erection, completion and safe operation of the equipment as required by
applicable codes though they may not have been specifically detailed in the technical
specifications unless included in the list of exclusions. All similar standard
components / parts of similar standard equipment provided, shall be inter-changeable
with one another.
3.0 EQUIPMENT PERFORMACNE GUARANTEE

3.1 The performance tests of the equipment under the scope of the contract are detailed in
the technical specifications. These guarantees shall supplement the general
performance guarantee provisions covered under general terms & conditions of
contract in clause entitled “ Guarantee”.
3.2 Liquidated damages for not meeting performance guarantee during the performance
and guarantee tests shall be assessed and recovered from the contractor, as detailed in
the technical specifications. Such liquidated damages shall be without any limitation
whatsoever and shall be in addition to damages, if any, payable under any other
clauses of conditions of contract.
4.0 ENGINEERING DATA

4.1 The furnishing of engineering data by the contractor shall be in accordance with the
schedule for each set of equipment as specified in the technical specifications. The
review of these data by the engineer will cover only general conformance of the data
to the specifications and documents, interfaces with the equipment provided under the
specifications, external connections and of the dimensions which might affect plant
layout. This review by the engineer may not indicate a thorough review of all
dimensions, quantities and details of the equipment, materials, any devices of items
indicated or the accuracy of the information submitted. This review and/or approval
by the engineer shall not be construed by the contractor, as limiting any of his
responsibilities and liabilities for mistakes and deviations from the requirements,
specified under these specifications and documents.
4.2 All engineering data submitted by the contractor after final process including review
and approval by the engineer shall form part of the contract documents and the entire
works covered under these specifications shall be performed in strict conformity,
unless other wise expressly requested by the engineer in writing.

5.0 DRAWING
5.1 All drawings submitted by the contractor including those submitted at the time of bid
shall be sufficiently detailed to indicate the type, size, arrangement, weight of each
component, break-up for packing and shipment the external-connections, fixing
arrangements required, the dimensions required for installation and inter-connections
with other equipment and materials, clearances and spaces required between various
portions of equipment and any other information specifically requested in the
specifications.
5.2 Each drawing submitted by the contractor shall be clearly marked with the name of
the owner, the unit designation, the specifications title, the specifications number and
the name of the project. If standard catalogue pages are submitted the applicable
items shall be indicated therein. All titles, notings, markings and writings on the
drawing shall be in English. All the dimensions should be in metric units.
5.3 The owner may use a 35 mm microfilm system in processing drawings. All drawings
shall be suitable for microfilming, Drawings which are not suitable for microfilming
will not be accepted. A copy of each drawings reviewed will be returned to the
contractor as stipulated herein. The owner may also accept and use floppies/disks for
computer based drawings.
5.3.1 Copies of drawings returned to the contractor will be in the form of a print with the
owner’s marking, or a print made from a microfilm of the marked up drawing or in
the form of aperture cards if the contractor has facilities to process such cards or print
made from floppies for computer based drawings.
5.4 The drawings submitted by the contractor shall be reviewed by the engineer as far as
practicable within four (4) weeks and shall be modified by the contractor if any
modifications and/or corrections are required by the engineer. The contractor shall
incorporate such modifications and/or corrections and submit the final drawings for
approval. Any delay arising out of failure by the contractor to rectify the drawings in
good time shall not alter the contract completion date.
5.5 Approval by the Nodal Officer or his Nominee: the Contractor shall submit
specifications and drawings showing the proposed Temporary works to the Nodal
Officer/Engineer-in-Charge or his Nominee who is to approve them if they comply
with the specifications and drawings. The Contractor shall be responsible for design
of Temporary Works.
The Nodal Officer/Engineer-in-charge or nominee’s approval shall not alter the
contractor’s responsibility for design of the Temporary Works.
5.6 The drawings sent for approval to the engineer shall be in quintuplicate. One print of
such drawings will be returned to the contractor by the engineer marked approved /
approved with corrections. The contractor shall thereupon furnish the owner with nine
prints and one reproducible original of the drawings after incorporating all
corrections.
5.7 Further work by the contractor shall be in strict accordance with these drawings and
no deviation shall be permitted without the written approval of the engineer, if so
required.
5.8 All manufacturing and fabrication work in connection with the equipment prior to the
approval of the drawings shall be at the contractor’s risk. The contractor may make
any changes in the design which are necessary to make the equipment conform, to the
provisions and intent of the contract and such changes will again be subject to
approval by the engineer. Approval of contractor’s drawings or work by the engineer
shall not relieve the contractor of any of his responsibilities and liabilities under the
contract.
5.9 Drawings shall include all installation and detailed piping drawings wherever
applicable. All piping 100 mm and larger shall be routed in detail and smaller pipe

shall be shown schematically or by isometric drawings. All drawings shall be fully
corrected to agree with actual as built construction.
5.10 Operating and Maintenance Manual : If “ as built” drawings and/or operating and
Maintenance Manuals are required the contract shall supply them by the dates stated
in the contract data.
If the Contractor does not supply the drawings and/or Manuals by the dates stated in
the contract data or they do not receive the Nodal Officer or his Nominee’s approval,
the Nodal Officer or his Nominee shall withhold the amount stated in the contract data
from payments due to the contractor.
6.0 INSTRUCTION MANUALS

6.1 The contractor shall submit to the engineer, preliminary instruction manuals for all the
equipment covered under the contract within the time agreed upon between the owner
& the contractor. The final instruction manuals complete in all respects shall be
submitted by the contractor thirty(30) days before the first shipment of the equipment.
The instruction manuals shall contain full details and drawings of all the equipment
furnished, the erection procedures, testing procedures, operation and maintenance
procedures of the equipment. These instruction manuals shall be submitted in the
form of one (1) reproducible original and twelve(12) copies.
6.2 If after the commissioning and initial operation of the plant, the instruction manuals
require any modifications/additions/changes, the same shall be incorporated and the
updated final instruction manuals in the form of one (1) reproducible original and
twelve(12) copies shall be submitted by the contractor to the owner.
6.3 The contractor shall furnish to the owner, twelve(12)sets of spare parts catalogue.
7.0 FIRST FILL OF CONSUMABLE, OILS AND LUBRICATNTS

All the first fill of consumable such as oils, lubricants and essential
chemicals etc, which will be required to put the equipment covered under the scope of
the specifications, into successful trial operation, shall be furnished by the contractor
unless specifically excluded under the exclusions in the specifications and other
documents.
8.0 MANUFACTURING SCHEDULE

The contractor shall submit to the engineer his manufacture and delivery schedules for
all equipment within thirty(30) days from the date of the letter of acceptance of
tender. Such schedules shall be in line with the detailed net-work for all phases of the
work of the contractor. Such schedules shall be reviewed up-dated and submitted to
the engineer, once every two(2) months thereafter, by the contractor. Schedule shall
also include the materials and equipment purchased from outside suppliers.
9.0 REFERENCE STANDARDS

9.1 The codes and/or standards referred to in these specifications shall govern, in all cases
wherever such references are made. In case of a conflict between such codes and/or
standards and the specifications, the latter shall govern. Such codes and/or standards
referred to shall mean the latest revisions, 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.
9.2 Other internationally acceptable standards which ensure equip or higher performance
than those specified shall also be accepted.

10.0 DESIGN IMPROVEMENT
10.1 The engineer 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.
10.2 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 change in the
price and/or schedule of completion before the contractor proceeds with the change.
Following such agreement the provision thereof, shall be deemed to have been
amended accordingly.
11.0 QUALITY ASSURANCE

11.1 Quality Assurance Programme
To ensure that the equipment and services under the scope of this contract whether
manufactured or performed within the contractor’s works or at his sub-contractor’s
premises or at the owner’s site or at any other place of work are in accordance with
the specifications, the contractor shall adopt suitable quality assurance programme to
control such activities at all points necessary. Such programme shall be outlined by
the contractor and shall be finally accepted by the engineer after discussions before
the issue of letter of acceptance of tender. 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. documentation control system.
c. qualification data for bidder’s key personnel.
d. 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.
e. system for shop manufacturing and site erection control including process control
and fabrication and assembly controls :
f. control of non-conforming items and system for corrective actions.
g. inspection and test procedure both for manufacture and field activities:
h. control of calibration and testing of measuring and testing equipment.
i. system for indication and appraisal of inspection status.
j. system for quality audits.
k. system for authorizing release of manufactured product to the owner.
l. system for maintenance of records.
m. system for handling storage and delivery: and
n. a quality plan detailing out the specific quality control procedure adopted for
controlling the quality characteristics relevant to each item of equipment furnished
and each work at different stages executed at work site.
11.2 Quality Assurance Documents
The contractor shall be required to submit the following Quality Assurance

Documents within three weeks after despatch of the equipment :
i. all non-destructive examination procedures stress relief and weld repair
procedure actually used during fabrication.
ii. welder and welding operator qualification certificates.
iii. welder identification list, listing welder’s and welding operator’s qualification
procedure and welding identification symbols.
iv. material mill test reports on components as specified by the specification.

v. the inspection plan with verification, inspection plan check points, verification
sketches, if used and methods used to verify that the inspection and testing
points in the inspection plan were performed satisfactorily.
vi. sketches and drawings used for indicating the method of traceability of the
radiographs to the location on the equipment.
vii. all non-destructive examination result reports including radiography
interpretation reports.
viii. stress relief time temperature charts.
ix. factory test results for testing required as per applicable codes and standard
referred in the specifications.
x. the engineer or his duly authorised representative reserves the right to carry
out quality audit and quality surveillance of the systems and procedures of the
contractor/his vendor’s quality management and control activities.
12.0 ENGINEER’S SUPERVISION

12.1 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 engineer and his
decision shall be final.
12.2 The work shall be performed under the direction and supervision of the engineer. The
scope of the duties of the engineer, 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

specification.
b. review and interpretation of all the contractor’s drawings, engineering data etc.
c. witness or authorise his 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 improvements in completion schedules
from time to time.
g. supervise the quality assurance programme implementation at all stages of the
works.
h. to receive and endorse the despatch documents enabling the contractor to clear
the consignments.
13.0 INSPECTION, TESTING AND INSPECTION CERTIFICATE

13.1 The engineer, his duly authorised representative and/or outside inspection agency
acting on behalf of the owner shall have at all reasonable times access to the
contractor’s premises or works and shall have the power 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
at other premises or works, the contractor shall obtain for the engineer 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.
13.2 The contractor shall give the Engineer/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. The Engineer/Inspector, unless witnessing of the
tests is virtually waived, will attend such tests within fifteen(15) days of the date on
which the equipment is notified as being ready for test/inspection, failing which the

contractor may proceed with the test which shall be deemed to have been made in the
inspector’s presence and he shall forthwith forward to the inspector duly certified
copies of tests in triplicate.
13.3 The Engineer or Inspector shall within fifteen(15) days from the date of inspection as
defined herein give notice in writing to the contractor, of any objection to any
drawings and all or any equipment and workmanship which in his opinion is not in
accordance with the contract. The contractor shall give due consideration to such
objections and shall either make the modifications that may be necessary to meet the
said objections or shall confirm in writing to the Engineer/inspector giving reasons
therein, that no modifications are necessary to comply with the contract.
13.4 When the factory tests have been completed at the contractor’s or sub-contractor’s
works, the Engineer/Inspector shall issue a certificate to this effect within fifteen(15)
days after completion of tests but if the tests are not witnessed by the
Engineer/inspector, the certificate shall be issued within fifteen(15) days of the receipt
of the contractor’s test certificate by the Engineer/Inspector. Failure of the
Engineer/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
certificate shall not bind the owner to accept the equipment should it, on further tests
after erection, be found not to comply with the contract.
13.5 In all cases where the contract provides for tests whether at the premises or works of
the contractor or of any sub-contractor, the contractor, except where otherwise
specified, shall provide free of charge such items as labour, materials, electricity, fuel,
water, stores apparatus and instruments as may be reasonably demanded by the
Engineer/ Inspector or his authorized representative to carry out effectively such tests
of the equipment in accordance with the contract and shall given facilities to the
Engineer/inspector or to his authorized representative to accomplish testing.
13.6 The inspection by Engineer 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.
14.0 TEST
14.1 Start up
14.1.1 On completion of erection of the equipment and before start-up, each item of the
equipment shall be thoroughly cleaned and then inspected jointly by the Engineer and
the contractor for correctness and completeness of installation and acceptability of
start-up , leading to initial pre-commissioning tests 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.
14.1.2 The contractor’s commissioning/start-up engineers specifically identified as far as
possible shall be responsible for carrying out all the pre-commissioning tests. On
completion of inspection, checking and after the pre-commissioning tests are
satisfactorily over, the complete equipment shall be placed on initial operation during
which period the complete equipment shall be operated integral with sub-systems and
supporting equipment as a complete plant referred hereinafter as plant.
14.2 Trial Operation

14.2.1 The plant shall then be on trial operation during which period all necessary
adjustments shall be made while operating over the full load-range enabling the plant
to be made ready for performance and guarantee tests.
14.2.2 The duration of trial 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.
The trial operation shall be considered successful, provided that each item of the
equipment can operate continuously at the specified operating characteristics, for the
period of trial operation.
14.2.3 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 trial operation shall be
prolonged for the period of interruption.
14.2.4 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 run, shall also include the dates of start and finish of the trial operations
and shall be signed by the representatives of both the parties. The report shall have
sheets, recording all the details of interruptions occurred, adjustments made and any
minor repairs done during the 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 engineer to enable the later 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.
14.3 Performance and guarantee test

14.3.1 The final test as to the performance and guarantees shall be conducted at site, by the
owner. Such tests will be commenced within 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.
14.3.2 These tests shall be binding on both the parties of the contract to determine
compliance of the equipment with the performance guarantees.
14.3.3 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, un-measurable parameters shall be taken into account in a
reasonable manner by the engineer, for the equipment 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.
14.3.4 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.
14.3.4 The guaranteed performance figures of the equipment 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
equipment 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 of equipment
is ready for re-tests 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. Duration of performance guarantee tests will be of one
month of which six(6) days continuous on load operation is the minimum
requirement and in case it fails, the process of performance guarantee tests will be
repeated.
14.3.6 The specific tests to be conducted on equipment has been brought out in the technical
specifications.

14.3.7 Performance and guarantee test shall make allowance for instrumentation errors as
may be decided by the engineer-in-charge.
14.4 TEST CODES :

The provisions outlined in the ASME performance test codes or other international
and Indian approved equivalents shall generally be used as a guide for all the above
test procedures unless otherwise specified in the technical specifications.
15.0 PACKING
15.1 All the equipment shall be suitably protected, coated, covered or boxed and created 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 availability of railway wagon sizes in India should be taken into account. The
contractor shall be responsible for any loss or damage during transportation, handling
and storage due to improper packing.
16.0 PROTECTION
All coated surfaces shall be protected against abrasions, impact, discoloration and any
other damages. All exposed threaded portions shall be suitable protected with either a
metallic or a non-metallic protecting device. All ends of all valves and piping and
conduit equipment connections shall be properly sealed with suitable devices to
protect them from damage. The parts which are likely to get rusted, due to exposure
to weather, should also be properly treated and protected in a suitable manner.
17.0 PRESERVATIVE SHOP COATING

17.1 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 before hand be treated and protected for the life of the
equipment. All surfaces shall be thoroughly cleaned of all mill scale, oxide 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. Transformers and other electrical equipment
if included shall be shop finished with two coats of primer and two coats of high
grade resistance enamel. The finished colours shall be as per manufacturers
standards, to be selected and specified by the engineering at a later date.
17.2 Shop primer for all steel surface which will be exposed to operating temperature
below 950 C shall be selected by the contractor, after obtaining specific approval of
the engineer regarding the quality of primer proposed to be applied. Special high
temperature primer shall be used on surfaces exposed to temperatures higher than 950
C and such primers shall also be subject to the approval of the engineer.
17.3 All other steel surfaces which are not to be painted shall be coated with suitable dust
preventive compound subject to the approval of the engineer.
18.0 PROTECTIVE GUARDS

Suitable guards shall be provided for protection of personnel on all exposed rotating
and/or moving machine parts. All such guards with necessary spares and accessories
shall be designed for easy installation and removal for maintenance purposes.
19.0 DESIGN CO-ORDINATION

The contractor shall be responsible for the selection and design of appropriate
equipment to provide the best co-ordinated performance of the entire system. The
basic design requirements are detailed out in Technical Specifications. The design of

various components, sub-assemblies and assemblies shall be so done, so that it
facilitates easy field assembly and maintenance. All the rotating components shall be
so selected that the natural frequency of the complete unit is not critical at or close to
the operating range of the unit.
20.0 DESIGN CO-ORDINATION MEETING

The contractor will be called upon to attend design co-ordination meetings with the
engineer, other contractors and the consultants of the owner during the period of
contract. The contractor shall attend such meetings at his own cost at mutually agreed
venue as and when required and fully co-operate with such persons and agencies
involved during those discussions.
21.0 TOOLS AND TACKLES

The contractor shall supply with the equipment one complete set of all special tools
and tackles for the erection, assembly, dis-assembly and maintenance of the
equipment. However, these tools and tackles shall be separately packed and brought
on to site.
22.0 NOISE LEVEL

The equivalent ‘A’ weighted sound level measured at a distance of 1.5 meters above
floor level in elevation and one meter horizontally from the base of any equipment
furnished and installed under these specifications, expressed in decibels to a reference
of 0.0002 microbar, shall not exceed 85 dBA.
23.0 TAKING OVER

Upon successful completion of all the tests to be performed at site on equipment
furnished and erected by the contractor, the engineer 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 be engineer 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.
24.0 INDIAN STANDARDS

Normally Indian Standards as published by BUREAU OF INDIAN STANDARDS
shall be followed. Wherever relevant Indian Standard is not published by the BIS,
International Standards or American Standard or German Standard or British
Standard, as decided by the Engineer in consultations with the Consultants employed
by the Owner, shall be followed.
25.0 WELDING
If the manufacturer has special requirements relating to the welding procedures for
welds at the terminals of the equipment to be procured by the owner under separate
specifications, the requirements shall be submitted to the engineer in advance of
commencement of erection work.
26.0 LUBRICATION
Equipment shall be lubricated by systems designed for continuous operation.
Lubricant level indicators shall be furnished and marked to indicate proper levels
under both stand-still and operating conditions.

27.0 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 /structural steel base unless otherwise agreed to
by the engineer. Each base plate shall support the unit and its drive assembly, shall
be of a neat design with pads for anchoring the units, shall have a raised lip all
around, and shall have threaded drain connections.
28.0 RATING PLATES, NAME PLATES AND LABELS.

28.1 Each main and auxiliary items of plant is to have permanently attached to it in a
conspicuous position a rating plate of non corrosive material upon which is to be
engraved the manufacturer’s name, equipment, type or serial numbers, together with
details of the loading conditions under which the item of plant in question have been
designed to operate, and such diagram plates as may be required by the engineer.
28.2 Each item of plant is to be provided with a nameplate or label designating the service
of the particular equipment. The inscriptions are to be approved by the engineer or
shall be as detailed in the appropriate sections of the technical specification.
28.3 Such nameplates or labels are to be of white non-hygroscopic material with engraved
black lettering or alternatively, in the case of indoor circuit breakers, starters etc of
transparent plastic material with suitably coloured lettering engraved on the back.
28.4 Items of plant such as valves, which are subject to handling are to be provided with an
engraved chromium plated nameplate or label with engraving filled with enamel.
28.5 All such name plates, instruction plates, lubrication charts 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.
29.0 COLOUR CODE FOR PIPE SERVICES

All pipe services wherever applicable are to be painted in accordance with the
owner’s standard colour scheme, by the contractor.
30.0 SERVICE BY THE OWNER

30.1 The following services shall be provided by the owner:
i) Drinking water at one point within 100 meters of the work site, charges to be
decided by the company.
ii) Auxiliary power for construction at one point within 100 meters of the work
site, charges to be decided by the company.
30.2 In the event of the contractor requiring these services at parameters other than those
specified above for any systems, equipment, instrument etc he shall make the
necessary arrangements himself.

ERECTION CONDITIONS OF CONTRACT
1.0 GENERAL
1.1 The following 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 to be performed at site.
1.2 The contractor upon signing of the contract shall, in addition to a project co-ordinator,
nominate another responsible officer as his representative at site suitably designated
for the purpose of overall responsibility and co-ordination of the works to be
performed at site. Such person shall function from the site office of the contractor
during the pendency of contract.
2.0 REGULATION OF LOCAL AUTHORITIES AND STATUES

2.1 The contractor shall comply with all the rules and regulations of local authorities
during the performance of his field activities. He shall also comply with the
minimum wages act, 1948 and the payment of wages act ( both of the Government of
India and the local State Government) and the rules made there under in respect of
any employee or workman employed or engaged by him or his sub-contractor. The
contractor shall make all necessary payments of the Provident Fund for the workmen
employed by him for the work as per the laws prevailing under provisions of CMPF
and Allied Schemes and CMPF and Miscellaneous Provisions Act 1948 or Employees
Provident Fund and Miscellaneous Provision Act 1952 as the case may be.
2.2 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 rules and
regulations of the Government 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 owner, shall be to the account of the owner. Should any such inspection or
registration need to be 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.
2.3 The Contractor shall provide all the technical parameters and specifications along
with drawings etc. to concerned Project/Area to process for approval of
D.G.M.S./Statutory authority by Project Authority. The Electrical Works shall be
done under the supervision of H.T Electrical Licensed Contactor/Supervisor. The
contractor shall be responsible for approval of the Complete System ( Electrical &
Mechanical etc.) by D.G.M.S./ Statutory authority.
3.0 OWNER’S LIEN ON EQUIPMENT

The owner shall have lien on all equipment including those of the contractor brought
to the site for the purpose of erection, testing and commissioning of the plant. The
owner shall continue to hold the lien on all such equipment throughout the period of
contract. No material brought to the site shall be removed from the site by the
contractor and/or his sub-contractors with out the prior written approval of the
engineer.
4.0 INSPECTION, TESTING AND INSPECTION CERTIFICATES

The provisions of the clause entitled inspection testing and inspection certificates
under section GTC shall also be applicable to the erection portion of the works. The
engineer 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

constructed and/or erected at site. If by the above inspection, the engineer rejects any
work or equipment, the contractor shall make good for such rejection either by
replacement or modifications /repairs as may be necessary, to the satisfaction of the
engineer. Such replacement will also include the replacement 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.
5.0 ACCESS TO SITE AND WORKS ON SITE

5.1 Suitable access to and possession of the site shall be accorded to the contractor by the
owner in reasonable time.
5.2 The works so far as it is carried out on the owner’s premises, shall be carried out at
such time as the owner may approve and the owner shall give the contractor
reasonable facilities for carrying out the works.
5.3 In the execution of the works, no persons 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 of the engineer or his
representative.
6.0 CONTRACTOR’S SITE OFFICE ESTABLISHMENT

The contractor shall establish a site office at the site and keep posted an authorised
representative for the purpose of the contract. Any written order or instruction of the
engineer or his duly authorised representative, shall be communicated to the said
authorised resident representing the contractor and the same shall be deemed to have
been communicated to the contractor at his legal address.
7.0 CO-OPERATION WITH OTHER CONTRACTORS

7.1 The contractor shall co-operate with all other contractors or tradesmen of the owner,
who may be performing other works on behalf of the owner and the workmen who
may be employed by the owner and doing work in the vicinity of the works under the
contract. The contractor shall also so arrange to perform his work as to minimise, to
the maximum extent possible, interference with the work of other contractors and his
workmen. Any injury or damage that may be sustained in the employees of the other
contractors and the owner, due to the contractor’s work shall promptly be made good
at his own expense. The engineer 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 owner in regard to their work. If the works of the
contractor is delayed because of any acts or omissions of another contractor, the
contractor shall have no claim against the owner on that account other than an
extension of time for completing his works.
7.2 The engineer shall be notified promptly by the contractor of any defects in the other
contractor’s works that could affect the contractor’s works. The engineer shall
determine the corrective measures if any, required to rectify this situation after
inspection of the works and such decisions by the engineer shall be binding on the
contractor.
8.0 DISCIPLINE OF WORKMEN

The contractor shall adhere to the disciplinary procedure set by the engineer in respect
of his employees and workmen at site. The engineer shall be at liberty to object to the
presence of any representative or employees of the contractor at the site, if in the
opinion of the engineer such employee has mis-conducted himself or be incompetent
or negligent or otherwise undesirable and then the contractor shall remove such a
person objected to and provide in his place a competent replacement.

9.0 CONTRACTOR’S FIELD OPERATION
9.1 The contractor shall keep the engineer 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 engineer 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 engineer or the owner or
any of his representatives and no claim of the contractor will be entertained because
of the failure or inefficiency of any such plan or schedule or method of work
reviewed. The contractor shall be solely responsible for the safety, adequacy and
efficiency of plant and equipment and his erection methods.
9.2 The contractor shall have 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 engineer is not intended to
include review of contractor’s safety measures in, on or near the work-site, and their
adequacy or otherwise.
10.0 PHOTOGRAPHS AND PROGRESS REPORT

10.1 The contractor shall furnish three (3) prints each to the engineer of progress
photographs of the work done at site. Photographs shall be taken as and when
indicated by the engineer 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.
10.2 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.
11.0 MAN-POWER REPORT

11.1 The contractor shall submit to the engineer, 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.
11.2 The contractor shall also submit to the engineer on the first day of every month, a man
power report of the previous months detailing the number of persons scheduled to
have been employed and actually employed, skill-wise and areas of employment of
such labour.
12.0 PROTECTION WORK.

The contractor shall have total responsibility for protecting his works till it is finally
taken over by the engineer. No claim will be entertained by the owner or the engineer
for any damage or loss to the contractor’s works and the contractor shall be
responsible for the complete restoration of the damaged works to its original
condition to comply with the specifications and drawings. Should any such damage
to the contractor’s works occur because of other party not under his supervision or
control, the contractor shall make his claim directly with the party concerned. If dis-
agreement 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 clause- 7.0 above entitled co-
operation with other contractors. The contractor shall not cause any delay in the
repair of such damaged works because of any delay in the resolution of such disputes.

The contractor shall proceed to repair the work immediately and the cause thereof
will be assigned pending resolution of such dispute.
13.0 EMPLOYMENT OF LABOUR

13.1 The contractor will be expected to employ on the work only his regular skilled
employees with experience of his particular work. No female labour shall be
employed after darkness no persons below the age of eighteen years shall be
employed.
13.2 All traveling expenses including provisions of all necessary transport to and from site
lodging allowances and other payments to contractor’s employees shall be the sole
responsibility of the contractor.
13.3 The hour of work on the site shall be decided by the owner and the contractor shall
adhere to it. Working hours will normally be eight(8) hours per day-Monday to
Saturday.
13.4. Contractor’s employees shall wear identification badges while on work on site.
13.5 In case the owner becomes liable to pay any wages or dues to the labour or to any
Government agency under any of the provisions of the Minimum Wages Act,
Workmen compensation Act. Contract Labour Regulation Abolition Act, CMPF
Act/EPF Act or any other law due to act of omission of the contractor, the owner may
make such payments and shall recover the same from the contractor’s bills.
14.0 FACILITIES TO BE PROVIDED BY THE OWNER
14.1 SPACE :
The contractor shall advise the owner within thirty(30) days from the date of
acceptance of the letter of award, about his exact requirement of space for his office,
mess-rooms storage area, pre-assembly and fabrication areas, labour colony area,
toilets, etc. The above requirement shall be reviewed by the engineer and space will
be allotted to the contractor for construction of his temporary structures like office,
storage sheds, labour and staff colony and other utilities etc. for his own as well as his
sub-contractor’s use.
14.2 ELECTRICITY
The contractor shall submit to the engineer within thirty(30) days from the date of
acceptance of the award letter, his electrical power requirements, if any, to allow the
planning of the temporary electrical distribution by the engineer. The contractor shall
be provided with supply of electricity for the purposes of the contract only at one
point in the project site. The contractor shall make his own further distribution
arrangement. All temporary wiring must comply with local regulations and will be
subject to engineer’s inspection and approval before connection to supply. The
contractor shall be charged for the power supplied at work site and labour colonies at
prevalent rate of power supplied by State Electricity Board.
14.3 WATER
Supply of water will be made available for the drinking purposes at an agreed single
point within 100 meters of the work site and charges to be decided by the company.
And further distribution will be the responsibility of the contractor. The contractor
shall have to do their own arrangement for construction water at site. In case the
owner arrange to supply the construction water at work site, the contractor shall be
charged @ 1% of the value of civil works and shall be deducted from the contractor’s
running/final bills.

15.0 FACILITIES TO BE PROVIDED BY THE CONTRACTOR
15.1 Tools, tackles and scaffoldings

The contractor shall provide all the construction equipment, tools, tackles and
scaffoldings required for pre-assembly, erection, testing and commissioning of the
equipment covered under the contract. He shall submit a list of all such materials to
the engineer 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
engineer.
15.2 Communication
The owner will extend the telephone & telex facilities, if available at site, for purposes
of contract. The contractor shall be charged at actual for such facilities.
15.3 First-aid
15.3.1 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.
15.3.2 The owner will provide the contractor in case of an emergency, the services of an
ambulance for transportation to the nearest hospital.
15.4 CLEANLINESS
15.4.1 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 engineer. Materials and stores shall be so arranged to
permit easy cleaning of the area in areas where equipment might drip oil and cause
damage to the floor surface, a suitable protective cover of a flame resistant, oil proof
sheet shall be provided to protect the floor from such damage.
15.4.2 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
engineer. Proper sanitary arrangement shall be provided by the contractor, in the
work areas, office and residential areas of the contractor.
16.0 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 engineer
at site at suitable points. These points shall be used as datum for the works under the
contract. The contractor shall inform the engineer 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 engineer to enable the contractor
to proceed with his works. Any work done without being properly located may be
removed and/or dismantled by the engineer at contractor’s expense.
17.0 FIRE PROTECTION

17.1 The work procedures that are to be used during the erection shall be those which
minimize fire hazards to the extent practicable. Combustible materials, combustible
waste and rubbish shall be collected and removed from the site at least once each
day. Fuels, oils and volatile or flammable materials shall be stored away from the

construction and equipment and materials storage areas in safe containers. Untreated
canvas paper, plastic or other flammable flexible materials shall not at all be used at
site for any other purpose unless otherwise specified. If any such materials are
received with the equipment at the site, the same shall be removed and replaced with
acceptable material before moving into the construction area or storage.
17.2 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 water proof and flame resistant type. All the other materials such as
working drawings, plants, 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.
17.3 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.
17.4 The contractor shall provide enough fire protection equipment of the types and
number for the ware-houses, office, temporary structures, labour colony area etc.
Access to such fire protection equipment, shall be easy and kept open at all times.
18.0 SECURITY
The contractor shall have total responsibility for all equipment and materials in his
custody stored, 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 project site only with the written permission of the engineer in the
prescribed manner.
19.0 CONTRACTOR’S AREA LIMITS

The engineer 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 contractor’s personnel to work out of the areas marked out for
him, the same shall be done only with the written permission of the engineer.
20.0 CONTRACTOR’S CO-OPERATION WITH THE OWNER

In cases where the performance of the erection work by the contractor affects the
operation of the system facilities of the owner, such erection work of the contractor
shall be scheduled to be performed only in the manner stipulated by the engineer and
the same shall be acceptable at all times to the contractor . The engineer may impose
such restrictions on the facilities provided to the contractor such as electricity, water,
etc. as he may think fit in the interest of the owner and the contractor shall strictly
adhere etc. such restrictions and co-operate with the engineer.
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 of the equipment system which are erected by him. The
contractor shall also be responsible for flushing and initial filing of all the oil and
lubricants required for the equipment furnished and erected 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
documents and specifications.
20.0 PRE-COMMISSIONING TRIALS AND INITIAL OPERATIONS

The pre-commissioning trials and initial operations of the equipment furnished and
erected by the contractor shall be the responsibility of the contractor as detailed in
relevant clauses in section GTC. The contractor shall provide, in addition, test
instruments, calibrating devices, etc. and the labour required for the successful
performance of these trials. 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 trials.
22.0 MATERIALS HANDLING AND STORAGE

22.1 All the equipment furnished under the contract and arriving at site shall be promptly
received, unloaded and transported and stored in the storage spaces by the contractor.
22.2 Contractor shall be responsible for examining all the shipment and notify the engineer
immediately or any damage, shortage, discrepancy, etc. for the purpose of engineer’s
information only. The contractor shall submit to the engineer 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 the site. Any demurrage, wharfage and other such
charges claimed by the transporters, railways etc shall be to the account of the
contractor.
22.3 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 engineer at any time.
22.4 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 engineer. The equipment stored shall
be properly protected to prevent damage either to the equipment or to the floor where
they are stored. The equipment from the store shall be moved to the actual location at
the appropriate time so as to avoid damage of such equipment at site.
22.5 All electrical panels, control 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.
22.6 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 engineer.
22.7 The contractor shall ensure that all the packing materials and protection devices used
for the various equipment during transit and storage are removed before the
equipment area installed.
22.8 The consumable and other supplies likely to deteriorate due to storage must be
thoroughly protected and stored in a suitable manner to prevent damage or
deterioration in quality by storage.
22.9 All the materials stored in the open or duty location must be covered with suitable
weather-proof and flameproof covering materials wherever applicable.

22.10 If the materials belonging to the contractor are stored in areas other than those
earmarked for him, the engineer will have the right to get it moved to the area
earmarked for the contractor at the contractor’s cost.
22.11 The contractor shall be responsible for making suitable indoor storage facilities to
store all equipment which require indoor storage. Normally, all the electrical
equipment such as motors, control gear generators, exciters and consumable like
electrodes, lubricants etc shall be stored in the closed storage space. The engineer, 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.
23.0 CONSTRUCTION MANAGEMENT

23.1 The field activities of the contractors working at site, will be co-ordinated by the
engineer and the engineer’s decision shall be final in resolving any disputes or
conflicts between the contractor and other contractors and tradesmen of the owner
regarding scheduling and co-ordination of work. Such decision by the engineer shall
not be a cause for extra compensation or extension of time for the contractor.
23.2 The engineer shall hold weekly meetings of all the contractors working at site, at a
time and a place to be designated by the engineer. The contractor shall attend such
meetings and take notes of discussions during the meeting and the decisions of the
engineer and shall strictly adhere to those decisions in performing his works. In
addition to the above weekly meetings, the engineer may call for other meetings either
with individual contractors or with selected number of contractors and in such a case
the contractor, if called will also attend such meetings.
23.3 Time is the essence of the contract and the contractor shall be responsible for
performance this 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 engineer, satisfying that his action will
compensate for the delay. The contractor shall not be allowed any extra
compensation for such action.
23.4 The engineer 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.
24.0 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 condition
of the equipment furnished and erected under the contract. Such drawings and
engineering data shall be submitted to the engineer in required number of copies.
Daily work programme with progress of the previous day and deployment of labour
related to work programme and attendance of workmen deployed during the previous
day shall be maintained in a register. This register shall be signed by authorised
representative of the contractor which will then be checked and signed by the
owner’s representative. Every three months this register shall be deposited to the
owner which shall then be owners property.

25.0 CONTRACTOR’S MATERIALS BROUGHT ON TO SITE
25.1 The contractor shall bring to site all equipment, parts, materials, including
construction equipment, tools and tackles for the purpose of the works with intimation
to the engineer. All such goods shall from the time of their being brought vest in the
owner, 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 engineer. The contractor shall nevertheless be solely liable and responsible for
any loss or destruction thereof and damage thereto.
25.2 The owner 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 owner shall be at liberty to sell and dispose of 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.
25.3 After the completion of the works, the contractor shall remove from the site under the
direction of the engineer the materials such as construction equipment, erection tools
and tackles, scaffolding etc. with the written permission of the engineer. If the
contractor fails to remove such materials, within fifteen(15) days of issue of a notice
by the engineer to do so then the engineer shall have the liberty to dispose of such
materials as detailed under clause 25.2 above and credit the proceeds thereto the
account of the contractor.
26.0 PROTECTION OF PROPERTY AND CONTRACTOR’S LIABILITY.

26.1 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 owner and the employees of other contractors and sub-contractors
and all public and private property including structures, buildings, other plants and
equipment and utilities either above or below the ground.
26.2 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
engineer and the owners 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 owners, related to removal and
or replacement or protection of such property and utilities.
27.0 PAINTING
All exposed metal parts of the equipment including pipings, structure railing etc.
wherever applicable, after installation unless otherwise surface protected, shall be first
painted with at least one coat of suitable primer which matches the shop primer paint
used, after thoroughly cleaning all such parts of all dirt, rust , scales, greases, oils and
other foreign materials by wire brushing, scarping or sand blasting, and the same
being inspected and approved by the engineer for painting. Afterwards, the above
parts shall be finished with two coats of alloyed resin machinery enamel paints. The
quality of the finish paint shall be as per the standards of ISI or equivalent and to be of
the colour as approved by the engineer.
28.0 INSURANCE
28.1 In addition to the conditions covered under the clause entitled insurance in general
terms and conditions of contract of this volume-1, the following provisions will also

apply to the portion of the works to be done beyond the contractor’s own or his sub-
contractor’s works.
28.2 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
Workmen’s compensation As per statutory provisions

Employer’s liability As per statutory provisions.
28.3 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 owner’s men
and damage to the property of others arising from the use of motor vehicles during on
or off the site operations, irrespective of the ownership of such vehicles.
28.4 Comprehensive General Liability Insurance

28.4.1 This 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. The
insurance shall also cover all the liabilities of the contractor arising out of the clause
entitled defence of suits under General Terms and Conditions of contracts of this
volume-I.
28.4.2 The hazards to be covered will pertain to all the works which and areas where the
contractor, his sub-contractors, his agents and his employees have to perform work
pursuant to the contract.
28.5 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.
29.0 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
unfavorable construction conditions. No field activities shall be performed by the
contractor under conditions which might adversely affect quality and efficiency
thereof, unless special precautions or measures are taken by the contractor in a proper
and satisfactory manner in performance of such works and with concurrence of the
engineer. Such unfavorable construction conditions will in no way relieve the
contractor of his responsibility to perform works as per the schedule.
30.0 PROTECTION OF MONUMENTS AND REFERENCE POINTS

The contractor shall ensure that any finds such as relic, antiquity, coins, fossils, etc
which he might come across during the course of performance of his works either
during excavation or elsewhere are properly protected and handed over to the
engineer. Similarly the contractor shall ensure that the bench marks, reference points,
etc., which are marked out either with the help of engineer or by the engineer shall not

be disturbed in any way during the performance of his works. If any works is to be
performed which disturbed such references, the same shall be done only after these
are transferred to other suitable locations under the direction of the engineer. The
contractor shall provide all necessary materials and assistance for such relocation of
reference points etc.
31.0 WORK AND SAFETY REGULATIONS

31.1 The contractor shall ensure proper safety of all the workmen, materials plant and
equipment belonging to him or the Company or to others, working at or near the site.
The contractor shall also be responsible for provision of all safety notices and safety
equipment required both by the relevant legislation and the engineer-in-charge as he
may deem necessary.
31.2 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. The engineer-in-
charge 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
contractor 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 the owner. Nor the owner shall entertain any
claim of the contractor towards additional safety provisions/conditions to be provided
for constructed as per engineer-in-charge’s instructions.
Further any such decision of engineer-in-charge shall not, in any way, absolve the
contractor of his responsibilities, and in case, use of such container or entry there of
into the site area is forbidden by engineer-in-charge, the contractor shall use
alternative methods with the approval of engineer-in-charge without any cost
implication to Company or extension of work schedule.
31.3 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 ( Explosive) or any statutory authorities, the
contractor shall be responsible for obtaining the same.
31.4 All equipment used in construction and erection by contractor shall meet Indian,
International Standards and where such standards do not exist the contractor shall
ensure these to be absolutely safe. All equipment shall be strictly operated and
maintained by the contractor in accordance with manufacturer’s operation manual
and safety instructions and per Guidelines/Rules of the Company in this regard.
31.5 Periodical Examinations and all tests for all lifting/hoisting equipment and tackles
shall be carried out in accordance with the relevant provisions of Factories Act 1948,
Indian Electricity Act 1910 and associated Laws / Rules enforced from time to time.
A register of such examinations and tests shall be properly maintained by the
contractor and will be promptly produced as and when desired by engineer-in-charge
or by the person authorized by him.
31.6 The contract shall be fully responsible for the safe storage of his and his sub-
contractors radio-active sources in accordance with BARC/DAE Rules and other
applicable provisions. All precautionary measures stipulated by BARC/DAE in

connection with use, storage and handling of such material will be taken by
contractor.
31.7 The contractor shall provide suitable safety equipment of prescribed standard to all
employee and workmen according to the need, as may be directed by engineer-in-
charge who will also have right to examine these safety equipment to determine their
suitability, reliability, acceptability and adaptability.
31.8 Where explosives are to be used, the same shall be used under the direct control and
supervision of an expert, experienced, qualified and competent person strictly in
accordance with the code practices/rules framed under Indian Explosives Act
pertaining to handling, storage and use of the explosives.
31.9 The contractor shall provide safe working conditions to all workmen and
employees at the site including safe means of access, railing, stairs, ladders,
scaffoldings etc. The scaffoldings, stairs, ladders etc shall be erected under the
control and supervision of an experienced and competent person. For erection, good
and standard quality of material only shall be used by the contractor.
31.10 The contractor shall not interfere or disturb electric fuses, wiring the other electrical
equipment belonging to the owner or other contractors under any circumstances,
whatsoever, unless expressly permitted in writing by the Company to handle such
fuses, wiring or electrical equipment.
31.11 Before the contractor connects any electrical appliances to any plug or socket
belonging to the other contractor or owner, he shall :
a) satisfy the engineer that the appliances is in good working condition
b) inform the engineer of the maximum current rating, voltage and phases of the
appliances.
c) obtain permission of the engineer detailing the sockets to which the appliances
may be connected.
31.12 The engineer will not grant permission to connect until he is satisfied that :
a) the appliance is in good condition and is fitted with a suitable plug.
b) the appliance is fitted with a suitable cable having two earth conductors, one
of which shall be an earthed metal sheath surrounding the cores.
31.13 No electric cable is in use by the contractor/owner 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.
31.14 No repair work shall be carried out on any live equipment. The equipment shall
must be declared safe by engineer-in-charge and a permit to work shall be issued by
engineer-in-charge before the contractor carries out any repair work. While working
on electric lines/equipments whether alive or dead, suitable type and sufficient
quantity of tools will have to be provided by contractor to
electricians/workmen/officers.
31.15 The contractor shall employ necessary number of qualified, full time
electricians/electrical supervisors to maintain in his temporary electrical installation.
31.16 The contractor employing more than 250 workmen whether temporary, casual,
probationer, regular or permanent or on contract, shall employ at least one full time
officer exclusively as safety officer to supervise safety aspects of the equipment and
workmen who will co-ordinate with the project safety officer. In case of work being
carried out through sub-contractor’s , the sub-contractor’s workmen/employees will
also be considered as the contractor’s employees/workmen for above purpose. The
name and address of a such safety officer of contractor will be promptly informed in
writing to engineer-in-charge with a copy to safety officer-in-charge before he starts
work or immediately after any change of the incumbent is made during currency of
the contract.

31.17 In case any accident occurs during the construction/erection or other associated
activities undertaken by the contractor thereby causing any 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 company’s engineer-in-charge in
prescribed from and also to all the authorities envisaged under the applicable laws.
31.18 The engineer-in-charge 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 equipment. 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 short comings promptly. The
contractor after stopping the specific work, can, if felt necessary, appeal against the
order of stoppage of work to the General Manager of the project within 3 days of
such stoppage of work and decision of the project GM in this respect shall be
conclusive and binding on the contractor.
31.19 The contractor shall not be entitled for any damages/compensation for stoppage of
work due to safety reasons as provided in para 31.18 above and the period of such
stoppage of work will not be taken as an extension of time for completion of work and
will not be the ground for waiver of levy of liquidated damages.
31.20 The contractor shall follow and comply with all the Company safety rules relevant
provisions of applicable laws pertaining to the safety of workmen, employees, plant
and equipment as may be prescribed from time to time without demur, protest or
content or reservation. In case of any inconformity between statutory requirement
and the Company safety rules referred above, the later shall be binding on the
contractor unless the statutory provisions are more stringent.
31.21 If the contractor fails in providing safe working environment as per the Company
safety rules or continues the work even after being instructed to stop work by
engineer-in-charge as provided in para 31.18 above., the contractor shall promptly pay
to the Company, on demand i.e. by the owner compensation at the rate of Rupees
5,000/- per day or part there of till the instructions are complied with an so certified
by engineer-in-charge.
However in case of accident taking place causing injury to any individual, the
provisions contained in para 31.22 shall also apply in addition to compensation
mentioned in this para.
31.22 If the contractor does not take all safety precautions and/or fails to comply with the
safety rules as prescribed by the Company or under the applicable laws for the safety
of the equipment and plant and for the safety of personnel and the contractor does not
prevent hazardous conditions which cause injury to his own employees or employees
of other contractors, or the Company employees or any other person who are at site
or adjacent thereto, the contractor shall be responsible for payment of compensation
under the relevant provisions of the workmen’s compensation act and rules framed
there under or any other applicable laws as applicable from time to time.
Permanent disablement shall have same meaning as indicated in workmen’s
compensation act. The compensation mentioned above shall be in addition to the
compensation payable to the workmen/employees under the relevant provisions of the
workmen’s compensation act and rules framed there under or any other applicable
laws as applicable from time to time.
In case the owner is made to pay such compensation then the contractor is liable to
reimburse the owner such amount.

32.0 CODE REQUIREMENTS
The erection requirements and procedures to be followed during the installation of the
equipment shall be in accordance with the relevant Indian Boiler Regulations. ASME
codes and accepted good engineering practice, the engineer’s drawings and other
applicable Indian recognized codes and the laws and regulations of the Government of
India.
33.0 FOUNDATION DRESSING AND GROUTING

33.1 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.
33.2 All the equipment bases and structural steel base plates shall be grouted and finished
as per these specifications unless otherwise recommended by the equipment
manufacturer.
33.3 The concrete foundation surfaces shall be properly prepared by chipping, grinding as
required to bring the type of such foundation to the required level, to provide the
necessary roughness for bondage and to assure enough bearing strength. All laitance
and surface film shall be removed and cleaned.
33.4 GROUTING MIX

The grouting mixtures shall be composed of Portland cement, sand and water. The
Portland cement to be used shall conform to ISI No.269 or equivalent , sand shall
conform to ISI No.383/2386 or equivalent. The grout proportions for flat based
where the grouting space does not exceed 35mm shall be 50 KG bag of cement to 75
KG of sand. Only the required quantity of water shall be added so as to make the
mix quaky and flow able and the mix shall not show excess water on top when it is
being puddle in place. For thicker grout beds upto 65 mm, the amount of sand shall
be increased to 105 KG per bag of cement. Bases which are hollow and are to be
filed full of grouting shall be filled to a level of 25 mm above the outside rim with a
mortar mix in the volumetric proportions of one bag of cement and 1.5 bags sand 1.5
part 6 mm granite gravel. An acceptable plasticiser may be added to the grout mixes
in a proportion recommended by the plasticisers manufacturer. All such grouts shall
be thoroughly mixed for not less than five minutes in an approved mechanical mixer
and shall be used immediately after mixing.
33.5 PLACING OF GROUT

33.5.1 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 25 mm 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 and forth to push the grout into every part of the
space under the base.
33.5.2 The grout shall be poured either through grout holes if provided or shall be poured at
one side or at two adjacent sides giving it a pressure head 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.

33.6 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 out off flush 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 smoothed 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.
33.7 CHECKING OF EQUIPMENT AFTER GROUTING

After the grout is set and cured, the contractor shall check and verify the alignment of
equipment, alignment of shafts of rotating machinery, the slopes of all bearing
pedestals, centring of rotors with respect to their sealing bores, couplings, etc. as
applicable and the like items to ensure that no displacement had taken place during
grouting. The values recorded prior to grouting shall be used during such post
grouting check-up and verifications. Such pre and post grout records of alignment
details shall be maintained by the contractor in a manner acceptable to the engineer.
34.0 SHAFT ALIGNMENTS

All the shafts of rotating equipment shall be properly aligned to those of the matching
equipment to as perfect an accuracy as practicable. The equipment shall be free from
excessive vibration so as to avoid over-heating of bearings or other conditions which
may tend to shorten the life of the equipment. All bearings, shafts and other rotating
parts shall be thoroughly cleaned and suitably lubricated before starting.
35.0 DOWELING
All the motors and other equipment shall be suitably doweled after alignment of
shafts with tapered machined dowels as per the direction of the engineer.
36.0 CHECK OUT OF CONTROL SYSTEMS / POWER SUPPLY

After completion of wiring, cabling furnished under separate specifications and laid
and terminated by the owner, the contractor shall check out the operation of all
control system for the equipment furnished and installed under these specifications
and documents. The contractor shall get the drawings pertaining to the control
system, power supply etc. approved from Directorate General of Mine Safety
(DGMS) or any other appropriate authority as necessary, wherever required as per the
rules and regulations of the of Indian Mines Act Governed by D.G.M.S.
37.0 COMMISSIONING SPARES

The contractor shall make arrangement for an adequate inventory at site of necessary
commissioning spares prior to commissioning of the equipment furnished and erected
so that any damage or loss during this commissioning activities necessitating the
requirements of spares will not come in the way of timely completion of the works
under the contract.
38.0 CABLING
38.1 All cables shall be supported by conduits or cable tray run in air or in cable channels.
These shall be installed in exposed runs parallel or perpendicular to dominant surfaces
with right angle turn made of symmetrical bends or fittings. When cables are run on

cable trays, they shall be clamped at a minimum interval of 2000 mm or otherwise as
directed by the engineer.
38.2 Each cable, whether power or control, shall be provided with a metallic or plastic of
an approved type, bearing a cable reference number indicated in the cable and conduit
list ( prepared by the contractor), at every 5 meter run or part there of and at both
ends or the cable adjacent to the terminations. Cable routing is to be done in such a
way that cables are accessible for any maintenance and for easy identification.
38.3 Sharp bending and kinking of cables shall be avoided. The minimum radii for PVC
insulated cables 1100 V grade shall be 15D, where D is the over all diameter of the
cable. Installation of other cables like high voltage, coaxial, screened, compensating,
mineral insulated shall be in accordance with the cable manufacturer’s
recommendations. Wherever cables cross roads and water, oil, sewage or gas lines,
special care should be taken for the protection of the cables in designing the cable
channels.
38.4 In each cable run some extra length shall be kept at a suitable point to enable one to
two straight through joints to be made should the cable develop fault at a later date.
38.5 Control cable terminations shall be made in accordance with wiring diagrams, using
identifying codes subject to engineer’s approval. Multicore control cable jackets
shall be removed as required to train and terminate the conductors. The cable jacket
shall be left on the cable, as far as possible, to the point of the first conductor branch.
The insulated conductors from which the jacket is removed shall be neatly twined in
bundles and terminated. The bundles shall be firmly but not tightly tied utilising
plastic or nylon ties or specially treated fungus protected cord made for this purpose.
Control cable conductor insulation shall be securely and evenly cut.
38.6 The connectors for control cables shall be covered with a transparent insulating sleeve
so as to prevent accidental contact with ground or adjacent terminals and shall
preferably terminate Elmex terminals and washers. The insulating sleeve shall be fire
resistant and shall be long enough to over-pass the conductor insulation. All control
cables shall be fanned out and connection made to terminal blocks and test equipment
for proper operation before cables are corded together.

SECTION - 5
FORMS OF BANK GURANTEES ,FORM
OF ARTICLE OF AGREEMENT &
ANNEXURE

PROFORMA OF BANK GURANTEE FOR PERFORMANCE SECURITY
OF THE CONTRACT
To
…………………………..
…………………………..
Re: Bank Guarantee in respect of Contract No………….

Dated……………. Between …………….. ( name of the Company )
and ……………………………….…….. ( name of the Contractor)
M/s. ………….. (Name and address of the Contractor) (hereinafter called “the
Contractor” with M/S. ………… (name of the Company) (hereinafter called “the Company”)
to execute …………. (name of the contract and brief description of work) on the terms and
conditions contained in the said contract.
It has been agreed that the Contractor shall furnish the Bank Guarantee from a bank as
per Annexure-X for a sum of Rs………….. as security for due compliance and performance
of the terms and conditions of the said contract.
The ……… (name of the Bank) having its Office at……..….. has at the request of the
Contractor agreed to give the Guarantor hereinafter contained.
We, the ………….… Bank (hereinafter called “the Bank” do hereby unconditionally
agreed with the Company that if the contractor shall in any way fail to observe or perform the
terms and conditions of the said contract or shall commit any breach of its obligation
thereunder, the Bank shall on demand and without any objection or demur to pay to the
company the said sum of Rs. …………… or such portion as shall then remain due with
interest without requiring the Company to have recourse to any legal remedy that may be
available to it to compel the Bank to pay the sum, or failing on the company to compel such
payment by the contractor.
Any such demand shall be conclusive as regards the liability of the Contractor to the
company and as regards the amount payable by the Bank under this Guarantee. The Bank
shall not be entitled to withhold payment on the ground that the Contractor has disputed its
liability to pay or has disputed the quantum of the amount or that any arbitration proceeding
or legal proceeding is pending between the company and the Contractor regarding the claim.
We, the ……….………. Bank further agree that the Guarantee shall come into force
from the date hereof and shall remain in force and effect till the period that will be taken for
the performance of the said Contract which is likely to be …………. day of ………….. but if
the period of Contract is extended either pursuant to the provisions in the said contract or by
mutual agreement between the contractor and the company the Bank shall renew the period
of the Bank Guarantee failing which it shall pay to the company the said sum of
Rs.………….…. or such lesser amount of the said sum of Rs.…………… as may be due to
the company and as the company may demand.
This Guarantee shall remain in force until the dues of the company in respect of the
said sum of Rs.………………. and interest are fully satisfied and the Company certifies that
the Contract has been fully carried out by the Contractor and discharged the guarantee.

The Bank further agrees with the company that the company shall have the fullest
liberty without consent of the Bank and without affecting in any way the obligations
hereunder to vary any of the terms and conditions of the said contract or to extend time for
performance of the said contract from time to time or to postpone for any time or from time
to time any of the powers exercisable by the Company against the contractor and to forebear
to enforce any of the terms and conditions relating to the said Contract and the Bank shall not
be relieved from its liability by reason of such failure or extension being granted to the
Contractor or to any forbearance, act or omissions on the part of the company or any
indulgence by the Company to the Contractor or any other matter or thing whatsoever which
under the law relating to sureties would but for this provision have the effect or relieving or
discharging the Guarantor.
The Bank further agrees that in case this Guarantee is required for a longer period and
it is not extended by the Bank beyond the period specified above the Bank shall pay to the
company the said sum of Rs.……….….. or such lesser sum as may then be deemed to the
Company and as the Company may require.
Notwithstanding anything contained herein the liability of the Bank under this
Guarantee is restricted to Rs.………..……. the guarantee shall remain in force till the day
………….. of ……..……. and unless the guarantee is renewed or claim is preferred against
the bank within six months from the said date all rights of the Company under this guarantee
shall cease and the Bank shall be relieved and discharged from all liabilities hereunder except
as provided in the preceding Clause.
This guarantee will not be discharged due to the change in the constitution of the
Bank or the Contractor.
The Bank has under its constitution power to give this Guarantee and
Sri……………………. who has signed it on behalf of the Bank has authority to do so.
Dated., this …………. day of ………..…….
Signature of the authorized person
For and on behalf of the Bank
Place
Under jurisdiction of ………………… court only.

ARTICLES OF AGREEMENT
This article of agreement made this......... day of .................20…., between the M/s
MAHANADI COALFIELDS LIMITED ( A Subsidiary of Coal India Limited ) , Sambalpur ,
of the one part (hereinafter referred to as the Company , which expression where the context
so admits shall include its successors in interest and assigns) and M/s
___________________________ through its Power of Attorney holder ………… of the
other part(hereinafter referred to as the Contractor , which expression where the context so
admits shall include its heirs , executors, administrators , legal representatives , successors in
business and assigns) .
Whereas the Company invited tender vide No._____________ Dt.

______________for the work
of__________________________________________________________________ .
And whereas Contractor submitted Tender and deposited Rs._______________ as

earnest money .
AND WHEREAS the tender of the Contractor has been accepted by the Company vide
Work Order / LOA No. ------ dated ------ for a sum of Rs.---------- (Rupees ---------------
only) and the Contractor has deposited Rs._______________( Rupees
_____________________ only) towards Performance Security Deposit vide Bank Guarantee
No.------ Dt. ---------.The Contractor has further agreed to the retention by the Company
towards Security Deposit @ 5% of the total Contract value i.e. Rs__________( Rupees
____________________________ only) from running account bills for the due fulfillment of
the contract to the satisfaction of the company. The Security Deposit and Performance
Security shall remain valid for the entire period of contract which includes the performance
guarantee period.
AND WHEREAS the Contractor has agreed to execute upon and subject to the
conditions set forth in the contract document, which are part of the Agreement and such other
conditions as are contained and set forth in the Annexure hereunder :
1) Articles of Agreement
2) Notice Inviting Tender including General Terms & Conditions, Special Terms
& Conditions, Scope of Work, Specifications & Drawings etc.
3) Technical Offer
4) Subsequent correspondences including clarifications asked and submitted by
the contractor during finalisation of tender
5) Letter of Intent
6) Letter of Acceptance
7) Acceptance of Letter of Acceptance by the firm
8) Detailed finalized work programme, Quality Plan and Payment Schedule etc
9) Integrity Pact
10) Joint Deed of Undertaking (JDU) ( In case of Consortium)

NOW THIS AGREEMENT WITNESSETH & IT IS HEREBY AGREED AS
FOLLOWS:-
1. In consideration for the payment of the said sum of Rs.-------------(Rupees ------------)

contractor shall upon and subject to the said terms and conditions execute and
complete the works as described in the said Tender Documents and any other terms &
conditions mutually agreed subsequently.
2. Time shall be considered as one of the essence of the contract and time for the
completion of the contract shall be counted from the 10th day of issue of the Letter of
Work Order or date of handing over of Site, whichever is later, and contract shall be
completed within two years from the date mentioned above.
3. The parties hereto shall respectively abide by and submit themselves to the terms and
conditions and stipulations contained in this Agreement and perform and discharge
their part of the contract accordingly.
4. Upon the terms and conditions of this Agreement, being fulfilled and performed to the
satisfaction of Mahanadi Coalfields Limited, the security deposit of the contractor(s)
as herein before recited or such portion thereof as they/he may be entitled to shall be
returned to the contractor(s) subject to the terms and conditions laid down in this
Agreement.
IN WITNESS WHEREOF the parties have hereunto set their respective hand & seals
at Sambalpur on the date, month and year first above written.
Signed by the Contractor/Contractors Signed on behalf of the

Company
Address Designation
In the presence of Witness In the presence of Witness

Address: Address :

ANNEXURE - I
(Ref. Clause – 3.3 of ITB)
Format for Affidavit
Non-Judicial Stamp Paper
AFFIDAVIT
I, ……………………………………………………………., Partner / Legal Attorney

/ Accredited Representative of M/s ………………………………………., solemnly declare
that :
1. We are submitting Tender for the Work…………………………………………

against Tender Notice No…………………. dated………………………. .
2. None of the Partners of our firm is relative of employee of ……………………..
( Name of the Company).
3. All information furnished by us in respect of fulfillment of eligibility criteria and
qualification information of this Tender is complete, correct and true.
4. All documents / credentials submitted along with this Tender are genuine,
authentic, true and valid.
5. If any information and document submitted is found to be false / incorrect at any
time, department may cancel my Tender and action as deemed fit may be taken
against us, including termination of the contract, forfeiture of all dues including
Earnest Money and banning / delisting of our firm and all partners of the firm etc.
Signature of the Bidder,
Dated …………………
Seal with signature of Notary

ANNEXURE -II
LETTER HEAD OF BIDDER
PROFORMA FOR CERTIFICATE AGAINST ADEQUATE WORKING

CAPITAL
The Working Capital of our firm i.e. ______________________________

__________ ( a Proprietorship / Partnership / Pvt. Ltd. / Limited Co. / Joint Venture /
Consortium / any other equivalent ) is Rs. _____________________ (Rupees
_________________________ ) as on dated ______________________ based on the annual
accounts.
We have sufficient own funds / loans / access to lines of credit to meet the working
capital requirements of this contract.
Full Signature
with Seal of the
Firm
To be certified by Chartered Accountant

mentioning their Registration No.
Others documents :
1. ………………………..
2. ………………………..
3. ………………………..

ANNEXURE –III
NON JUDICIAL STAMP PAPER OF Rs. 10/-
AFFIDAVIT
I / we, ……………………………………………. Partner / Legal Attorney /

Proprietor / Accredited Representative of M/s . ……………………………………
Solemnly declare that :
I / We are submitting tender for the work ……………………………………………..

…………………………………………………………………………………………
…………………………………………………………………………………………
…………………………………………………………………………………………
against tender notice No. …………………. Dated ……………………………
I / we shall abide by CMPF Clause of Tender Document and ensure implementation

of CMPF and Misc. Provision Act 1948 and allied scheme framed thereunder in
respect of the workers deployed by me / us.
Seal of Notary Signature of the Bidder

with signature Date

ANNEXURE - IV
MANDATE FORM FOR ELECTRONIC FUND TRANSFER / INTERNET BANKING
PAYMENT
To
The Mahanadi Coalfields Limited,
Jagruti Vihar,
Burla, Sambalpur – 768020
Dear Sir,
Sub : Authorisation for release of payment due from Mahanadi Coalfields Limited,
Burla through Electronic Fund Transfer / Internet Banking (SBI-NET / RTGS
Transfer).
Ref : Order No…………… Dt………… and / or Tender / Enquiry / Letter
No……….. Dt…………. .
( Please fill in the information in CAPITAL LETTERS, Please TICK wherever it is
applicable)
1. Name of the Party : ……………………………………………….

2. Address of the Party : ……………………………………………….
………………………………………………
City ………………. Pin Code ………………
E-Mail Id ……………………………………
Permanent Account Number …………………………………….
3. Particulars of Bank :
Bank Name Branch Name
Branch Place Branch City
Pin Code Branch Code
MICR No. RTGS Code
( 9 Digits code number appearing on the MICR Band of the cheque supplied by the Bank. Please
attach Xerox copy of a cheque of your bank ensuring accuracy of the bank name, ranch name &
code number)
Account Type Savings Current Cash Credit
Account Number ( as appearing in the Cheque
Book
4. Date from which the mandate should be effective
I hereby declare that the particulars given above are correct and complete. If any transaction is
delayed or not effected for reasons of incomplete or incorrect information, I shall not hold Mahanadi
Coalfields Limited responsible. I also undertake to advise any change in the particulars of my account
to facilitate updation of records for purpose of credit of amount through SBI Net / RTGS Transfer.
Place :
Date : Signature of the Party / Authorised Signatory
Certified that particulars furnished above are correct as per our records.
Banker’s Stamp
Date : ( Signature of the Party / authorized signatory.

ANNEXURE - V
Format
(Certificate to be furnished by the bidder in case the tender document is downloaded

from Website)
CERTIFICATE
( only for Bidder using downloaded tender document from Website)
We ………………………… undertake that the tender submitted by us is downloaded from

Website “(http://tenders.gov.in / www.mcl.gov.in / www.mahanadicoal.nic.in )”
and is same in content and form (verbatim), and any deviation, if detected, at any stage,
would entitle MCL authority to reject our bidding / offer without assigning any reason or
resource to any penal action, and would be legally binding on us.
Signature of Bidder with Seal

ANNEXURE - VI
PROFORMA FOR BANK GUARANTEE IN LIEU OF EARNEST MONEY
M/s Mahanadi Coalfields Limited,

P.O. : Jagruti Vihar, Burla,
Sambalpur – 768020(Orissa)
Dear Sir,
In consideration of the …………………………………………….having its Registered

Office at ………………………………………..(hereinafter called “the Company” which
expression shall unless repugnant to the subject or context includes its successors and assigns)
having agreed to exempt M/s ……………………………………………. Having its Registered
Office at ……………………………. ( hereinafter called “the said Bidders” which expression
shall unless repugnant to the subject or context includes its successors and assigns) from the
demand under the terms & conditions of Tender No. ………………………. For
……………….. ( hereinafter called “the said Tender”) of each earnest money for the due
fulfillment of the terms and conditions contained in the said Tender by the said Bidder on
production of Bank Guarantee for Rs. ………… . We ………………………….Bank
(hereinafter referred to as ‘the Bank”) do hereby undertake to pay the company an amount not
exceeding Rs. …………… on demand by the company for the reason of any breach by the
Bidder of any of the terms and conditions contained in the said Tender. The decision of the
company as to any such breach having been committed by the Bidder shall be final and binding
on us.
2. We, ………………Bank do hereby undertake to pay an amount due and payable under this
guarantee without any demur merely on a demand from the company stating that the amount
claimed is due from the Bidder for the reason of breach by the said Bidder of any of the terms
and conditions contained in the said Tender or for the reason of the Bidder failing to keep the
Tender open. Any such demand made on the Bank shall be conclusive. As regard the amount
due and payable by the Bank under this Guarantee shall be restricted to an amount not
exceeding Rs…
3. We, the said Bank further agree that Guarantee herein contained shall come into force from
the date hereof and shall remain in full force and effect till a demand or claim under this
Guarantee is made on us in writing on or before the …………………… we shall discharge all
liability under this Guarantee thereafter.
4. We, the said Bank lastly undertake not to revoke this Guarantee during its currency except
with the previous consent of the company in writing and agree that any change in the
constitution of the said Bidder or the Bank shall not discharge our liability hereunder.
5. This Guarantee is issued by Sri …………….. who is authorized by the Bank.
Under jurisdiction of …………………………………… court only.

ANNEXURE - VII
SPECIMEN OF LETTER OF CONTRACTOR’S ACCEPTANCE OF PROVISIONAL

REDUCTION OF RATE FOR SUBSTANDARD WORK.
No. dt.
To
……………………………….
……………………………….
Sir,
Subject: (Complete name of work)………………………
Reference: Your letter No………………………………..
I/We have carefully read the terms and conditions offered in your letter
dated…………… and they are acceptable to me/us.
Pending the decision of the Engineer in Charge of the final rates of payment
against the items of work specified in the statement attached to your above letter, which will
be final and binding. I/We agree to the same being paid at the provisional rates indicated
against each of the said item of work for the above work as mentioned in your statement.
Yours faithfully,
Seal & Signature of Bidder

ANNEXURE VIII
PROFORMA OF BANK GUARANTEE FOR MOBILISATION ADVANCE.
M/s. Coal India Limited,

10, Netaji Subhas Road,
Calcutta
Or
(Name of the Subsidiary Company with address).
Dear Sir,
In consideration of M/s Coal India Limited/Subsidiary Company having its Registered

Office at ………. (hereinafter called “the Company” which expression shall unless repugnant
to the subject or context includes its successors and assigns) having agreed under the terms and
conditions of the contract no………… dated……….. entered into between Coal India
Limited/Subsidiary Company and M/s…………….. having its Registered Office at …………..
(hereinafter called “the Contractor” to make mobilization advance lump-sum advance to the
tune of Rs.………… subject to submission of the Bank Guarantee for equal amount from any
Bank as per Annexure-X ( referred to as the said Bank) having its registered Office at
…………. do hereby undertake and agree to pay the company to the extent of Rs.…………. on
demand stating that the amount claimed by the Company is due and payable by the contractor
for the reasons of non refund and or non-recovery of the amount with interest thereon and to
unconditionally pay the amount claimed by the company on such demand without any demur
to the extent aforesaid.
We………… Bank agree that the company shall be the sole judge as to whether the
said contractor has failed/neglected in performing any of the terms and conditions of the said
contract and the decision of the company in this behalf shall be final and binding on us.
We the said Bank further agree that the Guarantee herein contained shall remain in
full force and effect upto ……….. and any claim received after the said date shall in no case
bind the Bank.
The Company shall have the fullest liberty without affecting in any way the liability
of the Bank under this guarantee or indemnity from time to time vary any of the terms and
conditions of the said contract or to extend the time of performance by the said contractor or to
postpone any time and from time to time any of the powers exercisable by it against the said
contractor and either to enforce or to forbear from enforcing any of the terms and conditions
governing the said contract or securities available to the company and the said Bank shall not
be released from its liability under these presents.
Notwithstanding anything contained herein the liability of the said Bank under this
guarantee is restricted to Rs.……. and this Guarantee shall come into force from the date
hereof and shall remain in full force and effect till …. Unless the written demand or claim
under this guarantee is made by the Company with us on or before … all rights of the company

under this guarantee shall cease to have any effect and we shall be relieved and discharged
from our liabilities hereunder.
We the said Bank lastly undertake not to revoke this guarantee during its currency except
with the previous consent of the company in writing and agree that any change in the
constitution of the said contractor or the said bank shall not discharge our liability hereunder.
This guarantee issued by Sri ……………… who is authorised by the Bank.
Under jurisdiction of ………… Court only.

ANNEXURE - IX
INTEGRITY PACT
Between
Mahanadi Coalfields Limited (MCL) hereinafter referred to as “The Principal”
And
…………………………………………….. hereinafter referred to as “The
Bidder/Contractor”
Preamble
The principal intends to award, under laid down organizational procedures, contracts
for……………………..The Principal values full compliance with all relevant laws and
regulations, and the principles of economic use of resources, and of fairness and transparency
in its relations with its Bidder/s and Contractor/s.
In order to achieve these goals, the Principal cooperates with the “International Non-
Governmental Organization” “Transparency International”(TI). Following TI’s national and
international experience, the Principal will appoint an external independent Monitor who will
monitor the tender process and the execution of the contract for compliance with the
principles mentioned above.
Section 1 – Commitments of the Principal
(1) The Principal commits itself to take all measures necessary to prevent corruption and
to observe the following principles:
i) No employee of the Principal, personally or through family members, will in

connection with the tender for, or the execution of a contract, demand, take a
promise for or accept, for him/herself or third person, any material or
immaterial benefit which he/she is not legally entitled to.
ii) The Principal will, during the tender process treat all Bidders with equity and
reason. The Principal will in particular, before and during the tender process,
provide to all Bidders the same information and will not provide to any Bidder
confidential/additional information through which the Bidder could obtain an
advantage in relation to the tender process or the contract execution.
iii) The Principal will exclude from the process all known prejudiced persons.
(2) If the Principal obtains information on the conduct of any of its employees which is a
criminal offence under the relevant Anti-Corruption Laws of India, or if there be a
substantive suspicion in this regard, the Principal will inform its Vigilance Office and
in addition can initiate disciplinary action.
Section 2 – Commitments of the Bidder/contractor
(1) The Bidder/Contractor commits itself to take all measures necessary to prevent
corruption. He commits himself to observe the following principles during his
participation in the tender process and during the contract execution.

i) The Bidder/Contractor will not, directly or through any other person or firm
offer, promise or give to any of the Principal’s employees involved in the
tender process or the execution of the contract or to any third person any
material or immaterial benefit which he/she is not legally entitled to, in order
to obtain in exchange any advantage of any kind whatsoever during the tender
process or during the execution of the contract.
ii) The Bidder/Contractor will not enter with other Bidders into any undisclosed
agreement or understanding, whether formal or informal. This applies in
particular to prices, specifications, certifications, subsidiary contracts,
submission or non-submission of bids or any other actions to restrict
competitiveness or to introduce cartelization in the bidding process.
iii) The Bidder/Contractor will not commit any offence under the relevant Anti-
corruption Laws of India; further the Bidder/Contractor will not use
improperly, for purposes of competition or personal gain, or pass on to others,
any information or document provided by the Principal as part of the business
relationship, regarding plans, technical proposals and business details,
including information contained or transmitted electronically.
iv) The Bidder/Contractor will, when presenting his bid, disclose any and all
payments he has made, is committed to or intends to make to agents, brokers
or any other intermediaries in connection with the award of the contract.
(2) The Bidder/Contractor will not instigate third persons to commit offences
outlined above or be an accessory to such offences.
Section 3 - Disqualification from tender process and execution from future contracts.
If the Bidder, before contract award has committed a transgression through a violation of
Section 2 or in any other form such as to put his reliability or credibility as Bidder into
question, the Principal is entitled to disqualify the Bidder from the tender process or to
terminate the contract, if already signed, for such reason.
i) If the Bidder/Contractor has committed a transgression through a violation of

Section 2 such as to put his reliability or credibility into question, the Principal
is entitled also to exclude the Bidder/Contractor from future contract award
processes. The imposition and duration of the exclusion will be determined by
the severity of the transgression. The severity will be determined by the
circumstances of the case, in particular the number of transgressions, the
position of the transgressors within the company hierarchy of the Bidder and
the amount of the damage. The exclusion will be imposed for a minimum of 6
months and maximum of 3 years.
ii) The Bidder accepts and undertakes to respect and uphold the Principal’s
absolute right to resort to and impose such exclusion and further accepts and
undertakes not to challenge or question such exclusion on any ground,
including the lack of any hearing before the decision to resort to such
exclusion is taken. This undertaking is given freely and after obtaining
independent legal advice.
iii) If the Bidder/Contractor can prove that he has restored/recouped the damage
caused by him and has installed a suitable corruption prevention system, the
Principal may revoke the exclusion prematurely.
iv) A transgression is considered to have occurred if in light or available evidence
no reasonable doubt is possible.

Section 4 – Compensation for Damages
i) If the Principal has disqualified the Bidder from the tender process prior to the
award according to Section 3, the Principal is entitled to demand and recover
from the Bidder liquidated damages equivalent to 3% of the value of the offer
or the amount equivalent to Earnest Money Deposit/Bid Security, whichever is
higher.
ii) If the Principal has terminated the contract according to Section 3, or if the
Principal is entitled to terminate the contract according to Section 3, the
Principal shall be entitled to demand and recover from the Contractor
liquidated damages equivalent to 5% of the Contract value or the amount
equivalent to Security Deposit/Performance Bank Guarantee whichever is
higher.
iii) The bidder agrees and undertakes to pay the said amounts without protest or
demur subject only to condition that if the Bidder/Contractor can prove and
establish that the exclusion of the Bidder from the tender process or the
termination of the contract after the contract award has caused no damage or
less damage than the amount of the liquidated damages, the Bidder/Contractor
shall compensate the Principal only to the extent of the damage in the amount
proved.
Section 5 – Previous transgression
i) The Bidder declares that no previous transgressions occurred in the last 3

years with any other Company in any country conforming to the TI approach
or with any other Public Sector Enterprise in India that could justify his
exclusion from the tender process.
ii) If the bidder makes incorrect statement on this subject, he can be disqualified
from the tender process or the contract, if already awarded, can be terminated
for such reason.
Section 6 – Equal treatment of all Bidders/Contractors/ Subcontractors
i) The Bidder/Contractor undertakes to demand from all subcontractors a

commitment in conformity with this Integrity Pact, and to submit it to the
Principal before contract signing.
ii) The Principal will enter into agreements with identical conditions as this one
with all Bidders, Contractors and Subcontractors.
iii) The Principal will disqualify from the tender process all bidders who do not
sign the pact or violate its provisions.
Section 7 – Criminal charges against violating Bidders / Contractors / Subcontractors
If the Principal obtains knowledge of conduct of a Bidder, Contractor or Subcontractor, or of

an employee or a representative or an associate of a Bidder, Contractor or Subcontractor
which constitutes corruption, or if the Principal has substantive suspicion in this regard, the
Principal will inform the same to the Vigilance Office.

Section 8 – External Independent Monitor/Monitors (three in number depending on
the size of the contract) ( to be decided by the Chairperson of the
Principal)
i) The Principal appoints competent and credible external Independent Monitor

for this Pact. The task of the Monitor is to review independently and
objectively, whether and to what extent the parties comply with the obligations
under this agreement.
ii) The Monitor is not subject to instructions by the representatives of the parties
and performs his functions neutrally and independently. He reports to the
Chairperson of the Board of the Principal.
iii) The Contractors accepts that the Monitor has the right to access without
restriction to all Project documentation of the Principal including that provided
by the Contractor. The Contractor will also grant the Monitor, upon his
request and demonstration of a valid interest, unrestricted and unconditional
access to his project documentation. The same is applicable to
Subcontractors. The Monitor is under contractual obligation to treat the
information and documents of the Bidder/Contractor/Subcontractor with
confidentiality.
iv) The Principal will provide to the Monitor sufficient information about all
meetings among the parties related to the Project provided such meetings
could have an impact on the contractual relations between the Principal and
the Contractor. The parties offer to Monitor the option to participate in such
meetings.
v) As soon as the monitor notices, or believes to notice, a violation of this
agreement, he will so inform the Management of the Principal and request the
Management to discontinue or heal the violation, or to take other relevant
action. The Monitor can in this regard submit non-binding recommendations.
Beyond this, the Monitor has no right to demand from the parties that they act
in a specific manner, refrain from action or tolerate action.
vi) The Monitor will submit a written report to the Chairperson of the Board of
the Principal within 8 to 10 weeks from the date of reference or intimation to
him by the ‘Principal’ and, should the occasion arise, submit proposals for
correcting problematic situations.
vii) Monitor shall be entitled to compensation on the same terms as being extended
to/provide to Outside Expert Committee members/Chairman as prevailing
with Principal.
viii) If the Monitor has reported to the Chairperson of the Board a substantiated
suspicion of an offence under relevant Anti-Corruption Laws of India, and the
Chairperson has not, within the reasonable time, taken visible action to
proceed against such offence or reported it to the Vigilance Office, the
Monitor may also transmit this information directly to the Central Vigilance
Commissioner, Government of India.
ix) The work ‘Monitor’ would include both singular and plural.
Section 9 – Pact Duration
This Pact begins when both parties have legally signed it. It expires for the Contractor 12
months after the last payment under the respective contract, and for all other Bidders 6
months after the contract has been awarded.

If any claim is made/lodged during this time, the same shall be binding and continue to be
valid despite the lapse of this pact as specified above, unless it is discharged/determined by
Chairperson of the Principal.
Section 10 – Other Provisions
i) This agreement is subject to Indian Law. Place of performance and jurisdiction

is the Registered Office of the Principal, i.e. Sambalpur.
ii) Changes and supplements as well as termination notices need to be made in
writing. Side agreement have not been made.
iii) If the Contractor is a partnership or a consortium, all partners or consortium
members must sign this agreement.
iv) Should one or several provisions of this agreement turn out to be invalid, the
remainder of this agreement remains valid. In this case, the parties will strive
to come to an agreement to their original intentions.
_____________________________ _____________________________
For the Principal For the Bidder/Contractor
Place: ____________________ Witness 1:___________________
Date: ____________________ Witness 2:___________________

ANNEXURE-X
LIST OF BANKS WHOSE BANK GUARANTEES WOULD BE ACCEPTABLE FOR

EMD / BID SECURITY & CONTRACT PERFORMANCE SECURITY /
GUARANTEE ETC.
(A) SBI AND ASSOCIATES (B) NATIONALISED BANK (C) SCHEDULED PRIVATE
BANKS ( INDIAN BANKS)
1. State Bank of India 1. Allahabad Bank 1. Bank of Rajasthan
2. State Bank of Bikaner and 2. Andhra Bank 2. Bharat Overseas Ltd
Jaipur 3. Bank of India 3. Catholic Syrian Bank
3. State Bank of Hyderabad 4. Bank of Maharashtra 4. City Union Bank
4. State Bank of Indore 5. Canara Bank 5. Dhanalakshmi Bank
5. State Bank of Mysore 6. Central Bank of India 6. Federal Bank Ltd
6. State Bank of Patiala 7. Corporation Bank 7. Jammu & Kashmir Bank Ltd
7. State Bank of Saurashtra 8. Dena Bank 8. Karnataka Bank Ltd
8. State Bank of Travancore 9. IndianBank 9. Karur Vysya Bank Ltd
10. Indian Overseas Bank 10. Lakshmi Vilas Bank Ltd
11. Oriental Bank of Commerce 11. Lord Krishna Bank Ltd
12. Punjab National Bank 12. Nainital Bank Ltd
13. Punjab & Sind Bank 13. Kotak Mahindra Bank
14. Syndicate Bank 14. Ratnakar Bank Ltd
15. Union Bank of India 15. Sangli Bank Ltd
16. United Bank of India 16. South Indian Bank Ltd
17. UCO Bank 17. Tamilnad Mercantile Bank
18. Vijaya Bank Ltd
19. Bank of Baroda 18. ING Vysya Bank Ltd
19. UTI Bank Ltd
20. SBI Commercial &
International Bank Ltd
21. Ganesh Bank Kurundwad
Ltd
22. Indusind Bank Ltd
23. ICICI Bank
24. HDFC Bank Ltd
25. Centurion Bank Ltd
26. Bank of Punjab Ltd
27. Development Credit Bank
Ltd

ANNEXURE-XI
FORMAT OF MEMORANDUM OF UNDERSTANDING WITH ASSOCIATE(s)
( Format for the MoU between the Bidder i.e. Lead Member & its Associate(s)
and to be submitted along with the Bid by the Bidder)
(To be executed on Non-Judicial Stamp Paper of appropriate value)
Memorandum of Understanding
Sub : Planning, Design, Engineering, Construction, Fabrication, Supply, Erection,

Commissioning & Trial Run of Coal Handling Plant with SILO Loading
Arrangement at Lingaraj OCP, Lingaraj Area complete with Civil, Structural,
Electrical & Mechanical works of Conveyor System & SILO having Rapid
Wagon Loading System along with allied auxiliary facilities such as Dust
Suppression System, Passenger Lift, Fire fighting System, Plant Cleaning
System, Illumination & Communication System, etc. as per requirement on
Turn-key basis.
Ref : NIT No……………………………..
We, M/s …………………………………. ( Name & Address of the Bidder i.e Lead
Member) and (i) M/s ………………………… , (ii) M/s ………………………. And (iii) M/s
………………………….. * ( Names and addresses of the Associate / Consortium partner)
have formed a Consortium for the subject work and hereby undertake :
1. to be held jointly and severally responsible for the subject work as well as
performance of the Contract.
2. that M/s …………………………. ( Bidder / Associate or Consortium partners)* have

the experience as prime contractor for construction of the work whose details are
given hereafter.
Details of the work of Design ,Supply, Construction & Commissioning of Integrated

bulk material handling system / CHP/ RLS/ UTLS with conveyor system for coal or
other materials and its allied works and also having experience of successfully
completed either a SILO of minimum capacity of 2400 Tonnes or RCC Bunker of
minimum capacity of 15,000 Tonnes for Coal or any other Minerals irrespective of
value and period and the same is in successful operation.
Name of Bidder / Associate (Consortium) partners : ………………………..

Sl. Location Details of the Works Date of Details of Remarks
No. of Plant Commissioning customer
1
2
3
( The Bidder as well as each Associate / Consortium Partner with experience as prime
contractor for the work as mentioned in this clause shall furnish their details
separately).

3. that M/s ………………………. shall be the Lead Member for this Associate /
Consortium.
4. That M/s ……………………… ( name of the Bidder i.e. Lead Member) has
associated with (i) M/s ……………………………. (ii) M/s ………………
………and (iii) M/s ……………. * ( name of Associate or Consortium partners) for
the subject work as per their role, tenure & % share in association, given hereafter :
Sl. Name of Bidder (LM) & Role of Bidder / Associate / Tenure of % share in
No. Associate / Consortium Consortium partners Association Association
partners **
1 M/s …….. ( Bidder / LM) Financial& technical For entire
qualification period
2 M/s ………(Associate (s) Financial& technical
qualification
5. that M/s ……………………………… ( Bidder i.e. Lead Member) have formed

consortium with (i) M/s ……………………… & (ii) M/s
………………………………. (names of Associate / Consortium partners) having
collective experience towards Technical & Financial Qualification / as per Cl. No.
3.4(a), (b), (c),(d) & 3.5 of Instruction to Bidders of NIT. We hereby undertake that
this MoU followed by JDU as per the provision of the Bid Document shall remain
valid for the tenure of association as specified at para 4.0 of this MoU.
5. that M/s …………………………. ( Bidder i.e. Lead Member) shall furnish the Joint
Deed of Undertaking (JDU) duly executed between the Bidder and the Associate(s) as
per the format given in the NIT by the date specified by MCL.
6. that this MoU shall valid till a valid JDU is submitted.
7. That the above MoU shall governed by substantive and procedural laws in India.
For and on behalf of : …………………………………..

( the Lead Member of Associate / Consortium )
Signature : …………………………………..
( the Authorised Signatory)
Name of the Signatory :
Designation :
Company’s Stamp / Seal :
For and on behalf of : (i) …………………… (ii) …………………….. (iii)

……………………
( the Associate )
Signature : (i) …………………… (ii) …………………….. (iii)

……………………
(the authorized Signatory)

Name of the Signatory:(i) …………………… (ii) …………………….. (iii)
……………………
Designation : (i) …………………… (ii) …………………….. (iii)

……………………
Company’s Stamp / Seal :
Witness (1) : Witness (2) :
Signature : …………………….. Signature : ……………………..
Name : …………………….. Name : ………………………

Official Address : ……………………. Official Address : …………………..
Date :
Place :
* Strike out which is not applicable

** Association / Consortium formed for execution of this subject work will be effective
from the date of signing of the Contract.

ANNEXURE-XII
Bidder i.e. Lead Member(LM) seeking Qualification having its own strength under CI.
No.3.4 (a), (b),(c) , (d) & 3.5 of Instructions to Bidders of NIT.
PROFORMA OF JOINT DEED OF UNDERTAKING (JDU) TO BE JOINTLY

EXECUTED BY THE BIDDER i.e. LEAD MEMBER AND HIS ASSOCIATE(S)
(on the strength of other associate(s) collectively meeting both the Technical &
Financial Qualification Requirement as per Clause No.3 of
Instructions to Bidders
(TO BE FURNISHED IN NON-JUDICIAL STAMP PAPER OF APPROPRIATE

VALUE IN ACCORDANCE WITH STAMP ACT)
[To be submitted before signing of the Contract by the Bidder

i.e. Lead Member]
This JOINT DEED OF UNDERTAKING (JDU) executed on this ……. day of ………
(month two thousand…….(year) by M/s……………………….. (Legal Status) having its
…………….(registered/principal/head etc.*) office at …………………(address of the
Bidder) hereinafter called “the Bidder” i.e. Lead Member (LM), which expression shall
unless repugnant to the context or meaning thereof, include its successors-in-interest,
administrators, executors and permitted assigns and M/s……………….. (Legal Status)
registered under the …………… Act, …………….. having its/ their
……….(registered/principal/head etc.*) office at (1)……………. (2)………. …………..
hereinafter called “the Associate” which expression shall unless repugnant to the context or
meaning thereof, include its/their successors-in-interest, administrators, executors and
permitted assigns in favour of Mahanadi Coalfields Limited, a company incorporated under
the Companies Act, 1956, having its Registered Office at Jagruti Vihar, P.O. – Jagruti Vihar,
Dist-Sambalpur, PIN-768020, Orissa, India (hereinafter called “Owner”/”Company” which
expression shall unless repugnant to the context or meaning thereof, include its successors in
interest, administrators, executors and assigns).
WHEREAS the Owner has invited Proposal for Planning, Design, Engineering, Construction,
Fabrication, Supply, Erection, Commissioning & Trial Run of Coal Handling Plant with
SILO Loading Arrangement at Lingaraj OCP, Lingaraj Area complete with Civil, Structural,
Electrical & Mechanical works of Conveyor System & SILO having Rapid Wagon Loading
System along with allied auxiliary facilities such as Dust Suppression System, Passenger Lift,
Fire fighting System, Plant Cleaning System, Illumination & Communication System, etc. as
per requirement on Turn-key basis vide its NIT No…………. dt. ……… .
AND WHEREAS, M/s………………………………(the Bidder/LM) has submitted its

Proposal bearing Ref. No……………dated…………… based on MoU dated……….. in
association with M/s………………………, and this Deed of Joint Undertaking under these
presents and the proposal, in accordance with the requirements of CI. No.3. of Instructions to
Bidders, have been signed jointly by us.

AND WHEREAS, M/s………………………………(the Bidder/LM) has requisite collective
experience as prime contractor , of Technical / Financial Qualification Requirement of
Clause No. 3.4 (a),(b), (c), (d) & 3.5 of Instructions to Bidders of NIT with associates
1) M/s -------------------------------------------2) M/s ---------------------------------------- and is
entitled to bid under Clause No.2.3 (ii) under associates / Consortium Route of as the Bidder
and thus after association, the Bidder & his Associate(s) collectively meet the requirements of
Construction of “ Design , Supply , Construction and Commissioning of Integrated Bulk
Material Handling System/ CHP./RLS/UTLS with Conveyor System for Coal and other
minerals and its allied works on turnkey basis and also having experience of successfully
completed either a SILO of minimum capacity of 2400 Tonnes or RCC Bunker of minimum
capacity of 15,000 Tonnes for Coal or any other Minerals irrespective of value and period
and the same is in successful operation as per CI. No.3.0 of Qualifying Requirements of
Instructions to Bidders of NIT. The said Bidder (LM) and its Associate(s) hereby furnish an
undertaking that they shall be held jointly and severally responsible and bound unto Owner
for Construction of Planning , Design , Engineering ,Construction , Fabrication, Supply ,
Erection and Commissioning & Trial Run of Coal Handling Plant with Silo Loading
Arrangement at Lingaraj OCP, Lingaraj Area as well as performance of the Contract for the
period for which the association has entered into this JDU, fully meeting the parameters
guaranteed for the above work as per the bidding documents/ specifications including
furnishing Financial Securities, in the event the Proposal is accepted by the Owner, resulting
in a Contract (hereinafter called the “Contract”).
The role, tenure & % share of the members of the Association/Consortium is as given
hereafter:
Sl. Name of Bidder(LM) & Role of Tenure of % Share in

No Associate/Consortium Bidder/Associate(s) Association* association
partners
1 M/s……………………… Technical & Financial Entire Contract
(Bidder i.e. LM) Qualification Period
2 M/s……….. (Associate Technical & Technical

(s) Qualification
NOW THEREFORE, THIS DEED Witnesses as Under:
1.0 That in consideration of the Award of the Contract by the Owner to

M/s………………….. (the Bidder i.e LM), we, the aforesaid Bidder (LM) and the
Associate(s), will jointly and severally be responsible in accordance with the Contract
to Owner for successful Construction of the work “ Planning , Design , Engineering
,Construction , Fabrication, Supply , Erection and Commissioning & Trial Run of
Coal Handling Plant with Silo Loading Arrangement Lingaraj OCP, Lingaraj Area as
well as performance of the Contract, fully meeting the guaranteed parameters required
as per the Contract Specification.
2.0 The Bidder (LM) along with the Associate(s) shall have responsibility of the work of
“ Planning , Design , Engineering, Construction , Fabrication, Supply , Erection and
Commissioning & Trial Run of Coal Handling Plant with Silo Loading Arrangement
at Lingaraj OCP, Lingaraj Area for entire term of the contract.

2.1 Without prejudice to the generally of the undertaking in paragraph 1.0 above, the
manner of achieving the objective set-forth in paragraph 1.0 above shall be as
follows:
a) M/s……………… (name of the Lead Member / Associate(s) having

Technical Qualification Requirement as per CI. No.3.4 (a) and 3.4(b) of
Instructions to Bidders shall be required to furnish the design and to advise
and provide necessary technical assistance to M/s……………… (the Bidder
i.e. LM) for the work of Construction of Coal Handling Plant with Silo
Loading Arrangement at Lingaraj OCP, Lingaraj Area, their quality
surveillance during manufacture, erection & commissioning and performance
testing both at the works site. Lead Member / All such Associate (s) further
shall depute their technical experts from time to time to the project site to
facilitate successful performance for the Construction of Coal Handling Plant
with Silo Loading Arrangement at Lingaraj OCP, Lingaraj Area, as stipulated
in the aforesaid Bidding Documents. Other Associate(s) shall also render all
the assistance during the period of contract.
b) The Lead Member / Associate(s) will be responsible to make detailed
drawings, supply, erect, commission and carry out the performance tests of the
Construction of Coal Handling Plant with Silo Loading Arrangement Lingaraj
OCP, Lingaraj Area, in accordance with the Bidder’s consent.
c) In the event, the Lead Member / Associate(s) and the Bidder (LM) fail to
demonstrate successful performance of the Construction of Coal Handling
Plant with Silo Loading Arrangement at Lingaraj OCP, Lingaraj Area, as set
forth in the Bidding Documents, the Associate(s) and the Bidder (LM) will be
jointly responsible for taking proper corrective measures.
d) Implementation of the corrected design and all other necessary corrective
repairs, replacements or modifications to the Construction of Coal Handling
Plant with Silo Loading Arrangement at Lingaraj OCP, Lingaraj Area, if
required, shall be the joint responsibility of the Associate(s) & the Bidder
(LM).
e) The Lead Member / Associate(s) will be fully responsible for the quality of all
the equipment/ main assemblies/ components manufactured at its works or at
its Vendor’s works and, if necessary, their repair or replacement, for
incorporation in the Construction of Coal Handling Plant with Silo Loading
Arrangement at Lingaraj OCP, Lingaraj Area, and timely completion as per
the Contract.
f) However, the Lead Member / Associate(s) having experience of Design,
Supply, Construction & Commissioning of Integrated Bulk Material Handling
System / CHP / RLS / UTLS with Conveyor System for Coal or other minerals
and its allied works on Turn-Key basis AND experience of successfully
completed either a SILO of minimum capacity of 2400 Tonnes or RCC
Bunker of minimum capacity of 15,000 Tonnes for Coal or any other Minerals
irrespective of value and period and the same is in successful operation as per
CI. No.3.4(a) and 3.4(b) of Instructions to Bidders, shall have exclusive
responsibility of Construction of Coal Handling Plant with Silo Loading
Arrangement at Lingaraj OCP, Lingaraj Area as per the tenure specified in this
JDU.
2.2 We, the Bidder(LM) and the Associate(s) are fully aware that for non-fulfillment of
any of the obligations either towards Construction of Coal Handling Plant with Silo
Loading Arrangement at Lingaraj OCP, Lingaraj Area, the Owner is free to take up

the matter either with the Lead Member and/ or any or all of the Associate(s) as per
the Owner’s convenience.
3.0 This Joint Deed of Undertaking shall be construed and interpreted in accordance with
the Laws of India. The Court of Sambalpur, Orissa and High Court of Orissa, Cuttack
shall have exclusive jurisdiction in all matters arising thereunder.
4.0 We, the Bidder (LM) and the Associate(s), undertake not to revoke this Undertaking
for the full term of the Contract and further stipulate that the undertaking herein
contained shall terminate upon satisfactory completion of such period.
5.0 In case of award, the Bidder(LM) & his Associate(s) shall furnish a Financial Security
in favour of the Owner from any reputed commercial bank as indicated in the NIT.
The value of such Financial Security Contract Performance Guarantee shall be
guaranteed towards the faithful performance/ compliance of this Joint Deed of
Undertaking in accordance with the terms & conditions specified herein. The
guarantee shall be unconditional, irrevocable and valid as stipulated under the
Contract. The guarantee amount shall be payable to Owner on demand without any
demur, reservation, protest or contest.
6.0 That this Deed will form an integral part of the Contract awarded to the Bidder(LM)
on acceptance of its Proposal and shall be operative from the date of the Contract
coming into force.
IN WITNESS WHERE OF, the Associate(s) and the Bidder(LM) have, though their
authorised representatives, set their hands and seal on the day, month and year first
mentioned above.
BIDDER
For and on behalf of M/s…………………………………(name of the Bidder/LM)
Signature………………………………(the Authorised Signatory)
Name of the Signatory……………………………………………
Designation……………………………………………………
Bidder’s
Stamp/Seal …………………………………………………….
WITNEESS (1) WITNEESS (2)
Signature……………………………… Signature………………………………
Name…………………………………. Name………………………………….
Official Address……………………… Official Address………………………

ASSOCIATE(S)
For and on behalf of M/s…………………………………
(Name of the Associates)
Signature …………………………………...
(Authorised Signatory)
Name of the Signatory ………………………………………..
Designation ………………………………………..
Company’s ………………………………………..
Stamp/Seal
WITNEESS (1) WITNEESS (2)
Signature……………………………… Signature………………………………
Name…………………………………. Name………………………………….
Official Address……………………… Official Address………………………
* Association/Consortium formed for execution of this subject work will be effective

from the date of signing of the Contract.

िनिवदा द तावेज
TENDER DOCUMENT
FOR
DESIGN, SUPPLY, ERECTION, COMMISSIONING AND
TESTING OF COAL HANDLING PLANT & SILO (16.0 Mtpa)
NEAR
LINGARAJ OCP
LINGARAJ AREA
महानदी कोलफी स िलिमटे ड

भाग -2
VOL II
(TEXT, SPECIFICATIONS)
िदस बर - 2011
से ट्रल माईन लािनंग ए ड िडजाइन इ सटी यट
ू
(कोल इि डया की अनुषंगी क पनी)
क्षेत्रीय स थान- 7
säwÂàçÎwÊ -751001
TENDER DOCUMENT FOR DESIGN, SUPPLY, ERECTION, COMMISSIONING AND TESTING OF
COAL HANDLING PLANT & SILO (16.0 Mtpa) NEAR LINGARAJ OCP
INDEX
CHAPTER DESCRIPTION PAGE NO
FROM TO
I PREAMBLE I-1 I-5
II BASIC DATA & SYSTEM DESCRIPTION II-1 II-28
III SCOPE OF SUPPLY AND WORK III-1 III-66
IV TECHNICAL SPECIFICATIONS
MECHANICAL IV-1 IV- 79
ELECTRICAL IV-80 IV-204
V DATA TO BE FURNISHED BY THE V-1 V-34

TENDERER
Job No 730176

LIST OF DRAWINGS

SL. SUBJECT DRAWING NO. PLATE NO.
NO.
1. LOCATION KEY PLAN R7-GEO-000000 PLATE NO.1
2. FLOW SHEET OF COAL FLOW DIAGRAM R7-E&M-100221 Rev-1 PLATE NO.2
3. SYSTEM PLAN R7-E&M-100222 Rev-1 PLATE NO.3
4. SCHEMATIC DIAGRAM OF C1A R7-E&M-100223 Rev-1 PLATE NO.4
5. SCHEMATIC DIAGRAM OF C1, C2A/C2B R7-E&M-100224 Rev-1 PLATE NO.5
6. SCHEMATIC DIAGRAM OF C3A/C3B R7-E&M-100225 Rev-1 PLATE NO.6
7. SCHEMATIC DIAGRAM OF C4A/C4B, C5A/C5B R7-E&M-100226 Rev-1 PLATE NO.7
8. SCHEMATIC DIAGRAM OF C6A/C6B, C7A/C7B R7-E&M-100227 Rev-1 PLATE NO.8/8a
9. SCHEMATIC DIAGRAM OF C8A/C8B & SILO R7-E&M-100228 Rev-1 PLATE NO.9
10. SCHEMATIC DIAGRAM OF TRUCK RECEIPT R7-E&M-100229 Rev-1 PLATE NO.10

HOPPER
11. SCHEMATIC DIAGRAM OF TH1 R7-E&M-100230 Rev-1 PLATE NO.11
13. SCHEMATIC DIAGRAM OF TH3, TH4, TH5 R7-E&M-100232 Rev-1 PLATE NO.13
18.. SCHEMATIC DIAGRAM OF TH10 R7-E&M-100237 Rev-1 PLATE NO.18
19. REMOTE & SEQUENCE CONTROL AND R7-E&M-400170 PLATE NO.19

INTERLOCKED SYSTEM (A-FLOW)
INTERLOCKED SYSTEM (B-FLOW)
INTERLOCKED SYSTEM (C-FLOW)
22. SINGLE LINE DIAGRAM FOR 33/3.3Kv R7-E&M-300913 PLATE NO.22
CHP SUBSTATION
23. SINGLE LINE DIAGRAM FOR 3.3Kv POWER R7-E&M-300914 PLATE NO.23
DISTRIBUTION AT SUBSTATION- I, II & III

JOB NO. 730176

TENDER DOCUMENT FOR DESIGN, SUPPLY, ERECTION, COMMISSIONING AND TESTING
OF COAL HANDLING PLANT & SILO (16.0 Mtpa) NEAR LINGARAJ OCP
CHAPTER-I
1.0 PREAMBLE
The present Tender document envisages design, construction, supply,

erection, commissioning, trial run and handing over of the complete plant
for transportation of coal from the 5 nos. of feeder breaker circuits and
truck receipt RCC hoppers by a system of belt conveyors, with a provision
of secondary crushers in line, storage in a 15000t semi ground storage
bunker with truck unloading facility, reclaim by plough feeders and loading
into the wagons through silo.
The tender document also covers all the associated sub-systems like
power supply, internal and external illumination, control communication,
dust suppression, fire fighting and plant cleaning systems etc.
It may be noted that this is a brief description but does not cover all the
aspects of tender, which are covered in subsequent chapters.
This tender is being issued in four volumes

• Vol – I : General & Commercial terms and conditions
• Vol – II : Text , specifications
• Vol – IIIA : Drawings
• Vol—III : Pricing Format
1.1 LOCATION
Lingaraj South block, comprising an area of 4.87 Sq.km falls between

Latitude 20o57’ 39” : 20o, 58’ 19” N and Longitude 85 o 9’33” : 85 o 9’33” :
85 o 12’12” E on the southern part of Talcher coalfield and is included in
the survey of India topo sheet No.73H/1. It is surrounded by Talcher,
Handidua and Deulbera collieries to the South, Bhubaneswari block to the
North Ananta OCP to the West and NH-23 to the East .
1.2 COMMUNICATION
The area is connected by an all weather metalled road from Bhubaneswar

which is at a distance of about 170 km. The nearest railway station is
Talcher on SE railway and is at a distance of about 6 km from the mine.
National highway No.23 passes through the Eastern boundary of the
project site at a distance of less than 1 km.
1.3 PHYSIOGRAPHY
As in other parts of the coalfield, Lingaraj block is gently undulating with a

very gentle general slope towards North. To the South and South east
bordering Talcher, Handidhua and Deulbera collieries, small hillocks of
JOB NO-730176 CH-I -1

conglomerate horizon above seam I are the prominent physical feature.

The gently undulating plains are usual sites of village forest, cultivation
and habitation. The south-western part of the block is covered by young
plants, the future forest site. Other than this cover of vegetation, the area
is devoid of any thick vegetation cover and the land is mostly under paddy
cultivation. The general range of altitude is between 90 to 110 m above
M.S.L. the gravel ridges bordering Talcher, Handidhua and Deulbera
colliereis are having the highest altitude.
1.4 CLIMATE
The climate in the area is more or less similar to that of other tropical parts
of India. Summer is very severe and temperature in May-June shoots ups
49 o C accompanied by high humidity. Winter is mild and enjoyable and the
minimum temperature so far recorded is 9oC in the month of January.
Monsoon breaks out by the end of June and continues intermittently till
middle of October.
1.5 DRAINAGE
The main drainage is controlled by the southernly flowing Brahmani River

situated at the eastern extremity of the coalfields and east of Talcher town.
The eastern boundary of Lingaraj south block is about 3 km west from this
river. There are small seasonal nallahs including a bifurcation of Bangaru
Jhora nallah within the block. Quite a number of small man-made ponds
are utilized by local villagers for irrigation and drinking water purposes.
1.6 ABOUT THIS TENDER
As described earlier this tender document is being issued in four volumes.

This volume- II shall deal with the general proposal, and technical
specifications etc.
The proposal is to install a Rapid loading system through Silo for fast
evacuation of coal at Lingaraj OCP.
At present ROM Coal brought by dumpers/tipping trucks is unloaded into
any one of the 7 nos. of feeder breaker circuits for crushing to (-)200 mm
size. Crushed coal is elevated and stored in 2x 100 t hoppers located near
the discharge end of the conveyor of the respective feeder breaker circuit.
Coal thus stored is loaded into tipping trucks for onward transportation
either to the wharf wall siding of NTPC bulb or to the Jagannath III & IV
siding. Trucks are weighed over the road weigh bridges for record
purposes. Coal stored near the wharf wall sidings is loaded into the
wagons by pay loaders. Tare and gross weights of wagons are recorded
by electronic in motion rail weigh bridges installed on the track from
Lingaraj siding to NTPC.
The blast free coal produced by surface miner is transported directly from
face of the mine to the wharf wall siding at Lingaraj OCP. About 60% of
JOB NO-730176 CH-I -2

the total coal production of Lingaraj OCP is being produced by surface

miners.
Lingaraj OCP has produced 13 Mty of coal in the year 2009-2010 and
major portion of it has been dispatched to Kaniha super thermal power
station of NTPC through wharf wall coal loading platform of NTPC siding.
The remaining coal has been dispatched to other Southern India power
stations, through wharf wall coal loading platform at Jagannath III and IV
siding. With the expansion of NTPC power plant demand of coal has also
increased and accordingly they desired construction of silos suitably to
facilitate rapid loading system with consequent construction of conveying
system from one no of crushing complex ( five feeder breaker circuits) to
carry the crushed coal up to the silos as well as truck receipt hoppers to
carry the coal produced by surface miners.
A truck receipt RCC hopper is envisaged for the blast free coal produced
by surface miners. Coal shall be reclaimed by rack & pinion gate and 600
TPH electromechanical vibro feeders to feed conveyors for onward
transportation.
5 Mty ROM coal brought by tipping trucks/dumpers shall be crushed to (-)
200 mm size by existing feeder breaker circuits excluding feeder breaker
circuits 1&2. The existing conveyors collecting coal from respective feeder
breakers, presently feeding coal into the 2x100 t storage hopper shall be
extended and crushed coal will be fed on belt conveyors C1 from existing
five feeder breakers. .
Coal shall be reclaimed from underneath the main bunker by plough
feeders of 3600 tph and fed on to conveyors C7A/C7B shall discharge the
coal into a Silo I of 4000 t capacity or silo conveyors C8A/C8B to
discharge coal in Silo II. Coal shall be loaded into the wagons of NTPC
rake by pre weigh hoppers and swing chutes to facilitate loading. Wagons
are weighed by electronic in motion rail weigh-bridges for record and
billing purposes. The coal samples collected by cutter type samplers at
pre-determined intervals shall be sent to laboratory for analysis.
The coal handling plant has also been provided with suitable fire and heat
detection, fire alarm system, fire fighting, automatic sampling arrangement
and communication facilities.
This tender document is for construction of Coal Handling Plant on turnkey
basis. The scope of this tender broadly includes approach road ( New
roads or diversion / modifications in the existing roads) , construction of
coal receiving arrangement , crushing of coal to (-)100mm size, storage of
crushed coal in a self flowing semi ground bunker, rapid loading system,
power supply, internal and external illumination, control communication,
dust suppression, fire fighting and plant cleaning systems, automatic coal
sampling etc. The plan showing the location of the CHP and silo is given
on the drawing bearing No. RI7-E&M-100222 rev 1
In case of any contradiction amongst these parts/ sections of the Tender
Documents, the Owner should be contacted for clarification. Also where
there are discrepancies in text and drawings, the data given in the text is
to be followed. All the equipment and facilities are to be supplied by the
JOB NO-730176 CH-I -3

successful bidder within the estimated time period. All equipment/ systems
shall be designed, fabricated and selected as per relevant Indian standard/
international standards and up to date engineering practices and
necessary inspections / test certificates shall be submitted along with
equipment supply to certify the quality and genuineness of critical
components and capacity and other technical parameters of the
equipment/ systems.
It may be noted that this is a brief description but does not cover all the
aspects of tender, which are covered in subsequent chapters.
• TECHNICAL SPECIFICATIONS
The bidder is required to give description of system with technical

specifications as broadly described in Chapter IV of this volume. All those
data which are standard or fixed as per relevant IS are essentially to be
furnished along with the bid submission.
1.7 VOLUME-III (PRICING FORMAT)
The pricing format should be properly filled and are given in volume - III.
The Bidders may quote their bids either item wise or broad head wise
as per the format described in Volume - III in separate sealed
envelope. The price should be quoted inclusive of all taxes and
duties.
In the pricing format, the bidder may be advised to indicate the price,
broad head wise separately under the sub head conveyors, mechanical
equipment, electrical equipment, mandatory spares, others item under the
head supply items and survey, soil testing and design engineering, civil
and structural works, developmental work and infrastructure, erection,
installation and commissioning, maintenance of plant under the head work
and services.
Further the bidder may submit the suitable alternative proposal of coal
handing plant with proper justification. It may be considered on due
discussions as well as competent approval.
1.8 VOLUME-IIA ( DRAWINGS )
Volume-IIIA consists of several drawings. These are layout drawing, coal

flow drawing, conveyor profiles and schematic arrangement of transfer
houses, single line electrical diagrams and others etc. The dimensions
indicated in these drawings are indicative only and may vary during detail
engineering as per system and design requirements; these are provided
as guideline for estimation only.
Further, the bidders are requested to collect the appropriate soil data from
the Lingaraj area office for better and accurate estimation purpose.
JOB NO-730176 CH-I -4

1.9 The bidders are requested to visit the site thoroughly for
participating in the Tender. Further the bidder may please note that any
item required for successful completion of the project and not specifically
mentioned in the document are in the scope of this tender.
JOB NO-730176 CH-I -5

CHAPTER-II
2.0 BASIC DATA & SYSTEM DESCRIPTION
2.1 BASIC DATA

2.1.1 GENERAL
(a) Location : Talcher Coalfield of Mahanadi
Coalfields Ltd., Orissa
(b) Mineable reserves of coal : 321.50 Million t(As on 1.4.10)
as per approved PR (16mty)
(c) Annual mine target : 16.0 M.t of coal
(d) Quality of coal : Grade – F
(e) Main consumer : Kaniha STPS of NTPC
2.1.2 COAL HANDLING & SILO LOADING ARRANGEMENT
2.1.2.1 GENERAL
(a) Handling capacity (Total) : 16Mty

• Blast free coal : 11Mty
• ROM coal : 5 Mty
(b) No. of working days/year : 330 days
(c) No. of working shifts/day : 3
(d) Effective working hr/shift : 5
(e) Bulk density
(i) For capacity calculation : 0.8 t/m3
(ii) For load calculation : 1.2 t/m3.
2.1.2.2 COAL RECEIPT & CRUSHING

(a) Type of crusher : Feeder breaker (Existing)
Sec. Roll Crusher (Proposed)
(b) No. of feeder breaker : 7 (in two places, 5 & 2)
(c) Secondary/Roll Crusher : 2 nos. 1600tph cap. each (Proposed
at one place)
2.1.2.3 BELT CONVEYOR SYSTEM

• No of belt conveyor : 16 Nos.
• Capacity of each conveyor : 500/1600/2000tph
• Capacity of reclaim conveyors : 3600tph
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• Width of belt conveyors up to Bunker : 1200mm/1600mm

(N/N& ST)
• Width of reclaim belt conveyors : 1800 mm (ST)
2.1.2.4 MAIN STORAGE
• Type of Bunker : Semi ground with truck

unloading facility
• Capacity : 15,000 t.
• Side slope : 55o
• Spreading equipment : Tripper conveyor
• Reclaim equipment : Plough feeder
• From reclaim equipment : 2 stream of 1800 mm. belt
conveyors.
2.1.2.5 RAPID LOADING SYSTEM
• Silo capacity 4000 t each
• No of Silos 2
• No. of Outlets 2 in each silo
• Type of loading Pre-weigh hopper
• No of Pre-weigh hoppers 2 Nos for each Silo
• Loading rate 5500 -6000 tph
• Type of Chute Swing chute
• Rake size 50 Box N / Equivalent wagons
• Wagon pay load 60 t
• Rake capacity 3000 t (approx.)
• Annual capacity 16Mty
2.1.2.6 WEIGHTMENT
a) Type of weighing system : Pre-weigh hopper system of loading.
: In motion rail weigh bridge
b)Wagon Marshalling By creep controlled loco. ( preferably
Electric loco) @0.8-1.1 km/hr
2.1.2.7 DUST SUPPRESSION : For whole proposed CHP .
2.1.2.8 FIRE FIGHTING & : For whole proposed CHP

PLANT CLEANING SYSTEM
.
2.1.2.9 OTHER ASSOCIATED SYSTEM : As described in the Report
JOB NO-730176 II-2

2.2 DESCRIPTION OF PROPOSED SYSTEM

(REF.: DRG NO.RI-7-E&M-100221REV1 TO RI-7-E&M-100237 REV1)
In the proposed system also ROM coal (5Mty) brought by tipping trucks /
dumpers shall be crushed to (-) 200 mm size in the existing feeder breaker
circuits (5Nos feeder breaker circuits located at one place.). The existing
conveyors collecting coal from respective feeder breakers, presently
feeding coal into the 2x100 t storage hopper shall be extended suitably
and crushed coal will be fed on belt conveyor C1 from existing feeder
breakers. One small link conveyor C1A has been envisaged to collect coal
from feeder breaker circuit 7 to feed into conveyor C1 for onward
transportation through conveyor C1. Collection of coal from the feeder
breakers (2 Nos) located at another place has been excluded from this
System.
In this scheme 11 Mty coal (-100mm) shall be produced from Surface
Miner A truck receipt RCC hopper with suitable liner has been envisaged
for this purpose. The truck receipt hopper shall be located at existing field
workshop site. The existing field workshop shall be shifted to another
location (Shifting of field workshop is not included in the scope of
bidder) Coal shall be reclaimed from RCC truck receipt hopper by rack &
pinion gate and 600 tph electromechanical vibro feeder to feed the
underneath conveyors C2A and C2B. This coal shall be discharged to
conveyorC3A & C3B for onward transportation. Coal collected from
conveyor C1 from feeder breaker circuits shall directly be fed to secondary
crusher. Conveyor C3A & C3B shall collect the coal underneath the
secondary crushers as well. The coal shall then be transported through a
series of belt conveyors C4A/C45B, C5A/C5B, C6A/C6B (tripper conveyor)
to the main storage semi ground bunker of 15000 t capacity. The tripper
conveyor C6A/C6B shall distribute coal evenly in the main semi ground
bunker of 15000 t capacity however provision has been made to feed
directly in to the hopper in case of emergency requirement.
Coal shall be reclaimed from underneath the main bunker by plough
feeders of 3600 tph and fed on to the reclaim conveyors C7A/7B which in
turn discharge the coal into a Silo-I of 4000 t capacity or silo bridge
conveyor C8A/8B to discharge coal in Silo-II. Coal shall be loaded into the
wagons of NTPC rake by swing chutes through pre weigh hoppers to
facilitate rapid loading in to the wagons. Wagons are weighed by electronic
in motion rail weigh-bridges also for record and billing purposes.
The automatic coal samples collected by cutter type samplers at pre-
determined intervals shall be sent to laboratory for analysis.
JOB NO-730176 II-3

The proposed system will be consisting of the following sub-systems;

a. Crushing Complex Feeder breaker circuits (existing)
b. Secondary crushers ( Proposed )
c. Belt conveyor system
d. Storage
e. Metal detectors and magnetic separators
f. Rapid loading system
g. Weighment
h. Sampling
i. Other associated systems like power supply, illumination, control &
communication, chute & dust suppression, motorized flap gate, fire
fighting& plant cleaning system and other materials handling
equipment.
2.2.1 CRUSHING COMPLEX
The existing crushing arrangement ( 5 Nos of feeder breaker circuit ) will

be utilised in the proposed system also with due modifications such as
extending the discharge head of existing conveyors suitably, thus enabling
the feeder breaker product to feed into the proposed conveying system
instead of discharging into existing hoppers. Two numbers of secondary
crushers / sizers of 1600 tph capacity each have been envisaged for
desired output of (-) 100mm. The location of secondary crusher has been
shown in the system plan. Conveyor C1 shall collect the coal from feeder
breaker circuits 3, 4,5,6,&7.
2.2.2 CONVEYING SYSTEM
The existing belt conveyors of each feeder breaker circuit shall be

extended to the required length (approximately 6m to 10m) over the
existing truck loading hoppers and coal will be discharged on belt
conveyor C1 installed so that this will not affect present coal dispatch
arrangements during the construction period of the proposed CHP and
shall also help coal dispatches during major break downs of the conveyor
system in future. The arrangement should be such that the crushed coal
can either be loaded on to the proposed belt conveyor C1 or in to the truck
loading hoppers as the case may be.
A link conveyor C1A has also been envisaged to collect coal from feeder
breaker circuit 7 to feed conveyor C1 directly. It is required because the
discharge end of circuit 7 is not situated in line with rest of the feeder
breaker circuits.
JOB NO-730176 II-4

Coal from C1 shall discharge the coal into secondary crusher directly.
Output from secondary crusher (-) 100mm size shall be collected by
conveyors C3A and C3B which shall carry it upto to the main bunker
through a series of belt conveyorsC4A/4B,C5A/C5B, and shall discharge
on to the tripper conveyor C6A/C6B. Conveyor C6A/C6B shall be fitted
with a reversible travelling tipper which shall evenly distribute coal in the
main bunker.
Coal from the main bunker shall be reclaimed by plough feeders and shall
be loaded on to elevating conveyors C7A/C7B which in turn shall load into
the silo-I or silo bridge conveyor C8A/8B to feed silo-II.
Conveyor drives of 200 kW and above should have Controlled Start
Transmission (CST) drive. It is a 2 in 1 gear box which combines a
planetary gear reducer with an integral wet clutch system for controlled
start and eliminated of fluid coupling. When coupled to an AC induction
motor, the CST gear box converts the motor’s high speed, low torque input
to a low speed, high torque output, suitable for direct coupling to a high
inertia load.
CST drive incorporated a wet clutch system that is located on the output
shaft side of the gearbox, allowing the motor to be started under no load
condition. The clutch system comprises a set of rotating friction plates and
opposing stationary plates, an oil pressure activated piston for
engagement, and a spring mechanism for clutch release. Oil circulated
between the plates by a closed circuit pump and cooled through a heat
exchanger.
Two way chute with motorized flap gate has been envisaged at discharge
end of conveyor C1 to feed either of the secondary crushers, and then to
feed from each crusher to either conveyor C3A or C3B. Also, it is
envisaged at silo-I top to feed either into Silo-II or conveyors C8A/8B.
2.2.3 STORAGE & RECLAIM
A semi ground bunker of 15,000 t has been envisaged in the proposed

system. Stacking of the coal in the bunker will be by travelling tripper on
conveyors C6A/6B. The proposed bunker shall be of self flowing type with
an arrangement of side feeding of blast free coal by truck / dumper. There
will be 2 nos. slit type openings beneath the Semi ground bunker. There
will be two nos. of plough feeders for each slit, one working and the other
stand-by. For maintenance of plough feeders it shall be carried out from
maintenance bay/machinery well, located on either side of the semi
ground bunker. The proposed bay will have hoisting arrangement. The
rated capacity of the plough feeders will be 3600 TPH each. Below each
JOB NO-730176 II-5

slit one no. reclaim cum loading conveyor will be installed. These
conveyors C7A/7B will carry the coal discharged from plough feeders and
subsequently load into the silos of 4000 t (5000 cu.m) capacity each.
2.2.4 RAPID LOADING SYSTEM
The coal carried by the conveyor C7A/7B will be discharged into first silo
of 4000 t capacity or onto the conveyor C8A/8B to feed into the second
Silo. There will be two outlets at the bottom of each silo 6 m apart. These
outlets / pockets at the silo bottom are fitted with pre weigh hoppers. The
loading from the silo into wagons will be through pre weigh hoppers and
the loading rate will be 5500-6000 tph from each of these outlets. The silos
will be designed in such a way that two rakes can be loaded
simultaneously on two parallel railway tracks . The rake capacity will be
around 3000/3600t (50/58 nos. of box N or equivalent type of wagons of
60 t capacity each).
The silos shall be of R.C.C. construction and designed to take all the loads
as expected in the system. Arch breakers, necessary silo discharge and
maintenance gates, load cells for two numbers of pre-weigh hopper
system of loading, two numbers of pre-weigh hoppers, swing chutes,
shear and crushing sections, hydraulic power pack, accumulator, cooling
system, air compressors, hydraulic cylinders and valves, control deskwith
computer and color monitors to operate the RLS through relay logic and all
other miscellaneous items for the operation of two numbers of pre-weigh
hopper system of loading, freight cum passenger lift, staircases , etc. will
form part of the silo loading system. In addition to the above, calibrating
test weight blocks, level sensors, air blasters etc are also envisaged.
2.2.5 WEIGHMENT
Two numbers of pre-weigh hoppers shall be fitted underneath each silo for
accurate weighment of the wagons loaded. These shall load coal of pre-
determined quantities into any one or two number of wagons of the rakes
placed on two numbers of parallel railway tracks..
+ 0.05% Weighing accuracy
+ 0.02% Weighing accuracy for complete rake.
The weighment of the wagons will also be carried out twice, before and
after loading with the help of in motion electronic rail weigh bridges. There
will be 2 nos. of in-motion electronic weigh rail bridges on each loading
track one for weighing empty wagons and the other for loaded wagons.
Computerised output will give the details of weighment.
JOB NO-730176 II-6

The main consumer of Lingaraj coal is Kaniha STPS. As per prevalent

practice in MCL, NTPC is accepting the weighment being recorded by
pre-weighing system which are annually certified by Weights and measure
department, Govt. of Odisha. MCL and NTPC are jointly calibrating these
preweigh hoppers once in a month. The 4 Nos of in motion rail
weighbridges provided shall be utilized for cross examining of the
weighment. Also in case of breakdown of pre-weighing system it shall be
utilized. Further in future M/s NTPC is supposed to receive coal from
KanihaOCP , the in motion rail weighbridge shall be utilized for weighment
for basket linkage.
2.2.6 COAL SAMPLING
It is proposed to install fully automatic sampling system in the CHP. Coal

from conveyor C7A/7B will be collected by the sampler at predetermined
intervals by cutter type samplers to assess the quality of the coal being
dispatched. The coal samplers will be installed on the conveyors C7A/7B
at suitable location.
2.2.7 OTHER ASSOCIATED SYSTEMS
2.2.7.1 DUST SUPPRESSION SYSTEM
The objective of this system is to eliminate air pollution. Adequate number

of nozzles will be installed at pre-determined transfer points for
suppression of dust by spraying water in atomized condition. The dust
suppression system shall be inter-locked with the conveyor system so that
it will be in operation only when conveyors are running. The dust
suppression system shall cover the following premises in the CHP:
- Transfer houses
-Truck receipt hoppers
- Semi ground bunker
- Loading points
- Any other vulnerable area
2.2.7.2 NOISE CONTROL MEASURES
It is an accepted fact that noise is very uncomfortable to operating

personnel. Provision will be made to keep down the noise level to the
recommended levels. All machines requiring heavy foundations will be
fitted with energy absorbing anti vibration pads/sheets for reducing the
JOB NO-730176 II-7

vibration and thereby noise. All transfer points and hoppers shall have
wear resistant rubber/synthetic liners of suitable specifications to reduce
the noise and wear as per design requirement.
2.2.7.3 FIRE FIGHTING SYSTEM
A suitably designed fire-fighting system has been envisaged for the plant
including fire, heat and smoke detection, fire alarm provisions and fire
fighting systems-both water reliant and aerosol reliant. It shall include fire
hydrant system at locations vulnerable for fire at predetermined locations
at suitable spacing with suitable high pressure water supply pipelines,
hoses, hose boxes as per the standard practice. Suitable fire extinguishers
will be provided to deal with electrical/oil/ordinary fires at all the required
points in the plant like control room, sub-station buildings, office premises,
drive houses etc. In addition to the above, required nos. of sand buckets
shall also be provided at key locations. A control unit to monitor firefighting
activities shall be provided near bunker at Switching station II.
2.2.7.4 PLANT CLEANING SYSTEM
Fire fighting system provided shall also be used for plant cleaning
purposes. Effluents discharged from the system shall also be connected to
the existing effluent treatment plant provided in the mine or disposed
suitably.
2.2.7.5 TRAMP METAL REMOVAL
Inline magnet separators will be installed on conveyors C1 and C3A/3B to

dispatch clean coal without any non ferrous/ferrous metals. Ferrous
materials shall be attracted out from the coal stream by these which shall
be subsequently disposed off. On conveyors C3A/3B metal detectors have
also been envisaged. The metal detectors shall give a signal whenever
non magnetic materials pass with the coal stream over the conveyor and
the system shall be stopped temporarily to pick the non ferrous metals.
2.2.7.6 PREVENTIVE MAINTENANCE
For effective maintenance of all the equipment there will be sufficient

working space for each equipment/machinery. All the equipment, transfer
points etc. shall be covered and will have housing complete with handrail,
ladder, cross over ladder etc. as required. Necessary number of electrical
JOB NO-730176 II-8

hoist and chain pulley blocks of adequate capacity will also be provided at
respective locations.
2.2.7.7 WORKSHOP FACILITY
There exists an E&M workshop nearby to cater the need of the proposed
coal handing plant.
2.3 ELECTRICAL SYSTEM DESCRIPTION
2.3.1 POWER SUPPLY ARRANGEMENT: (Ref: Drg no R7/E&M/300913)
To cater the additional loads of the proposed conveyors and the RLS
system at Silo, it is proposed to install two numbers 5 MVA 33/3.3 kV
Power transformers in the existing 33 kV Lingaraj Project Substation. The
secondary neutral of the transformers shall be earthed through neutral
grounding resistor of suitable capacity. All the equipments, conveyors and
the RLS system at Silo will operate at 3.3 kV/415 V, 3 phases, 50 Hz
supply system. Three numbers of 3.3kV substations are proposed to install
for feeding the loads of CHP & SILO. For feeding power to 3.3 kV
substations two sets of double circuit 3.3 kV overhead lines with ACSR,
WOLF conductors will be drawn. The first lines will be drawn from 33/ 3.3
kV substation up to the proposed 3.3kV substation-I and terminated on a
DP/4 poles structure. The second lines will be drawn from 33/3.3 kV
substation up to the proposed 3.3 kV substation-II and terminated on a
DP/4 pole structure. The same overhead lines will be extended up to the
proposed 3.3 kV substation-III and terminated on a DP/4 pole structures.
The Over Head lines shall have pin type/disc type insulators, necessary
cradle guards for road crossing, stay rods, double poles as per
requirement, earthing, sag & clearances and other accessories conforming
to relevant IS, IEE Rules.
2.3.2 POWER DISTRIBUTION ARRANGEMENT: (Ref: Drg no

R7/E&M/300914)
Considering the load centre of the proposed CHP, length of conveyors and
the power requirements for different drives, rapid loading and control
system, it is proposed to construct three numbers 3.3 kV substations i,e
Substation-I , II &III at the CHP. These substations will receive power by
tapping 3.3 kV overhead lines drawn from 33/3.3 kV Project substation.
Substation-I shall be located near the proposed crusher house, the
Substation-II shall be located near discharge end of bunker, and the
Substation-III shall be located near SILO. A tentative power supply
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arrangement is shown in the drawing which is enclosed in this document.

However, the details have to be worked out by the Bidder.
2.3.2.1 3.3 KV SUBSTATION - I
The 3.3 kV substation-I will be installed near the crusher house for
supplying power to the drives of belt conveyors C1, C2A/C2B, C3A/C3B,
Twin shaft crusher at 3.3 kV and drives of belt conveyors C1A, C4A/C4B,
motorized hoist, electromagnetic brakes, space heater in the drive houses,
electromagnetic vibro feeders, Belt cleaner, Metal detector, Motorized flab
gate, other misc. loads at 415V and lighting loads. The following will be
provided at this substation:
2.3.2.1.1 OUTDOOR YARD
i) Isolator with earthing switch, 3.3 kV, air break, pole mounted, gang
operated.
ii) Lightning arrestor (LA), station class, 3 KA, suitable for 3.3 kV supply.
2.3.2.1.2 INDOOR
i). 3.3 kV, vacuum circuit breakers/ vacuum contactor panel -1 set
ii). Motor control center (MCC-I) -1 set
iii). Power transformer of 3.3kV/415V -2 nos
iv). 3.3 kV capacitor bank panel -2 nos
v). Lighting transformer of 100 kVA, 3.3kV/230V(L-L) -1 no
vi). 230V Lighting main distribution board. -1 set.
2.3.2.1.3 3.3 KV VACUUM CIRCUIT BREAKERS/VACUUM CONTACTORS

PANEL
A sectionalised 20 panels, 3.3 kV vacuum circuit breakers/vacuum

contactor panels will be provided in the substation for control of the feeders
as described below:
i). Incoming feeder control circuit breakers -2 nos.

ii). Sectionaliser circuit breaker (bus coupler) - 1 no.
iii). Circuit breaker for Primary control of 3.3 kV/ 415V
Power transformers - 2nos.
iv). Circuit breaker for Primary control of 3.3 kV/ 230 V (L-L)
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Lighting transformer - 1 no
v). Circuit breaker for control of 3.3 kV capacitor bank Panel - 2nos
vi). Outgoing feeder control Vacuum Contactor for Twin
Shaft Crusher - 2 nos.
vii). Outgoing feeder control Vacuum contactor for
Conv.C1 - 1 no.
viii). Outgoing feeder control Vacuum contactor for
Conv.C2A/C2B - 2 nos.
ix). Outgoing feeder control Vacuum contactor for
conv.C3A/C3B - 2 nos.
x). Reserve vacuum contactor panel - 3 nos.
xi). Reserve vacuum circuit breaker - 2 nos.
Total - 20 nos.
All the circuit breakers and contactor panels will be suitable for operation
on restricted earth neutral system. The circuit breakers and contactor
panels will have protection against short circuit, overload, Earth leakage,
earth fault etc. Provision shall be kept for expansion in future. The
incoming cable from isolator on 4 pole structures will be terminated on the
incoming feeder control circuit breakers.
2.3.2.1.4 MOTOR CONTROL CENTER- I (MCC-I)
The Motor Control Center- I (MCC-I) will be of 415V, 3ph-N type of multi-
tire construction of required capacity. This will be modular construction
having number of panels. 10% of spare outgoing modules for each type of
modules (minimum one) have to be provided in the MCC. The panels will
consist of Isolator with switch fuse unit, contactor, starter panel etc with
required protections as per requirement with a provision to start the
equipment from a remote place. The MCC will have a sectionaliser which
divides MCC into two sections. Efforts will be made to distribute load
equally (to the extent possible) and connected to the two sections of the
MCC. The incoming feeders and sectionaliser will be controlled through
suitable capacity Air circuit breakers (ACBs). No parallel operation of the
transformers is envisaged. This Motor Control Center will receive power
from secondary side of 3.3kV/415V power transformers installed in this
substation. This MCC will be installed in the substation building for control
of cables feeding power to various loads at 415V.
JOB NO-730176 II-11

2.3.2.1.5 POWER TRANSFORMER
Two numbers of 3.3 kV /415V transformer (indoor type) of suitable

capacity will be provided in this substation to meet the requirements of
power Motor Control Center-I. The capacity of the transformer shall be
selected based on the following:
i). The transformer shall be loaded 50%-60% of rated capacity

ii). The transformer shall be of preferred capacity as per Indian
standards.
iii). It shall meet the requirements of loads connected to it.
iv). The capacity shall commensurate with the starting requirement of the
biggest motor along with the other loads in operation.
2.3.2.1.6 LIGHTING MAIN DISTRIBUTION BOARD –I (LMDB-I)
This lighting distribution board will be of 230V, 3ph type of required

capacity. The board will receive power from the secondary of the 100 kVA,
3.3kV/230V (L-L) lighting transformer installed in this substation. The
lighting main distribution board will consist of the following:
i). Incomer feeder control MCCB, 3 pole of suitable capacity - 1 no.

ii). Outgoing feeder control MCCB, 3 pole of suitable capacity -As per
design.
iii). Reserve MCCB s - 10% of outgoing feeder control MCCB s
2.3.2.1.7 LIGHTING TRANSFORMER
One number 100 kVA, 3.3 kV/230V (L-L) transformer (indoor type), will be
provided in this substation to meet the requirements of lighting loads fed
from this substation.
2.3.2.1.8 415V POWER DISTRIBUTION BOARDS (PDB I & II)
Total two numbers of Power Distribution Boards will be installed near truck
receiving hoppers located near tail end of conveyor C2A/C2B for feeding
power to vibro feeders and other LT loads at hopper house. These
distribution boards will be 415V, 3 ph. – N type of required capacity. These
distribution boards will receive power from MCC-I installed at 3.3 kV
substation -I.
JOB NO-730176 II-12

i). Incoming feeder (from MCC-I) control modules having Isolator with
switch fuse unit, contactor and other required protections.
ii). Outgoing motor feeder control modules having Isolator with switch
fuse unit, DOL/RDOL starters, contactor and other required
protections.
iii). Outgoing other feeder control modules having Isolator with switch
fuse unit, contactor and other required protections.
iv). Spares modules minimum one of each type
2.3.2.2 3.3 KV SUBSTATION - II
The 3.3 kV substation-II will be installed near discharge end of the bunker
for supplying power to the drives of belt conveyors C6A/C6B, C7A/C7B at
3.3 kV and drives of belt conveyors C5A/C5B, Tripper drive of C6A/C6B,
motorised hoist, electromagnetic brakes, space heater in the drive house,
plough feeder, belt cleaner, metal detector, tramp iron magnet, belt pulling
device, belt weigher, sampling equipment, dust suppression, dust
extraction & fire fighting equipments, other misc. loads at 415V and lighting
loads. The following will be provided at this substation:

i). Isolator with earthing switch, 3.3 kV, air break, pole mounted, gang
operated.
ii). Lightning arrestor (LA), station class, 3 KA, suitable for 3.3kV supply.
2.3.2.2.2 INDOOR
i). 3.3 kV, vacuum circuit breakers/ vacuum contactor panel -1 set
ii). Motor control center (MCC-II) -1 set
JOB NO-730176 II-13

2.3.2.2.3 3.3 KV VACUUM CIRCUIT BREAKERS/VACUUM CONTACTORS

PANEL
A sectionalised19 panels, 3.3 kV vacuum circuit breakers/vacuum

contactor panels will be provided in the substation for control of the feeders
as described below:
i). Incoming feeder control circuit breakers - 2 nos.

Power transformers - 2 nos.
iv). Circuit breaker for Primary control of 3.3 kV/ 230 V (L-L)
Lighting transformer - 1 no.
v). Circuit breaker for control of 3.3 kV capacitor bank
Panel - 2 nos.
vi). Outgoing feeder control Vacuum contactor for
vii). Outgoing feeder control Vacuum contactor for
viii). Reserve vacuum contactor panel - 3 nos.
ix). Reserve vacuum circuit breaker - 2 no
Total - 19 nos.
All the circuit breakers and contactor panels will be suitable for operation
on restricted earth neutral system. The circuit breakers and contactor
panels will have protection against short circuit, overload, earth leakage,
earth fault etc. Provision shall be kept for expansion in future. The
incoming cable from isolator on 4 pole structures will be terminated on the
incoming feeder control circuit breakers.
2.3.2.2.4 MOTOR CONTROL CENTER- I (MCC-II)
The Motor Control Center- II (MCC-II) will be of 415V, 3ph-N type of multi-
tire construction of required capacity. This will be modular construction
having number of panels. 10% spare outgoing modules for each type of
modules (minimum one) have to be provided in the MCC. The panels will
consist of Isolator with switch fuse unit, contactor, starter panel etc with
required protections as per requirement with a provision to start the
equipment from a remote place. The MCC will have a sectionaliser which
JOB NO-730176 II-14

divides MCC into two sections. Efforts will be made to distribute load
equally (to the extent possible) and connected to the two sections of the
MCC. The incoming feeders, sectionaliser and outgoing feeders for plough
feeder will be controlled through suitable capacity Air circuit breakers
(ACBs). No parallel operation of the transformers is envisaged. This Motor
Control Center will receive power from secondary side of 3.3kV/415V
power transformers installed in this substation. This MCC will be installed
in the substation building for control of cables feeding power to various
loads at 415V.

power Motor Control Center-II. The capacity of the transformer shall be
i). The transformer shall be loaded 50%-60% of rated capacity

ii). The transformer shall be of preferred capacity as per Indian
standards.
iii). It shall meet the requirements of loads connected to it.
iv). The capacity shall commensurate with the starting requirement of the
2.3.2.2.6 LIGHTING MAIN DISTRIBUTION BOARD –II (LMDB-II)
This lighting distribution board will be of 230V, 3 ph type of required

i). Incomer feeder control MCCB, 3 pole of suitable capacity - 1 no.

ii). Outgoing feeder control MCCB, 3 pole of suitable capacity -As per
design
iii). Reserve MCCB s - 10% of outgoing feeder control MCCB s
JOB NO-730176 II-15

One number 100 kVA, 3.3 kV /230V (L-L) transformer (indoor type), will be
2.3.2.3 3.3 KV SUBSTATION - III
The 3.3 kV substation - III will be installed near SILO for supplying power
to the drives of belt conveyors C8A/C8B, motorized hoist at different level
of Silos, motorized flab gate, Belt cleaner, electromagnetic brakes, space
heater in the drive house, various loads at silos, other misc. loads at 415V
and lighting loads. The following will be provided at this substation:
i). Isolator with earthing switch, 3.3 kV, air break, pole mounted, gang
operated.
ii). Lightning arrestor (LA), station class, 3 KA, suitable for 3.3 kV supply.
2.3.2.3.2 INDOOR
i). 3.3 kV, vacuum circuit breaker panel -1 set

ii). Motor control center (MCC-III) -1 set
2.3.2.3.3 3.3 KV VACUUM CIRCUIT BREAKERS PANEL
A sectionalized 10 panels, 3.3 kV vacuum circuit breakers panels will be

provided in the substation for control of the feeders as described below:
i). Incoming feeder control circuit breakers - 2 nos.

Power transformers - 2 nos.
iv). Circuit breaker for Primary control of 3.3kV/ 230 V (L-L)
Lighting transformer - 1 no
JOB NO-730176 II-16

v). Circuit breaker for control of 3.3kV capacitor bank

Panel - 2 nos
vi). Reserve vacuum circuit breaker - 2 nos
Total - 10nos
All the circuit breakers will be suitable for operation on restricted earth
neutral system. The circuit breaker panels will have protection against
short circuit, overload, earth leakage, earth fault etc. Provision shall be
kept for expansion in future. The incoming cable from isolator on 4 pole
structures will be terminated on the incoming feeder control circuit
breakers.
2.3.2.3.4 MOTOR CONTROL CENTER- I (MCC-III):-
The Motor Control Center- III (MCC-III) will be of 415V, 3ph-N type of
multi-tire construction of required capacity. This will be modular
construction having number of panels. 10% spare outgoing modules for
each type of modules (minimum one) have to be provided in the MCC. The
panels will consist of Isolator with switch fuse unit, contactor, starter panel
etc with required protections as per requirement with a provision to start
the equipment from a remote place. The MCC will have a sectionaliser
which divides MCC into two sections. Efforts will be made to distribute
load equally (to the extent possible) and connected to the two sections of
the MCC. The incoming feeders and sectionaliser will be controlled
through suitable capacity of Air circuit breakers (ACBs). No parallel
operation of the transformers is envisaged. This Motor Control Center will
receive power from secondary side of 3.3kV/415V power transformers
installed in this substation. This MCC will be installed in the substation
building for control of cables feeding power to various loads at 415V.

power Motor Control Center-III. The capacity of the transformer shall be
i) The transformer shall be loaded 50%-60% of rated capacity
ii) The transformer shall be of preferred capacity as per Indian

standards.
iii) It shall meet the requirements of loads connected to it.
JOB NO-730176 II-17

iv) The capacity shall commensurate with the starting requirement of the
2.3.2.3.6 LIGHTING MAIN DISTRIBUTION BOARD –III (LMDB-III):
This lighting distribution board will be of 230V, 3 ph type of required

i) Incomer feeder control MCCB, 3 pole of suitable capacity - 1 no.
ii) Outgoing feeder control MCCB, 3 pole of suitable capacity -As per
design
iii) Reserve MCCB s - 10% of outgoing feeder control MCCB s
One number 100 kVA, 3.3 kV /230V (L-L) transformer (indoor type), will be
2.3.3 CONTROL SYSTEM
The control scheme of the CHP and rapid loading system along with
sequencing shall be done through microprocessor based programmable
logic controller (PLC) suitable for industrial control system.
2.3.4 UTILISATION VOLTAGE
All motors 110kW & above shall get power at 3.3 kV. All other motors &
equipments below 110 kW shall get power at 415V. However Plough
Feeders may have HT/LT drives.
2.3.5 POWER FACTOR
The power factor of the plant has to be improved to a level above 0.98
lagging at the 3300 volts switch board of substations. For this purpose 2
sets of capacitor bank with manual control panel will be provided in each
substation considering the load of the CHP & silo.
JOB NO-730176 II-18

2.3.6 ILLUMINATION
2.3.6.1 The plant area indoor as well as outdoor shall be properly illuminated for
ease in operation, safety and security. The minimum illumination level and
type of luminaries required at various major locations shall be as given
below:
Sl.no Location Level of Type of lighting fixture

illumination
(Lux)
1 Substations/switching 200 Single /Double,

stations , Maintenance cum Fluorescent tube lights
testing room, stores/ tools (36/40W) with industrial
room, engineer’s room type lighting fixtures with
compressor room, Pump energy efficient choke
house etc.
2 Control Room 300 Single/Double, fluorescent
tube lights (36/40 W) or
four fluorescent tube lights
(18/20 W) with Decorative
lighting fixture with energy
efficient choke
3 Conveyor Gantries, tunnel, 70 Metal Halide/ HPSV lamps
Ground Bunker, Loop take- (70 watts) with well glass
up house, floor of tripper and lighting fixtures
reclaim conveyor in O/H
bunkers,
4 Transfer houses, drive 150 Metal Halide/ HPSV lamps
houses, Hopper complex, (70/150/ 250W) with flood
Floor of hoppers, various light fitting
platforms in silo and Sampler
house, Silo loading area.
5 Substation outdoor yard, 10 Metal Halide/ HPSV lamp
roads inside area and along (150 /250 /400W) with
the conveyers street Light/Flood light
fitting
6 Lighting near truck receiving 20 Lighting through 15 m/30m
stations, outside bunker and high lighting mast Metal
SILO complex Halide/ HPSV (400 W)
flood light fittings.
The Bidder shall calculate the number of luminaries required to achieve the
above illumination levels after considering the maintenance factor of 0.6,
co-efficient of utilisation factor depending on the area to be illuminated,
internal/external areas etc. The internal area of conveyor gantry, drive
houses, silo floors, substation, control room, pump house, compressor
JOB NO-730176 II-19

room, Engineer’s room, testing room, stores etc shall be determined by the
bidder depending on the system requirements.
The actual external area to be illuminated shall be worked out by the

bidder during detail design and accordingly luminaries shall be provided.
2.3.6.2 POWER SUPPLY ARRANGEMENT
Three numbers of Lighting Main Distribution boards will be provided in the

different substation buildings for feeding power to various luminaries
through lighting sub-distribution board. These Lighting Main Distribution
boards will receive power from 3.3kV/230V (L-L), 100 kVA transformer
installed at 3.3 kV substation no I, II& III.
The Lighting Main Distribution board shall consist of a MCCB with suitable
back up HRC fuse for control of incoming cable. The outgoing feeders will
be controlled by means of MCCB’s backed by HRC fuses of suitable
rating. In the event of any fault, if fault current is higher than MCCB rating
the fuse shall blow first to protect MCCB. Sufficient number of lighting sub-
distribution boards will be provided along the conveyor gantries, drive
houses, substations, pump house, compressor room (if any), control room,
outdoor yard etc. for supplying power to various luminaries. These sub-
distribution boards will receive power from lighting main distribution
boards. The sub-distribution board shall consist of MCCB as incomer
control and MCB’s as outgoing feeder control with back up HRC fuses.
The minimum rating of each MCB shall not less than 16 A. Each sub-
distribution board will be provided with a timer & contactor for automatic
control of switching.
2.3.6.3 CABLES
All the cables connecting the lighting main distribution boards with lighting
sub- distribution boards, lighting main distribution board with secondary
side of transformer will be of 1100V grade, 31/2 , 3 Core, aluminum
conductors, single wire armoured, PVC insulated, PVC sheathed with
FRLS properties in outer sheathing. The cables between sub-distribution
board and Junction box for luminaries will be of 1100V grade, 2 core,
aluminum conductors, single wire armoured, PVC insulated, PVC
sheathed with FRLS properties in outer sheathing. The size of the cables
shall be selected giving due consideration to continuous rating, de-rating
factor, voltage drop limit and short circuit with stand capacity. However the
minimum size of the cable from main to sub-distribution board shall not be
less than 16sq. mm and sub-distribution board to individual circuits shall
not be less than 10sq. mm. In the conveyor gantry cables for feeding
power to luminaries shall be laid on the walkway side on separate steel
hangers/cable trays. In the other houses also illumination cables shall be
provided on separate steel hangers/cable trays. These hangers/trays shall
be fixed to the structural members, walls etc. In the substation these will
JOB NO-730176 II-20

be laid in cable trenches/ cable vaults. In other places these will be laid in
the ground at least at a depth of minimum 800mm as per standard
practice.
2.3.6.4 EMERGENCY LIGHTING
Emergency lights will be provided in control rooms and substation

buildings suitable for operation through invertors. For feeding power to
these emergency lights an automatic battery charger-cum-inverter device
along with suitable AH capacity battery to run for at least 3 hours will be
provided. These lights will be starts automatically in case of any power
failure. The emergency lights shall be suitable type to meet the site
conditions. For this separate wiring will be done along with the provision of
separate luminaries.
2.3.7 EARTHING & LIGHTNING PROTECTION
Proper earthing arrangement for the plant has to be provided as per I.E
Rules. Additional earthing grid shall have to be developed around the
periphery of 33 kV substation and 3.3 kV substation/ switch station I, II &
III. The earth grid shall be formed by interconnecting GI strip of size not
less than 65 mm x 5 mm.
Each motor, transformer, switch panel and other electrical equipment

should be earthed by two separate earthing strips. In addition all the
motors will be earthed through the armoring of the connecting cable. All
the poles of the Lightning Arrestors, body and neutral of the transformers
shall be earthed separately. Size of earthing strip and electrodes shall be
as requirement, as per relevant IS, to be finalized by the bidder during
detailed engineering stage. However, the size of main earth bus strip shall
not be less than 65 mm x 5 mm where as that of the connecting earthing
strip shall not be less than 25 mm x 5 mm. All the Power & Distribution
Transformer Secondary shall be earthed through resistance as per
requirement.
Adequate care shall be taken towards earthing of light fittings, welding

sockets etc. G.I. strips will run along the conveyor for earthing of light
fittings, junction boxes, control switches (pull chord switches, belt sway
switches etc.) As Talcher coalfield is a lightning prone area, proper
lightning protection shall be provided as per IS 2309 (latest amendment).
Air Termination network shall be provided for buildings, conveyor gantries,
switching stations / substations, OH bunker and silo buildings.
In order to protect the substation building, drive stations of belt conveyors

OH bunker and silo buildings. etc. from direct lightning strokes a proper
lightning protection system as per relevant Indian standards shall be
provided. For this purpose required numbers of spikes/interceptors of at
least 2m height will be provided on the roof tops of the above buildings
JOB NO-730176 II-21

and drive houses. The spikes/interceptors provided on each building and

will be interconnected by means of suitable size G.I. flats supported on
saddles to form a grid.
Separate earth pits independent of the earth pits provided for equipment
earthing will be provided around the buildings and interconnected by
means of suitable Galvanized steel flats. The above flats will be laid in the
ground at a depth of 700 mm. The earth pits will be constructed as per
Indian Standards.
The value of earth resistance shall not exceed one ohm in all the time
throughout the year. Earth pits/ Earth electrodes shall be located near 33
kV substation and 3.3 kV substation - I, II & III, ground bunker, Silos,
transfer houses, hopper house, intermittent points along conveyor gantries
etc.
2.3.8 WELDING SOCKETS
415V, 3 Ph 4 pins industrial type dust proof plug interlocked power plug &
socket with switch shall be provided. Welding receptacles shall be
connected with each other in loop-in loop-out connection (to the extent of 5
nos. max.) located at an interval of 50 m along the conveyor and both side
of ground bunker and minimum one no shall be provided in all equipment,
floor of Transfer Points, drive houses, floor of hoppers, silo floors,
substation/switch stations etc. The sockets receive power from MCCs
through PVCSWA cables of 1100 V grade, 3 cores Aluminum conductors
of suitable size. Necessary portable transformer welding sets are to be
provided for this purpose.
2.3.9 CABLES
All the cables used for connecting the transformers with 3.3 kV vacuum
circuit breakers, 3.3 kV VCP with HT motors, cables from isolators to
circuit breakers will be of 3.3 kV grade as per requirement. All other
cables will be of 1100V grade. All the 3.3 kV grade cables will be of 3
cores and 1100V grade will be of 3 1/2 or 4 core for switchgear connection
and 3 cores for motor connection. The HT cable shall be XLPE, single
layer armored with aluminum conductor, suitable sheathed, having FRLS
properties in outer sheathing and the LT cable shall be with single wire
armoring, PVC insulated and PVC sheathed Aluminum conductors of
stranded wires with FRLS properties in outer sheathing. The size of the
cables shall be selected giving due consideration to continuous rating, de-
rating factor, voltage drop limit, short circuit withstand capacity etc. In the
conveyor gantries power cables will be installed in the walkway side on
cable hangers/cable trays. In the other houses these cables shall be
provided on separate hangers/trays fitted to the walls or structural
JOB NO-730176 II-22

members. In the substation these will be laid on cable hangers provided in

the cable trenches/ cable vaults. In the other places these will be laid in
ground at a depth of 800mm as per standard practice. Route indicators will
be provided for identification of the route. Hume pipes are to be provided in
case of road crossing. Power cable of different voltage grades, control
cable & signaling cable shall run separately in the cable tray. In case of
necessity bus-ducts will be provided between secondary side of power
transformer and MCCs.
Cable Trenches/Trays are to be provided complying with the relevant IE

Rules & Code of Practices amended up to date.
2.3.10 CENTRALIZED MONITORING AND AUTO REMOTE AND AUTO

SEQUENCE CONTROL
2.3.10.1 PRINCIPLES OF CONTROL
The auto control of CHP operations i.e. auto remote, auto sequence of
interlock, de-interlock, local/manual, local/central, signaling, data logging,
data display, etc. to be achieved by dual redundant PLC from the main
control room.
A back up UPS system of minimum 30 minutes capacity will also be

provided to operate the equipment in control desk in case of power failure
for keeping the memory of computer system alive. Battery system shall be
rechargeable type & maintenance free.
The equipment in coal flow line in each section shall be started

automatically in sequence in the reverse of coal flow. Similarly, the
stopping shall also be in sequence and in the same direction as of coal
flow. However, the sequence of starting and stopping of equipment shall
have predetermined time lag.
The concept of control of CHP through PLC is briefly given below to

facilitate preparation of suitable control system by the tenderer. The
contractor however will supply comprehensive scheme incorporating all
the features with latest technology.
The control scheme of the entire plant shall be done through

microprocessor based programmable logic controller (PLC) suitable for
industrial control system. The PLC shall provide the facilities for
interlocking, sequence control, process control, data logging, data display
and printing, supervisory control etc. All the PLCs should be provided with
UPS.
JOB NO-730176 II-23

The PLC shall provide a complete control system philosophy based upon
functional controls distribution around the plant as per requirement.
The offer for PLC control of the plant shall normally bring out the basic
features of the system along with summary and other additional features,
which the PLC is capable of performing. Each PLC shall be complete with
continuous laminated colour dynamic graphic mimic and its own VDU
screen which will in turn, drive the colour monitors. Each control system
shall be provided with dual redundancy and automatic change over facility
to avoid stoppage of the plant. The coordinated action shall be taken care
of by the central controller in the control room. The control room shall be
provided with control desk with continuous laminated colour graphic
dynamic mimic, VDU screen and annunciation panel with all facilities.
PCs for operation and engineering shall be provided and located in the
central control room.
The mimic of the storage & reclamation section at the main control room
shall show the status of silo and mimic of silo loading at silo control room
shall also show the status of vibratory feeders and reclaim conveyor.
2.3.10.2 CONTROL AND MONITORING OF EQUIPMENT
The conveyors and equipment should be able to trip on occurrence of the

following conditions:
• Under speed (for conveyors only)

• Belt sway operated with the arrangement to bypass belt sway
switches at the time of the starting of the plant and also during
normal running if found necessary (for conveyors only)
• Pull chord switch operated (for conveyors only)
• Single phasing of the power supply
• Motor winding and bearing overheating (HT motors only)
• Bearing temperature of mechanical equipment like gear box (HT
drives)
• Operation of safety and protection device
• Motor overload
• Any other fault if found necessary during detailed engineering stage
by the Customer
2.3.10.3 FAULT ANNUNCIATION SYSTEM
There will be provision for audio-visual fault annunciation system, which

will be carried on to the control desk for annunciation of number of group
feature like:
JOB NO-730176 II-24

i). Pull chord switch operation

ii). Belt sway switching operation
iii). Winding/bearing temperature high for HT motors
iv). High bearing temperature for gear boxes (HT drive only)
v). Emergency stop operation
vi). Fall in hydraulic pressure
vii). Transformers
viii). 6.6 kV VCB
ix). Any other item as found necessary during detailed engineering stage
by the customer/consultant.
2.3.10.4 SIGNALLING AND ALARM
Prior to starting of the plant, a provision of inspection shall be there to take

care of the stage of readiness of the entire plant. All the local points shall be
provided with audio-visual signaling arrangement for communicating the
permission to start.
Two way communication circuits shall be incorporated to ensure rapid
communication between control room operator and attendant of the different
equipment and any other person working in the plant.
The centralized control system shall have the following provisions:
Provision of selecting auto de-interlock/local mode shall be made. Remote

control operation may be through PLC or through control desk. Through
PLC all equipment shall have auto-sequence start whereas through control
desk all equipment shall have manual sequence start.
Provision for diagnostic packs for self fault detection of PLC system shall be
provided.
Provision for off line programming facility shall be provided.
Provision to start the plant from remote, only when the start permissive
signal is received from operators located at strategic location in the plant
through the operation of push buttons (TWC).
Provision to run one or both the flow in the standby system depending upon
the load shall be provided.
Provision of display through continuously luminous mimic panel to indicate

status of operation of different equipment shall be provided.
JOB NO-730176 II-25

Start of all the connected equipment from the respective control desk in
sequence in case of failure of auto sequence control.
In-feed conveyors will be filling coal into the Silo continuously. Below the
outlet of silo a hand operated hydraulic Rolling slide Gate for maintenance
purpose and below that a double bladed rolling overlapping type slide gate
called ‘discharge’ gate will be mounted. Below this Gate there will be a
pre-weigh hopper from which a swing chute will be mounted. At the bottom
of the chute there will be a Duplex type flow control gate mounted to
control the flow of material.
Wagon position is automatically identified by using infra-red sensors. Once

the front of the wagon is identified, the PLC automatically opens the flow
control and closing of flow control gate shall be automatic by detecting the
end of wagon. If end of the wagon approaches before the target amount is
loaded (By Operator), then with the help of infra-red sensors, flow control
Gate will be closed.
An operator console will be provided in front of each loading point, so that

operator will be able to see and control the loading.
Necessary ‘Annunciation’ indications will be provided and in case of any

alarming condition or in the event of power failure, Discharge and flow
control gate shall move to ‘FAIL TO SAFE’ condition and spillage does not
occur at any point of time.
In the event of loco approaching the chute and the chute is at loading
position, to avoid the shearing of shear section, a sensor shall be fixed up
suitably at the chute to detect the loco and to retract the chute to store
position.
2.3.11 COMMUNICATION
The following communication system shall be installed in the coal handling

plant.
2.3.11.1 PROJECT ADMINISTRATIVE COMMUNICATION SYSTEM
Required nos. of automatic dial type telephone sets shall be provided at

various locations in the Coal Handling Plant as stated below:
i). Truck receiving hopper Complex - 2 Nos.

ii). Office - 3 nos.
JOB NO-730176 II-26

iii). Bunker - 2 nos.

iv). Substation (one each at 33kV, 3.3kV S/S I, II & III) - 4nos.
v). Central control room - 1 no.
vi). Silo control room - 2 Nos.
These telephone sets shall be wired and brought to a common junction

box in the plant. Then this will be connected to the existing auto exchange
to make it an integrated communication system.
2.3.12 PRESSURISATION AND AIR CONDITIONING
All the panel rooms of 3.3 kV substation/switching stations shall be

pressurized with conditioning of inlet air and control of humidity for proper
operation of equipment and comfortable working of personnel inside the
room. The number of air changes shall not be less than 15 per hour. Split
type air conditioners of suitable capacities should be provided at Central
and Silo Control room. PLC rooms, Engineer-in-charge’s room shall also
be provided with Split type air conditioners of adequate capacity.
Design and construction of all the MCCs, substation rooms etc. shall be
done so as to prevent entry of dust and at the same time maintaining the
proper temperature inside for proper working of the equipment and the
personnel. Sufficient numbers of ceiling fan and exhaust fan shall be
provided wherever required.
JOB NO-730176 II-27

2.4 CIVIL CONSTRUCTION
The civil and structural works are related mainly to the following areas (but
not limited to):
• RCC silo -4000 te capacity (5000 cum with staircase, silo control
room, lift etc 2 nos.
• 15000 te semi ground bunker with truck unloading facility
• Truck Receipt Hoppers 1200 te cap.with 12 nos.of outlets &
truck unloading facility.
• Transfer Houses
• Transfer Houses due to extension of 5 nos. of Discharge Pulley of
existing CHP conveyors.( As indicated in drawings)
• Drive Houses
• Conveyor Gantries & Trestles
• CHP office along with Time office, Security post, rest shelter, cycle
& scooter parking shed, car parking shed, toilet, canteen and first
aid facility
• Service buildings like 3 nos. of Sub stations, 1 control room, a store
shed etc.
• Underground reservoir
• Road diversions and new roads to approach all Transfer houses,
drive houses, service buildings, control rooms, CHP office etc.
• Proper drainage for entire system
• Industrial and drinking water arrangement
• Any other item not mentioned but required for successful
completion of the Project.
JOB NO-730176 II-28

CHAPTER-III
SCOPE OF SUPPLY AND WORKS
3.0 GENERAL
This is a pre-engineered turnkey assignment for design, supply, erection,

commissioning, trial run and handing over of all the equipment and other
sub-systems of the proposed coal transportation and silo loading
arrangement at Lingaraj OCP, Talcher coalfields of MCL as elaborated in
subsequent paras in this chapter.
• The contract for the package will not be split. The contract will be
treated as acombined contract.
• The equipment and works mentioned hereinafter to be read in
conjunction with preamble (Chapter-I), system description and
basic data sheet (Chapter-II), and technical specification (Chapter-
IV) whichare indicative and notlimited to the description and/or list
given.
• All mechanical & electrical equipment and systems and civil works
are within thescope of supply and works of contractor.
3.1 SCOPE OF SUPPLY
• List of conveyors and belting Annexure-III.1A

• List of MechEquipment&Accessories Annexure-III.1B
• List of Electrical Equipment,Accessories Annexure-III.2A
• List of ElectricalTesting Equipment Annexure-III.2B
• List of Accessories & Facilities Annexure-III.2C
• List of mandatory spare parts (Mech) Annexure-III.3A
• List of Electrical spare parts Annexure-III.3B
• List of tools and tackles (Mech) Annexure-III.4
• Location for installation of electric hoist
& chain pulley blocks Appendix-A
• List of approved vendors for Mech. &
Elec equipment Appendix-B
• Format for Vendor Evaluation Appendix-C
JOB NO-730176 III-1

3.2 SCOPE OF WORKS AND SERVICES
3.2.1.1 The Scope of Work under this tender shall include design, construction,
supply of equipment including transportation to site, all mechanical,
electrical, civil and structural works, erection of equipment and structures,
carrying out detailed survey and supply of drawing, drawing showing
contours, supply of detailed design, working manuals, working drawings
including all relevant calculations, testing and commissioning, elimination
of all teething troubles, carrying out all performance tests and handing
over of the plant as envisaged in detailed scope of work and system
description. Due consideration shall be given for economy, architecture
and functional utilities. This being a turn-key work, all works needed for
successful completion and operation of the plant together with the
associated systems shall be covered in the scope of work, whether
specifically mentioned here or not.
3.2.1.2 All the works including designs, drawings, construction, fabrication, testing,
erection, etc. shall be done strictly as per IS Code of Practices. Wherever
no Indian Standard are available, British, American, German, or any other
International standards may be used on prior approval from the
Purchaser/Owner.
3.2.1.3 The jobs to be carried out are broadly classified into three categories.
These are civil & structural, mechanical, and electrical. However, the jobs
are to be carried out on turnkey basis by carrying out interface works also.
• The bidder shall be required to complete the following works to the
complete satisfaction of customer (MCL) and their consultants
(CMPDI).
• Design & Engineering of all civil and structural, mechanical,
electrical, instrumentation works of the plant.
• One set of reproducible soft copy in Auto Cad format of all design
and installation drawing (as built drawings) in six sets of prints
suitably bound, shall be presented.
• Manual of spare parts, operation, maintenance and repair manual
shall be presented in eight sets.
• The Contractor shall strictly follow the design as asked for in
various chapters. However, any minor deviation needed to suit the
requirement of the plant, betterment of the system suggested in the
NIT will be done during detailed engineering stage after obtaining
prior approval of the company.
• If any clarifications or approvals are required to be taken from
statutory bodies, the same shall be the responsibility of the
Contractor
JOB NO-730176 III-2

• Conducting tests prescribed in the relevant acts, rules, regulations,

codes of practices of Indian Standard and as necessitated by
generally adopted sound engineering practices during erection and
commissioning shall be followed.
• Rectification of problems detected during testing, erection and
commissioning by making necessary changes in the design and / or
installation and supply of equipment, accessories and material.
• Addition and or alteration as found necessary during tests, erection
and commissioning to achieve the objective.
• If any other work not specifically mentioned but are required to be
done to complete the plant shall be deemed to be included in the
scope of work.
• Obtaining approvals from Weights and Measure Department is the
responsibilityof the bidder.
• The technical parameters to be furnished are subject to
scrutiny/approval at thedetailed design stage which may undergo
minor changes keeping in view thesystem requirement and various
codes of practices/regulation by the statutorybodies. This is also
true for drawings. The parameters not specifically mentionedin the
bid document shall be decided at the time of detailed engineering
subjectto owner’s approval.
3.2.2 DETAILS OF WORKS AND SERVICES
3.2.2.1 DESIGN ENGINEERING
i. Elaboration and furnishing of system design/drawing, based on

actualparameters of equipment to be supplied. The system design
as proposed inthe plant description shall form the basis of this
elaboration.
ii. Preparation and furnishing of all relevant detailed engineering
drawingsbased on elaborated system design drawing duly
approved by consultant inwriting. This includes fabrication,
assembly, installation and erectiondrawings also.
iii. Furnishing of detail design calculations in support of different
design andequipment parameters.
iv. Furnishing of equipment specification supported by manufacturer’s
illustrative pamphlets and literature.
v. Furnishing of operational, maintenance and spare parts manual
supportedby the illustrative pamphlet and literature of
manufacturers.
vi. All approved drawings and documents shall be supplied in six
copies inaddition to one copy in AutoCAD formaton CD. Final
JOB NO-730176 III-3

drawing/literature shall be presented in the formof document along

with the soft copy.
vii. All drawings shall comply with current Indian Standard
specifications andshall be sufficiently detailed with dimensions and
shall be clear and legible.
viii. The bidder shall submit detailed time schedule in the form of
PERTNETWORK for complete plant and subsequently for each
major activity formonitoring purpose. The same shall be updated
from time to time. This isessential in view of maintaining time
schedule. The successful bidder shallhave to submit
monthly/quarterly progress report of the various works
beingcarried out.
ix. Provision of equipment (Motorised belt reeling drum) for belt
erection/replacement and vulcanising during maintenance of
conveyor belt shallbemade available at site by the bidder.
3.2.2.2 ERECTION AND COMMISSIONING
i. Erection & commissioning of tail end frame with drum, external

cleaner, skirtboard, intermediate structures, take-up, drive head
including motor, gear box &couplings, discharge drum, conveyor
rollers, single / two way discharge chute forconveyors, safety
switches and laying of suitable belting and vulcanising of
conveyors .
ii. Erection & commissioning of secondary roll crusher / Sizer for
secondary crushing( (-) 100mm) , Rapid loading system, belt
weigher, magnetic separator, metal detector, chainpulley block,
electric hoist, fire fighting system along with associated
accessoriesand condition monitoring equipment, erection and
commissioning of dustextraction, dust suppression and ventilation
equipment at different locations wherever required.
iii. Construction of over groundreceiving hopper with 12 nos. of
input/output facilities to receive coal from surface miners by trucks
/dumpers. The receiving hopper of 1200 te capacity shall be of
RCC.
iv. Extension of discharge head of existing feeder breaker circuits
(5Nos) suitably for further transportation by belt.
v. Construction of 15000t semi ground bunker of slit type for
installation of plough feeder andtripper conveyors. This 15000t
shall facilitate also the receipt of coal by truck/dumpers also.
vi. All Transfer points
JOB NO-730176 III-4

vii. 5000 cum RCC silo with pre weigh-hopper consisting of hydraulic
power pack, cylinders, guillotinetype gates for high speed load out,
arch breakers, load cells, wagon loading swing typechute and
temperature sensors.
viii. Rapid loading system-The loading will be done through rapid
loading system on an average one wagon perminute. The loading
shall be controlled from control room located at first floor of the
silo.The rate of loading will be around 5500tph-6000tph matching
the creep speed of locomotive. The rakes will be hauled by a
creep controlled locomotive at 0.8 to1.2 km/hr. Ultrasoniclevel
indicators will be provided in the silo to show the coal level
position. Air blastersshall be provided to avoid /break the arch
formation inside the silo and to ensuresmooth coal flow through
the silo. The system shall have the switches for emergencystop of
feed conveyors in case of over filling of silo. There shall be
temperature sensorsto indicate the abnormal temperature inside
the silo and provide caution so that firefighting measures can be
taken up.Lift for the silos have also been envisaged.To ensure
better loading and weighing accuracy pre-weigh loading system
shall beadopted .In addition in motion rail weighbridge wagon
weighing system is required separately. There shall be two
loadingpockets over two rail track as indicated in the drawing. Silo
shall be provided with periodic inspection facilities.Provision of two
silos are to be provided as indicated in the drawings.
ix. Sampling system-For determining the quality of coal dispatched by
each rake there shall be provision ofautomatic sampling of coal,
cutter type, from the feed conveyors to the silo at suitable location.
Thesampling system shall conform to BIS/ISO/ASTM
specifications and shall consist of aprimary sampler fitted to each
in feed conveyor and a primary sample belt conveyor ofmin
650mm width to collect coal samples from the two separate
sample dischargechutes and to convey the primary sampled coal
to the sample preparation system.
3.2.2.3 MISCELLANEOUS SYSTEMS
I. SAFETY DEVICES
All the equipment and conveyors in the circuit shall be provided

with necessary safetydevices such as emergency stop switches,
overload protection, wire-netting, railing or guards, pull chords
switches, belt sway switches, zero speed switches,
brakes,holdback devices, etc wherever applicable. All equipment
JOB NO-730176 III-5
in both the streams will bestarted and stopped from the central
control room in a pre-determined sequenceconsecutively i.e. one
by one with a definite time lag. The sequence of starting of drive
will be in the reverse direction of coal flow, whilestopping of the
drives will be in the direction of coal flow. In case of stoppage of
anyequipment in the circuit for any reason, all the preceding
equipment/conveyors shall bestopped automatically.
Pre-start hooters shall be blown to alarm the operating and
maintenance personnel. Allthe floors and distant transfer houses
shall be provided with audiovisual signals to alarmthe working
personnel locally. Necessary walkways andcrossovers shall be
provided along the conveyors. Under-netting shall be
providedwherever conveyors cross any roads or working areas as
elaborated elsewhere.
II. POLLUTION CONTROL
• DUST SUPPRESSION AND EXTRACTION
Proper water supply arrangement for dust suppression and dust

extraction will be madeat dust generating points so that all working
space remains free of dust. For dust suppression water jets will
have to be provided in receiving pit area, silo loading point,transfer
houses and dust extraction arrangements will be done at bunker
location. Alternatively, fog type dust suppression can also be
used at critical location. For properventilation in all the working
floors, arrangements for installing exhaust fans/ventilation fans
with ducting will have to be made as detailed elsewhere in the
tender document. Allcivil works pertaining to dust suppression and
extraction shall be as per systemrequirement. The pumping sets
for the dust suppression/ control should have100% stand-by at
each locationNecessary arrangements of infrastructure for
reusing/recycling of used water should be made. Arrangement for
rain water harvesting shouldbe made for storage of water in lean
periods.Necessary measures shall also be taken for noise and
vibration control.
JOB NO-730176 III-6

III. REPAIR FACILITIES
Necessary spot repair facilities shall be provided for plant and

equipment including liftingtools and tackles. Provision for site
storage of spares and tools shall also be made. Alllubrication
charging points shall be dust free. A drum of suitable diameter and
slowspeed drive arrangement shall be provided at each drive
house of conveyor system.This will facilitate automatic changing of
conveyor belt.
IV. CHUTES AND LINERS
Chutes shall be designed for a smooth flow of coal and they shall
be lined with suitablereplaceable polyurethane liners. Wherever
the flow of coal is likely to beobstructed due to moist nature of coal
or due to long arm of chute, the facility of chuteactuators shall be
provided as specified. Conveyor chutes shall be carefully
designedwith respect to the coal trajectory to minimize
impingement and wear on lining plates
V. DRINKING WATER AND OTHER FACILITIES
Facilities for distribution of drinking water shall be provided all

along the plant withprovision of toilet facilities at suitable points as
detailed in civil section.
VI. PLANT CLEANING AND DRAINAGE
Suitable arrangements shall be made for cleaning of plant

especially at thespillage point with the help of water hydrants and
vacuum cleaners in case ofelectrical panels and plant equipment.
Plant cleaning points shall be provided at each receiving pit
complex, drive house, tailend, transfer points, semi ground bunker
and along all conveyors at a maximuminterval of 50 metres. The
effluent shall be discharged into a suitable location/ ETP
bydrainage or through pumps, pipes, etc. Compressed air points
should be provided in the receiving pit, crusher house, and near
the plough feeders forcleaning. These shall be served by portable
compressors as envisaged in the biddocument. Water and
compressed air pipe line net work along with
connection/tappingpoints with control valves at suitable intervals
shall be provided in the receivingpit floors, pent houses, transfer
JOB NO-730176 III-7
and drive houses, conveyor galleries, substations,semi ground

bunker etc. for pressure cleaning of floor chutes,walkways etc.
Proper drainage arrangement will have to be made all along
theplant so that water or slush accumulation is avoided. At every
probable spillagepoint suitable arrangement will have to be made
for mechanized or manualcleaning.
VII. FIRE FIGHTING OF TOTAL COAL HANDLING PLANT
Fire fighting system shall comprise of fire/heat/smoke detection,

fire alarm system and fire fighting system both water and aerosol
reliant.
There shall be a Control unit to monitor firefighting activities near
the bunker at Substation II.
Fire fighting system shall be designed to meet the various
requirements laiddown in the fire protection manual by the Tariff
Advisory Committee (TAC), Indiaand National Fire Alarm Code by
NFPA (USA).
• HYDRANT SYSTEM:
The fire hydrant system shall be designed considering theentire

plant generally as ordinary hazard as per TAC manual and shall
consistsof a net work of over ground piping feeding pressurised
water to a number ofdouble headed hydrant valves located
throughout the entire coal handling plant.
• PORTABLE & MOBILE EXTINGUISHERS:
Portable extinguishers of carbon dioxidetype, dry powder type &

soda acid/ DCP type shall be installed at suitablelocations all
along the plant as per TAC manual. Mobile extinguishers of
requirednumber shall be provided. Different types, as described
above, shall conform tothe latest BIS standards.
• VENTILATION
Proper ventilation system shall be provided at suitable locations as
per requirement.
JOB NO-730176 III-8

• SITE OFFICE AND REST ROOM, ETC
A site office of suitable size for engineers/supervisors and a rest

room forworkers shall be provided. Other service buildings shall be
provided as detailedelsewhere and/or, as per requirement.
3.3 ELECTRICAL
• Design Engineering, Erection, Commissioning, trial run, rectification

of teething troubles and handing over of three numbers of 3.3 kV
substationsand modification & extension of existing 33kV substation.
• Power supply arrangement for all the electrical power driven
equipment provided in the system.
• Earthing and Lightning Protection System (traveling waves and direct
stroke lightning) of the entire CHP, substations, SILOs etc. For
designing the earthing system the contractor shall carry out tests at
his own cost to determine the soil resistivity from a reputed firm
acceptable to the company.
• During construction of substation switchyards, following points are
to be taken care of.
a).Modification& extension of the existing 33kV substation

including civil and foundation work, extension of tubular bus
bar, erection and commissioning of required nos. of bays
including GI structures, insulators and other accessories as
per requirement.
b) Proper roads are to be provided within the switchyard to
facilitate the transporting of equipments to their respective site.
c) Soak pits are to be provided for all the Power transformers.
d) Proper drainage system of the leakage transformer oil up to
the soak pit should be provided.
e) Baffle wall should be provided between two Power
transformers.
f) Full proof drainage system should be established to protect
the electrical equipments from submerging.
g) Switching yard should be covered with gravels as per
requirement.
h) The 33kV switchyard should be fenced and properly earthed.
However, the total compound (including switchyard and
control room) should be covered within the existing boundary
wall.
i) Cable tray & cable trench are to be constructed as per
requirement.
j) After preparation of substation drawings, approval should be
taken from the competent authority.
JOB NO-730176 III-9

3.3.1 During construction of the CHP, following points are to be taken care of
• Erection and commissioning of overhead line from 33kV substation to

3.3kV substations, DP/4 pole structures, power receiving &
distribution centre as per requirement.
• Internal and external illumination arrangement of the entire CHP.
• Power Supply System for lighting and welding sockets.
• Control system for Centralized auto-remote and auto sequence
interlock control manual control, etc. The control shall be
implemented by PLC.
• Communication and signaling system.
• Air Conditioning System for Engineer-in-charge room, central control
room, Silo control rooms etc.
• Pressurisation system for the Switchgear room of all the 3.3 kV
substations– I, II & III.
• Selection and provision of exhaust fans and ceiling fans in all the
buildings wherever necessary.
• Preparation of installation drawing in accordance with approved
design. Final approval shall be given by the Customer.
• All other electrical/civil/mechanical works not mentioned here but
required to be done as per system requirement for commissioning of
the whole plant will be deemed to be included.
• The ratings shown in drawings are only indicative and for tendering
purposes only. The Contractor however shall give detail drawings,
ratings specifications of every item.
3.3.2 Selection of equipment, accessories and materials shall be according to

design referred above and approved by the Customer.
¾ Preparation and execution of maintenance schedule during and

after the guarantee period as per approval of the Customer.
¾ Illumination system of enter CHP including Rapid loading Complex,
adjacent areas and gantry of conveyors, substations etc.
¾ Lightning Protection System for structures having height of 10 m
and above.
¾ Earthing system of all the electrical equipment covering electrical
system for entire CHP including rapid loading complex, electrical
equipment of conveyors, substations etc.
¾ Battery and Charger, if required.
¾ Power, Lighting and Control Cabling.
¾ Control Desk cum mimic panel and annunciation Panel for control
of equipment of Rapid Loading Complex, Loading Conveyors and
other miscellaneous electrical drives.
¾ Control, automation, interlocks, Signaling and instrumentation of
Rapid Loading complex including sequence operation of loading
conveyors with silo level indicator and dove-tailing of sequence
JOB NO-730176 III-10

operation of Reclaim Conveyors with plough feeders below ground

bunker.
¾ The rating of equipment indicated in the drawings are minimum and
bidders are required to assess the rating of equipment as per
system requirement and quote accordingly.
¾ Provision of inverter base emergency lighting in substations and
control rooms in case of failure of power.
¾ Transformer capacity mentioned in the drawing is minimum
capacity. Bidders shall make their own assessment and shall
indicate higher capacity, if required. All the transformers including
that of lighting shall be located indoor only
¾ All the electrical installations shall be as per Indian Electricity Rules
and DGMS Regulations. Approval of DGMS shall be obtained by
the contractor along with submission of necessary Test
certificates/drawings/circuit diagrams
3.3.3 MAINTENANCE AND SAFETY

Suitable provision for maintenance of equipment and safety shall be
made.General requirement for maintenance and safety.
3.3.4 APPROVED VENDORS

Plant and Equipment supplied within the country shall be from approved
vendors as listed in Approved Vendor List. at Appendix-B. In case the
bidderintends to supply P&M from vendors not listed in approved vendor
list, writtenapproval of the customer / owner shall be taken who, after
evaluating of eligibility andqualification of such vendors, may choose to
include them in approved vendorlist. Bidder shall furnish information for
evaluation andqualification of each such vendor. The criteria and formats
for evaluation of vendors aregiven in appendix-C.
For plant and equipment supplied from vendors abroad, information
forevaluation and qualification of each vendor shall be furnished and
thewritten approval of employer for approved foreign vendors shall be
taken.

3.4 CIVIL AND STRUCTURAL WORKS
3.4.1 GENERAL
The scope of work under this contract shall include design, construction
and successfully commissioning of all civil and structural works including
supply of detailed survey drawing showing contour, geo-technical
investigation, supply of geo-technical report, supply of detailed design,
working drawings including all relevant calculations and all necessary
works as may be needed for testing and commissioning, elimination of all
teething trouble, performance test and handing over of the plant as
envisaged in detailed scope of work and system description. The
necessary construction, erection, commissioning equipment related to civil
engineering works shall be provided and transported to the site of work by
the contractor. Due consideration shall be given for economy, architecture
and functional utilities. This is a contract for complete installation including
planning and design, supply, execution and erection of civil & structural
work. Accordingly, all works needed for successful completion and
operation of the plant shall be covered in the scope of work whether
specifically mentioned here or not.
Adherence to Indian Standards
All the works including designs, drawings, construction, fabrication, testing,

erection, etc. shall be done strictly as per relevant BIS Code of Practices,
wherever no Indian Standard is available, British, American, German,
Russian or other international standards may be used only as per its
applicability and justification.
3.4.2 BASIC SCOPE
The scope of work covers all the related civil and structural works, detail
designing of the same and successfully commissioning of the civil and
structural works for handing over the plant. This shall inter alia, include the
following:
3.4.2.1 Design & engineering of all civil and structural works of the plant.
3.4.2.2 Execution of all civil/structural works consisting of the following:
a) Detailed survey of site including contour map preparation
b) All the geo-technical investigation required for the work including
furnishing the geo-technical report, Collection of hydrological,
blasting and rainfall data including any other data related to design
and execution.
c) Preparation of construction site.

d) Supply of structural steel for the work as required.
e) Supply of all civil construction materials and other materials as
required.
f) Execution of all civil works.
g) Fabrication and erection of structural steel work.
h) All civil and structural works of connected equipment and
accessories undersupply.
i) Excavation/ construction/ erection/ installation and commissioning
of allauxiliary services such as sanitary, drainage, roads, retaining
walls,pavements, office and service buildings, lighting towers,
landscaping/grading/leveling/fencing/site clearing as detailed
elsewhere.
j) Transportation of all construction materials to site, whether
procured within thecountry or from other countries.
k) Water supply arrangement for potable, industrial and fire fighting
purposes.
l) Drainage and sewerage
m)Fire fighting arrangement.
n) All the protective measures for proper drainage for safety of
structures, against ingress of water / seepage due to seasonal
nallahs and its tributarieswhich are flowing through the construction
site area as per actual siteconditions and requirement.
o) All the protective measures for safety of men and materials
duringconstruction against rail/dumper movements on existing
railway tracks/haulroads.
p) Works required for erection and commissioning of all the plants and
equipments.
q) Inspection and testing.
r) Performance guarantee.
3.4.2.3 Perception and remedial measures for the safety of entire CHP area under
thescope keeping in view the adjoining natural and artificial features such
as hill slopes, nallah, buildings, etc.
3.4.2.4 Any other works/services not mentioned but required for the completion
andcommissioning of the plant.
.

3.4.3 DESIGN/ENGINEERING
3.4.3.1 DESIGN CRITERIA
All detailed design and working drawings will be developed with proper co-
ordinationand inter-relation with mechanical and electrical equipment. The
design of RCCstructure shall be carried out in general as per code of
practice of plain and reinforcedconcrete for general buildings construction
BIS 456-2000 and other relevant standardsincluding up-to-date
amendments. The steel structure shall be designed and fabricatedas per
Code of practice for use of structural steel in general building construction
BIS800 (latest edition) with up to date amendments and other relevant IS
standards. Thebuilding/structure shall conform to local by-laws, rules and
regulations for industrialbuildings and as per relevant Indian Standards.
Latest codes of practice withamendments up to date shall be strictly
followed. In the absence of BIS codes, Britishstandards Institution or the
approved international bodies’ codes could be considered fordesign as per
its applicability and justification.The bidder shall be responsible for and
shall pay for any alterations of the work due toany discrepancies, errors or
omissions in the design and drawings or other particularssupplied by him,
whether such design, drawings or other particulars have been approvedby
customer or not.
3.4.3.2 LOAD CONSIDERATION
Loads to be considered in design shall be as per relevant BIS codes of

practices.Generally, in design the effect of dead loads, live loads, load due
to impact, vibration,erection, wind load, seismic loads, dust load and load
due to surcharge and movingvehicles, effect of blasting etc. wherever
applicable shall be considered. The loads dueto equipment shall be
supplied by the bidders which shall be considered for designing of civil
&structural. In general, live load, wind loads, etc shallbe as per BIS-875
(latest edition). Seismic loads to be considered in design shall be asper
BIS 1893 (latest edition). The maximum bulk density of coal will be taken
as1.2t/m3 for load design calculation in respect of coal retaining structures.
However,this is to be verified through lab test and reports to be submitted
by the bidder beforeapproval of drawings. Effect due to blasting is to be
considered while designing thestructures, as per the provision of BIS:
6922 with latest revision. The topography factor for the calculation of
design wind pressure shall becalculated as per BIS 875 read with the
latest amendment.

3.4.3.3 ANALYSIS & DESIGN
All RCC and steel structure shall be designed in accordance with relevant
ISCodes of practice of latest revision. In the analysis of structures, the
worstloading combination of belt pulls, equipment loads, their impact,
wind/seismicloads/blasting effect, coal and other loads as envisaged shall
be considered.
3.4.3.4 DESIGN DRAWING & DETAILED ENGINEERING
Broadly all the dimensions as given in the tender document drawings are
to be followed for bidingpurpose. These dimensions are indicative & may
require changes during detaildesign.
3.4.3.5 PREPARATION
All the drawings shall be prepared in accordance with the provision of

latestIndian Standards. All drawings shall be sufficiently detailed and
dimensioned tohelp in speedy construction, fabrication and erection of
structures. Wherever, any structure is presented in more than one sheet of
drawings, same scale andnotations shall be used in all the sheets for
linking the drawings with each other.All modifications made in structure
during various stages of construction shouldbe duly incorporated in
working drawings.Bar bending schedule, detailed material list and
specification of works shall beprepared / detailed. Working drawing shall
also include general arrangementdrawings showing plans at different
levels with sectional elevations. Separatedetailed drawing shall be
prepared for inserts and anchor bolts including theirfixing details. The
design drawings associated with steel structure should showthe force in
the members, complete details of all members, joints, gusset plates,
welding, riveting, bolting, etc. The drawings should also show the weight of
each assembly/sub-assembly as far as possible. In addition to design
drawings, fabrication drawings shall also to be prepared, showing item-
wise details,erection units, materials list, details of fasteners with
assembly, etc.

3.4.3.6 SUBMISSION OF DESIGN/DRAWINGS
The tenderer shall submit Geo-technical report, all the relevant detail
designcalculations, general arrangement/detail drawings, bar bending
schedule,detailed material lists, specification of works including contour
plan for approvalof owner / consultant on standard size sheet.Scrutiny and
approval of drawings may be carried out through the consultantengaged
by owner. All design details and drawings shall be submitted forapproval of
the following:
• General Arrangement Drawings
• Detail design calculations
• All detail civil/structural/fabrication drawings
• Any other drawings relevant for execution/fabrication of
civil/structural works
Contractor shall submit for approval six sets of drawings along with
detaileddesign calculations including analysis of force/stress in the
structure along withthe source from where data, except BIS codes, have
been taken. Photocopies ofsuch data should be submitted along with the
design. Along with the six sets of hard copies a soft copy in CD in autocad
format shall also to be furnished.
3.4.3.7 PROCEDURE OF APPROVAL OF DRAWINGS
The Owner shall have the final say in the approval of drawings. Drawings
sosubmitted will become the property of the Owner. The approval of the
drawingsdoes not absolve the Contractor from the overall responsibility of
the plant for its successful operation. The Contractor shall be responsible
for and shall pay forany alterations of the work due to any discrepancy,
errors or omissions in thedrawings or particulars supplied by him, whether
Owner has approved suchdrawings or other particulars.
Approval by Owner / ConsultantDesign & drawing, submitted by the
contractor, shall be scrutinized by owner.Out of six sets of drawing
submitted to the owner, one copy will be sent tocontractor after scrutiny
comments, modification or approval as the case may be.The contractor
shall carry out the necessary rectification in drawings afterdiscussion with
owner in a reasonable time as agreed upon mutually and resubmitsix
copies of such revised drawings for approval of owner. Reviseddrawings
shall then be scrutinized and approved if the comments made by
theOwner are incorporated / taken care of. One copy of such drawing will
be sent tothe Contractor after approval.

3.4.3.8 AS BUILT DRAWINGS
Contractor shall make necessary correction / modification in the drawing

as peractual work and shall prepare as built drawing. The Contractor shall
supply such8 (eight) sets of prints of as built drawing to the Owner along
with one set ofreproducible drawings in AutoCAD format. The same will
hold good forother documents also to be supplied by the Contractor under
the heading ofbasic scope. All drawings should be prepared on AutoCAD
in standard formatand CD containing such drawing shall also be supplied
along with hard prints.
3.4.4 DETAILED SCOPE OF WORK
3.4.4.1 GENERAL
The civil and structural work under, its scope shall cover all aspects of
work,including soil and hydrological investigation, collection of rainfall data,
detailedsurvey, preparation of preliminary drawings with proper co-
ordination and interrelation with equipment, detailed design and
preparation of the complete civiland structural working drawings, execution
and erection of the complete civil andstructural works, including roads and
pavements, sanitation, water supply forindustrial, drinking and fire fighting
purpose besides water supply to variousbuildings and structure for dust
suppression and extraction and cleaning as persystem requirement and
land development.The execution of civil and structural work consist of
providing all labour,supervision, materials, scaffolding, construction
equipment, tools and plants, supply, transportation, and all incidental items
not specified but implied forsuccessful completion of the works in
accordance with drawing and specification.
The nature of work shall generally involve chemical testing of construction
waterfor corrosive action of chemical and other deleterious materials, earth
work infilling and excavation in all types of soil and rock, dewatering,
shoring, back fillingaround completed structures, disposal and form work,
brick work, fabrication anderection of structural/miscellaneous steel,
inserts, anchor bolts, RCC, chequeredplates, trench covers, water pipe
lines, sewerage, roads, surfaceand storm water drainage, ventilation,
dampproofing and other ancillary works related to the coal handling plant.
The drawings as mentioned elsewhere in thiscontract documents give a
general idea about the work to be performed.These are preliminary
drawings for bidding purpose only and are by no meansthe final drawings
showing the full range of the work under the scope. Work hasto be
executed according to approved working drawings, fabrications
drawingswith additions, alterations and modification made from time to

time as required orapproved by the customer.
COMPONENTS OF CHP – IN BREIF
The civil and structural works are related mainly to the following areas
(but not limited to):
• TRUCK RECEIPT HOPPERS COMPLEX - Truck Receipt

Hoppers Complex with all provision of civil and structural work of
1200 t capacity as indicated in the enclosed drawing.
• 15000 T CAPACITY SEMI- GROUND BUNKER WITH WMM
PAVEMENT This shall be designed and constructed as per
system requirement as shown in the drawing.
• RAPID LOADING COMPLEX - Loading complex with two nos. of
silo, each of 4000 T capacity, elevator, staircase , pavement for
railway track etc. shall be designed and constructed as per
system requirement as shown in the drawing.
¾ THE SILO SHALL BE DESIGNED FOR THE

FOLLOWING :
o Wt. of the Coal of silo : 4000 T (considering

bulk density 0.8t /
cu.m)
o Self flowing volume of the silo : 5000 cum
o c) Air volume capacity of silo : As per system drawing
o d) Maximum wt of coal inside : 6000 T for design at
bulk density1.2t / cum
o e) Material size : (-) 100mm

o f) Silo slope angle : 700 (Min)
o g) No. of outlet for wagon loading: Two on the same
track
o h) Outlet size for flood loding : Suitable for discharge
rate of 5500 TPH
(average)
o i) Diameter of silo (inside) : 18 m

• CONVEYOR GALLERY FOR CONVEYOR (GROUND AND

OVERHEAD)- This shall be designed and constructed as per system
requirement as shown in the drawing.
• TRIPPER CONVEYOR GALLERY- This shall be designed and
constructed as per system requirement as shown in the different G.A
drawings.
• TRANSFER HOUSES, DRIVE HOUSES AND SECONDARY ROLL
CRUSHER HOUSE are to be designed and constructed as per system
requirement as shown in the different G.A drawings.
• 33/3.3 KV SUBSTATION- The 33/3.3 kV substation building having
plinth area 150m2(minimum)for the proposed CHP shall be constructed in
the existing campus of 33 kV project substation. Construction of
substation building and yard is in the scope of this work.
• SERVICE BUILDINGS
a) Service building such as main CHP office, Plinth area 350m2

rest room, First aid centre, canteen etc. (Minimum)
with provision of separate room for each
executive and supervisor (Double storied)
(b) One no. Store near main CHP office Plinth area 72m2
(minimum)
(c) One no. security post/ time office near main Plinth area …20m2
CHP office (minimum)
(d) Light vehicle parking shed for 6 Nos. of Plinth area…
vehicles near main CHP office 54m2(minimum)
(e) Shed for 30 cycles and 20 scooters Plinth area …54 m2
(minimum)
(f) Common toilet Plinth area … 5m2
(minimum)
(g) Three (3) Nos. of electrical sub-stations(3.3 Plinth area and other
kv)i.esub-station no. I,II, III in the plant area. facilities as per system and
functional requirement but
not less than 450m2 for
substation-II (Double
storied), and 450m2 each
for substation-I &sub-
station –III
All buildings are to be designed by the bidder as per functional

requirement but cannot have plinth area less than that mentioned above.
• Road - As required
• Pavement area - As required
• Boundary wall - As required

• RETAINING WALL, DRAINS, CULVERTS, ETC – AS PER

REQUIREMENT
• Drainage and sewerage including septic tank, soak pits, etc. - As per
requirement
• Water supply arrangement including receiving, storage and distribution
of water for potable, fire fighting purposes, dust suppression purpose,
etc. is covered in the scope of work. Separate sump shall be provided
for potable water.
• The capacity of Ground water reservoir shall not be less than the
following:
o For dust suppression & fire fighting reservoir – 450 cu.m
(minimum)
o For potable water - As per requirement
o PVC Tank shall be provided at all the required places for potable
water.
o The tank/reservoir shall be covered with provision for regular
inspection and cleaning.
• OTHER WORKS AND REQUIREMENTS

i) Development works such as grading/leveling/dressing of
the site etc.
ii) Fencing/boundary walls with gates
iii) Architectural requirements
iv) Landscaping and Arboriculture
v) Fire fighting
vi) Dust suppression and extraction
vii) Plant cleaning
viii) Survey, Soil investigation and collection of rainfall and
hydrological data
ix) Construction, Fabrication, Erection and Commissioning of
the plant
x) Inspection and testing
xi) Remedial measures for safety and successful operation of
the plant
xii) Other miscellaneous works/services/requirements etc. as
may be necessary for successful commissioning of the
plant.

3.4.4.2 DETAILS OF COMPONENTS OF CHP
The civil and structural works are related mainly to the following areas (but
notlimited to):
3.4.4.3 LOADING COMPLEX
The loading complex consists of two nos of 5000 Cu.m RCC Silo. The
loading complex shall be as per requirement shown in the drawing and
shall include Silo, Staircase, lift etc. The Silo capacity shall be 4000 t.The
height of Silo shown in drawing shall be suitably modified, if required.
3.4.4.3.1 THE RCC SILO (5000 CUM)
The Silo shall be of RCC constructionand shall include two nos. of silo,
each having capacity to store 4000 T of coal.. The height of the silo shown
in the drawing shall be suitable modified, if required, based on design data.
Suitable freight-cum-passenger lift should be provided in each Silo along
with necessary arrangement for lift well etc. Stair case of structural steel
shall be provided in each Silo as an alternative arrangement to facilitate
the mobility of men and materials.
Silo shall be provided with necessary arrangements to facilitate inspection,
maintenance and repair from inside and outside of silo. Necessary platform
shall be provided all along the periphery of the silo with suitable approach
at least at two levels in order to facilitate maintenance of air blasters, heat
sensors etc. The silo shall have two pre-weigh hoppers. Necessary
arrangements shall be made for its installation.
There shall be sufficient areas of platforms and floors below silo hopper
with proper accessibility and head room for inspection and maintenance of
pre weigh hopper gates and its allied equipments.
In addition to the control rooms and platforms for pre weigh hoppers,
separate rooms with sufficient floor areas and head room will be provided
to house, the power packs, compressors, dust suppression pumps
including suppressant tanks (if any), the air and gas cylinders for arch
breaking as well as fire extinguishing at suitable locations.
The connection between Silo hopper openings and pre weigh hopper shall
be adequately designed to avoid any slippage. Stainless steel or non
corrosive bolts with nuts and washers shall be provided to connect the pre
weigh hopper with Silo.
The silo roof shall have necessary openings for the inflow of coal.
Structures above this roof shall be of structural steel and will house the
head drum, drive units. Additional openings with precast slab covers shall
also be provided for inspection and maintenance of the interior of silo.
Necessary arrangements for installation of level sensor shall be made at
the roof of silo. The roofing and side cladding of the structure shall be
provided with pre coated galvanized iron profile sheet fixed on trusses and

purlins. Minimum 12% of the roof area and8% of the side cladding area
shall be covered with translucent sheets. Necessary arrangements for
lifting device shall be provided in the structure.
All the facilities of maintenance, hoist, monorails etc. shall be provided as
per requirement. All the necessary inserts shall have to be provided for
fixing cables, supporting structures for conveyors etc.
Foundations and construction of silo up to roof level and associated
structures at the top is included in the Scope of work. In this context, the
contractor shall investigate the soil condition at constructionsite o in detail
at their own cost at the time of design/construction.
Control rooms of adequate size with suitable access from outside, shall be
provided. It will house electrical and control equipment including mimic
panels for entire loading system including control console, CRT display
and printer etc. It shall be provided with air conditioning facilities with
provision of fully glazed aluminium double door and false ceiling. Fully
glazed fixed panels in aluminium frame with toughened glass sheet shall
be provided on the loading chute side for clear visibility of loading
operations from control panel. All the internal surfaces of control rooms
shall be finished with plastic emulsion paint of approved quality and shade.
Suitable flooring shall be provided as per functional/safety requirement.
The Silo shall be designed on mass flow condition so as to achieve the
required loading rate without bridging, arching and rat holing inside the
Silo. Internal lining of the Silo shall be as given below:
a) Hopper Wall portion 8 mm thick stainless steel plate liners

with 409 M grade steel.
(Conical Wall)
b) Silo Wall (Vertical wall) 25 mm thick ferrosite lining
Provision shall be made for easy replacementof plate liners in case of

wear.
In anticipation of arching and bridging taking place in silo due to fluctuation
in coal characteristics, suitable number of holes with necessary pipe
fittings shall be provided in the Silo and hopper walls for arch breaking with
the use of compressed air. These piping shall also be used for blowing
inert gas/nitrogen at high pressure into silo for fire fighting.
3.4.4.3.2 SAMPLER HOUSE
One sampler house of steel structure shall beprovided at suitable location

on reclaim conveyors. The sampler house shall have sufficient space to
accommodate cutter type sampler/primary sampler, primary sample feeder
conveyor, crushers, secondary tertiary sampler, sample collector, bucket
elevator ( if required), necessary power supply, control etc. to make the
Sampling system complete.There shall be provision of electrical/manual
hoist as per requirement. Suitable approach to all equipment levels shall

be provided. The side cladding and roof shall be of pre coated galvanized
iron profile sheet. There shall be provision for ventilation and lighting.
3.4.4.3.3 RAILWAY TRACK NEAR SILO
At ground level, railway track shall be provided below the silo for loading
through RLS for which a rigid pavement suitable for ballast less track as
per norms of RITES, Indian Railways, shall be provided. Proper drainage
system shall be provided around the silo to prevent stagnation of water
during peak precipitation. Extent of pavement for railway track below the
silo shall be as per manufacturer’s recommendations but not less than
50m on either side of centre line of silo. However, laying of track is not in
the scope of the work.
3.4.4.4 15000 TE SEMI GROUND BUNKER WITH WMM PAVEMENT
The bunker shall be semi-ground type with capacity to store 15,000 tonnes
of coal and shall be of RCCconstruction. The layout of the bunker shall be
as per requirement as shown in thedrawing .The bunker will be fed by
tripper conveyors for which necessary supporting arrangement for tripper
conveyor should be provided.Additional arrangement shall be made to
feed the bunker through tipping trucks / dumpers of capacity not less than
25/30Te. Accordingly pavement shall be constructed alongwith ramp on
both sides of the bunker as per system drawing .The pavement shall be of
WMM type to sustain the movement of loaded tippers. Proper slope in the
pavement should be provided to avoid accumulation of water during rain.
The ramp for approach up to truck receiving platform should not be steeper
than 1 in 16.Proper care is to be taken to protect the pavement area and
ramp from soil erosion and settlement as it is on filled up soil.
The reclaim tunnel inside the bunker should accommodate two conveyors
with required spacing on both the sides as indicated in the drawing. Weep
holes shall be provided in the walls for exit of water. There should be
provision for installation of conveyor belt and other accessories including
feeders as per system requirement.
Tripper conveyor gallery/gantry above semi-ground bunker shall be of
structural steel. The gallery shall be for tripper conveyors as shown in the
system drawing. The roof and side cladding shall be of pre coated
galvanized iron profile sheet. Walkway shall be provided with chequered
plates. Hand railing shall be provided. The gallery should be supported on
steel portals with RCC foundation.
The side slope of the bunker shall be 55 degrees to horizontal. The
inclined portion of bunker slab shall be provided with 25 mm thick abrasion
resistant lining of ferrosite/ ironite. The roof of the bunker shall be covered
with pre coated galvanized iron profile sheet.. Suitable wind ties shall be
provided.
Provision shall be made for R.C.C escape tunnel with suitable slope to
have additional approach from the ground level to tail end of the conveyor
inside the bunker tunnel. It should be of at least 3m in width and 2.4m in

height. Steps of at least 1.2 m width shall be provided with suitable trade
and rise. Balance width should be provided with suitable flooring.
Necessary shutter shall be provided at the exit end of the escape tunnel
as per requirement.
All the facilities of maintenance, hoist, monorails, etc. shall be provided as
per system requirement. All the necessary inserts shall have to be
provided for fixing cables, supporting structures for conveyors, etc. The
shelves for plough feeders shall be extended upto a minimum distance of 5
m at both ends from vertical wall of the ground bunkerfor maintenance
purpose.
Bunker floors shall be of RCC. The floor shall be provided with suitable
slope along and across the conveyor for proper drainage. Road shall be
provided around the ground bunker as per system requirement.
• MACHINERY WELL (MAINTENANCE BAY)
Provision have been made for two machinery wells of suitable size on the
both the ends of the ground bunker. The floor of the wells shall be same as
of the bunker floors. Roof and wall of the machinery well shall be designed
and constructed as per system requirement.
Arrangements should be made for providing electric hoists of adequate
capacity. Monorail facilities should also be provided so that equipment can
be lifted/ repaired and loaded in trucks. Stairs of minimum 1.2 meter width
shall be provided in both the wells. Necessary doors with shutters and
windows shall be provided as per requirement.
3.4.4.5 TRUCK RECEIVING HOPPERS
Truck receiving hoppers (over ground type) of RCC construction shall be

provided. It shall consist of six numbers of truck unloading facility in series
in two rows and hence of 12 nos of total outlet pockets are to be provided
as indicated in drawing enclosed. The total capacity of the hoppers shall
be 1200t. The hopper should be of RCC having walls of suitable slope to
facilitate smooth flow of coal to the openings. Ironite/ ferrosite liners are to
be provided suitably. There shall be no unevenness in the slope of the
hopper. A platform of suitable area (minimum 30 m )all around the hopper
for plying the huge number of trucks/ dumpers at the loading platform and
rampof suitable gradient shall be provided. The ramp for approach up to
truck receiving platform should not be steeper than 1 in 16.
The surface of the platform shall be suitable to sustain the movement of
trucks/ dumpers. Proper care is to be taken to protect the pavement area
and ramp from soil erosion and settlement as it is on filled up soil.
The hoppers will be covered by a shed to prevent entry of rain water. A
steel fabricated maintenance platform is to be provided for the vibro
feeders placed underneath the outlet pockets.
3.4.4.6 CONVEYOR GANTRY/GALLERY FOR SINGLE/DOUBLE (GROUND

AND OVERHEAD)
• CONVEYOR GALLERIES
The details of single/double conveyors gallery as shown inthe different
drawings are under the scope of this contract including installation of
conveyors.
The supporting arrangement of the galleries is to be designed such that
any part of the structure is not affected by water even during highest water
accumulation. Final leveling, dressing and compaction of the filled up
ground, if any, along the alignment of conveyor, is also included in the
scope of this work. Before start of actual construction over earth/ OB filling,
(If any) assessment of soil condition and all steps for its improvement as
per design requirement are included in the scope of this work. The
foundations shall be designed in such a way that there is no appreciable
settlement in due course of time. Rectification of any subsequent
settlement during entire contract period is covered under the scope of this
work. Proper drainage arrangement for storm water all along the conveyor
alignment, considering the adjoining catchment area shall be provided. No
intermediate support shall be provided inside the conveyor gallery.
The bidder may visit the site to have first hand information about ground
profile and other necessary details before bidding.
• GROUND CONVEYORS
The conveyor shall be housed in a suitable enclosed gallery of structural
steel with walkway as per drawing.The roof covering shall be of pre coated
galvanized iron profile sheet. At least 50% of the side area shall be
covered by brick masonry. 12% of the roofing area and 8% of the side
cladding area shall be covered with translucent sheets. As part of the
conveyor will be on the ground, some amount of cutting of different type of
soil and rock may be required for laying out the conveyor system.The
foundation top of the conveyor posts shall be placed at a height of
minimum 150mm from the ground level and at a maximum interval of 3.0
m. The floor of the gallery shall be extended at least 1.2M all around
beyond the gallery. Proper drainage arrangement for storm water all along
the conveyor alignment, shall be provided. The floor of ground conveyor
shall be of concrete with IPS flooring on top.
Cross over in conveyor gallery shall be provided as required. In general

cross over will be at interval of 100 m. However, this interval may be less
or more at some places depending upon the location of the structures and
machinery etc.

• OVERHEAD CONVEYORS
Overhead conveyor shall be housed in a suitable enclosed gallery of

structural steel having minimum of 1.0 metre walkway/catway for each
conveyor with checkered plate flooring. Steel trestle with RCC foundation
shall be provided for supporting gallery. For double conveyor gallery 1.0m
walkway / catway is required where as for single conveyor gallery 1.0 m
walkway is to be provided at one side and minimum of 600mm on other
side. Walkway shall be kept normally at a distance of 1000mm from belt
top; however variation at kink shall be min of 800mm to max of
1250mm.Trestles are to be provided at every kink point. Cable tray and
other utilities are to be accommodated within the gantry space. Hand
railing shall also be provided.
Structural steel trestle with RCC foundation shall be provided to support
gallery. The height of trestles may vary. Trestles shall be provided with
due consideration to stability and permissible vibration. The trestles of the
conveyors shall be so designed that the RCC portions of pedestal are
1.5m above the ground.
The spacing of trestle for overhead conveyor gallery shall be suitably
spaced. Adequate clearance and safety arrangement should be provided
for trestles nearby railway line, roads and other infrastructures. Additional
guide plate shall be providedto protect the trestle from any damage if
required.
Roof covering and side cladding should be of pre coated galvanized iron
profile sheet with necessary wind ties for all conveyors. 12% of roof area
and 8% of side cladding area shall be covered with translucent sheets.
Overall clear width of the galleries as indicated in the system drawing is
minimum. This may vary on higher side depending upon the width of
walkway and width of conveyor belt and its supporting arrangement.
Suitable toe guard shall be provided on the conveyor side of the walkway
for protection in all the conveyor galleries.
Cross over in conveyor gallery shall be provided as required. In general
cross over will be at interval of 100 m. However, this interval may be less
or more at some places depending upon the location of the structures and
machinery etc.
At the point of crossing sufficient clearance shall be provided between
road and the conveyor floor, so that dumpers could pass through safely.
Wherever the conveyors are crossing the roads/haul road, the spacing of
trestles shall be adjusted accordingly. At such locations, opening in floor
of conveyor gallery shall be covered with sheet plate to avoid spillage of
coal on roads/haul roads.

3.4.4.7 TRANSFER HOUSE, DRIVE HOUSE & SECONDARY ROLL CRUSHER

HOUSE
The drive house and transfer house shall be of structural steel construction
and shall be provided with monorails, with hoist block / chain pulley block
for material handling purposes. The drive arrangement should be kept
within the Transfer House as far as possible. Drive houses and take up
arrangement of suitable size are included in the scope of the Contract.
The roofcovering and side sheeting of the structure shall be provided with
pre coatedgalvanized iron profile sheet. 12% of roof and and 8% of side
cladding area shall be provided with translucent sheets.. Dusts down
comers are to be provided in all floors. Openings for electric cable entry
are to be provided on all the floors suitably. Different floors of the transfer
houses shall be made with minimum 6 mm thick chequered plate. The
ground floor of the transfer house and drive house shall be at least 450
mm above the final accepted ground level and shall have concrete floor
with ironite flooring on top. This floor shall be extended 1.5M all around
beyond the transfer house. All the intermediate floors shall be of structural
steel.
The locations of these structures shall be as per system requirement and
tentatively shown in drawings. Necessary approach arrangement shall be
provided for each transfer/ drive house. The mono rail routing for electric
hoist is to be done in such way that only one no. of .electric hoist shall
cover all equipments like pulleys, drives etc. For tail pulley maintenance a
manual hoist of suitable capacity is to be used. Cantilever platforms are to
be avoided as far as possible. Emergency ladder is to be provided for all
floors .Stairs for approach at different levels shall be provided within the
transfer house. Lockable door is to be provided for each transfer
house/drive house.
In TH-2, there shall be provision for separate platforms for secondary roll
crushers.
In all Transfer Houses, provision shall be made for dry fog system to act
as a surge in dust suppression system.
3.4.4.8 MODIFICATION IN EXISTING HOPPERS
Modification in existing Hoppers, construction of new transfer houses to

accommodate discharge ends of feeder breaker conveyors and shifting of
discharge pulleys of 5 nos of belt conveyors of feeder breakers circuits as
indicated in the drawings and as per system requirements is covered in
the scope of work.

3.4.4.9 SUB-STATION BUILDINGS
Three numbers 3.3kV sub-station namely I, II, and IIIshall be of RCC

framed structure, plastered and finished with acrylic based smooth exterior
paint from outside. Inside painting shall be done with plastic emulsion
paint.
The location of substations has been shown in the system drawing. The
substation I & III will be a single storey building whereas the substation II
which also have a control room for the plant shall be a double storied
building. Each3.3kV substations shall have the minimum plinth area of 450
sq.m. which may change during detail engineering as per equipment
requirement. Necessary clearance shall be provided along all the
equipment installed in the substations as per the norms. The Substations
will have transformer rooms, MCC rooms, tool room, capacitor bank room,
control room, Engineer-in-charge room, electrician room, etc. with toilet
facilities. The floor of the building will be vitrified or other type, depending
uponspecificfunctional/safety requirement. The details of equipment have
been mentioned in the electrical sections of the document. The layout of
the cable trench/ cable vault will be as per system requirement. The invert
level of the cable trench shall be kept minimum 0.5 m above finished
ground levels and the plinth of the building shall be fixed accordingly. The
building shall be provided with RCC roof. There will be suitable
arrangement for lifting the transformer in case of breakdown/maintenance
for which suitable RCC platform shall be constructed at same level outside
the substation building to facilitate handling of the transformer and other
equipment. The scope covers construction of complete building with cable
trench and foundation of the equipment in all respect.
Pressurization in MCC rooms of substation shall be done. Air conditioning
facilities shall be provided in all control/PLC rooms of 3.3kV sub-stations.
The entrance to both the MCC room, control room/PLC room shall be
suitably designed to prevent sudden pressure loss. Air required for
pressurization of MCC room shall be free of dust. For this, adequate
arrangements for cleaning, filtering and treatment of air to maintain the
desired humidity is included with scope of work. In case of Control and
MCC rooms, the sound level within the rooms should be kept below 60dB.
The 33/3.3 kV substation for the proposed CHP shall be constructed in the
existing campus of 33 kV project substation.Construction of substation
building and yard for CHP is in the scope of this work.

3.4.4.10 SERVICE BUILDINGS
All the buildings except otherwise mentioned below shall be of RCC

framed structure, plastered and finished with acrylic based smooth
exterior paint from outside.Inside painting shall be done with plastic
emulsion paint.
However, lighting towers, light vehicle parking, scooter / bi-cycle sheds
may be of structural steel. The area for the various service buildings to be
provided has been given earlier. Plinth level of service buildings shall be
minimum450 mm above final accepted graded level around the buildings.
Flush doors, rolling shutters, collapsible gates and steel grill, aluminimum
windows etc. are to be fitted as per requirement.All the buildings shall be
given pre-construction anti-termite treatment. The floor shall be of vitrified
type/ any other type depending on specific functional requirement. The
store floors shall be of RCC withironite topping. The floor of the battery
room shall be anti-acidic. The battery room should be provided with
exhaust fan to exhaust the fumes.
• CHP OFFICE
The main office shall be situated near the bunker as located in the plan.
Besides Officers’ room, the CHP Office shall include a rest room, a first
aid facility and a canteen. The CHP Office shall be a double storied
building and have a minimum plinth area of 350 Sq. m with cycle / scooter
shed and car parking shed for the required operational/maintenance
manpower of the CHP. A separate store of 72 Sq. m shall also be
provided adjacent to the office campus.
• SECURITY POST/TIME OFFICE

One Security Post with time office of suitable size with appropriate
verandah opening,shall be providednear the main office. Security Postis
to be designed from functional and aesthetic point of view.
• TOILET
In addition to the toilets in service buildings, one common toilet shall be
provided as per requirement. The facilities shall include water closet,
urinals, washbasin, looking mirror, cistern, towel rail, glass shelf, flush
doors etc. The floor and wall of toilet should be tiled with ceramic tiles.
Anti skid floor tile shall be provided.

3.4.4.11 SERVICES
• INDUSTRIAL WATER/DUST SUPPRESION/FIRE FIGHTING
WATER
Ground water reservoir of minimum 450 cu.m shall be provided for fire
fighting and dust suppression purpose. The capacitiy of the reservoir shall
be fixed after calculation of water requirement on the basis of relevant
norms/system requirements. Ground water reservoir shall be covered, with
provision of necessary ladders, wash out etc . Separate water pipe line
and arrangements shall be provided for fire fighting and dust suppression
purpose.` Pumping facilities shall be provided with 100% standby
arrangement.
The water supply point shall be made available near the boundary wall by
the client at the time of commissioning of the plant. However, pipe line
including its connection from water point ( provided by the client) to water
reservoir is covered in the scope of work.
All pipe lines and pumping arrangement including pump house from water
reservoir to feeding points is in the scope of this work.
• DRINKING WATER
Individual PVC over head tanks of required capacity but not less than 1.0
m3 capacity shall be provided over each switching stations/MCC rooms,
offices, and other service buildings as per requirement. Necessary
receiving and distribution piping and pumping arrangement is covered in
the scope of the work. Adequate drinking points with PVC tank, shall be
provided at all drive houses, transfer points, truck receipt hoppers
complex, bunker, silo etc. The distribution system for drinking water shall
be done as per requirement. The facility for drinking water shall also be
provided at suitable points in offices, service buildings, toilets, etc. with all
necessary fittings and fixtures. A separate portable water reservoir of
suitable capacity shall be constructed nearby the main ground water
reservoir.
• DRAINAGE ARRANGEMENT
Proper surface drainage facilities of adequate dimensions, specifications

and slope shall be provided for the entire CHP to take care of all the storm
water which is likely to be encountered considering the topography and the
natural drainage of the construction sites and the adjoining area.
Dimensions and specification of drains and culvert/cross drainage works
shall be so engineered and constructed so as to receive and discharge all
the storm water entering into the proposed plant area including run off from
the area outside the proposed construction site which is likely to enter the
proposed plant area. The storm water shall be disposed off to the nearest

nallah or shall be taken to a suitable distance beyond the boundary of

CHP, where it can be properly disposed. Drain shall be provided with pre-
cast RCC covers, wherever necessary. All the drains shall be constructed
with brick masonry.
• SEWERAGE
Proper sewerage shall be provided for handling of sewage. This will
include provision of septic tank, soak pit, sewer line, man hole, inspection
chamber,and all other fittings and fixtures needed for the same.
Industrial effluent from the entire CHP shall be disposed off beyond the
boundary of CHP. However, construction of ETP is not in the scope of the
work.
3.4.4.12 ROADS
Whole of the proposed CHP area shall be well connected with PCC roads
for movement of men and materials. These roads shall be well connected
with the existing road network. These roads shall have 7.50 m wide
carriage way with minimum 1.5 m wide shoulders and drains of suitable
size and specification on both sides of the road. The road shall be
designed for movement of LMVs like cars, jeeps, trucks, rubber tyres
mounted mobile cranes etc., considering the prevailing soil conditions.
Suitable culverts, if required for free flow of surface drainage shall be
properly designed and provided. The ground bunker, drive houses, all
service buildings, water reservoirs, pump houses, offices, switching
stations etc. shall be well connected with PCC road. Diversions of existing
roads are also covered in the scope of work.
• WMM PAVEMENT AROUND TRUCK RECEIVING HOPPER

COMPLEX AND SEMI GROUND BUNKER
WMM pavement shall be provided to sustain the movement of loaded

tippers of capacities not less than 25/30Te. Proper slope in the pavement
should be provided to avoid accumulation of water during rain. Ramp of
suitable gradient shall be provided to connect the approach road. At any
point, the slope of the ramp should not be steeper than 1 in 20. Proper
arrangement like retaining wall, pitching etc, shall be provided to protect
the pavement area and ramp from soil erosion and settlement, as it is on
filled up soil.
• OTHER WORKS/REQUIREMENTS

3.4.4.13 SURVEY, SOIL INVESTIGATION AND COLLECTION OF

RAINFALL AND HYDROLOGICAL DATA
No data regarding the above are made available in this tender document.
The bidder is required to inspect and examine the site and its surroundings
and satisfy himself as to the nature of ground, rainfall and the soil, the
availability and suitability of other requirements, as required for fair bidding
purposes. The successful bidder shall have to undertake detailed survey,
detailed soil investigation and collection of hydrological data, rainfall data,
prepare and submit a comprehensive soil report with recommendations for
type of foundation, bearing capacities, method of deep excavation,
probable settlement for foundations etc. for approval of the
owner/consultant. Reports approved by the owner/consultant shall be
finally adopted for design and engineering. Soil investigation should be
done in the presence of the owner/consultant. No extra claim shall be
made over contract price for variation in soil, rainfall and hydrological
investigation reports which may result in change of design and type of
foundation. All works related to site survey shall be conducted as per
standard practice and also as per system requirement.
• EARTHWORK IN EXCAVATION
Excavation of earth for all types of soil for construction of all the civil
structures is covered in the scope of this contract. Final grading/ levelling
and dressing of ground in and around the proposed CHP area is under the
scope of this contract as per technical and functional requirement.
Excavation for proper drainage of rain/ subsoil water around the truck
receipt hoppers complex,ground conveyor, service buildings, transfer
houses, drive houses, switching stations etc. is covered under the scope of
this tender. The depth and size of the excavation will be as per approved
system requirement and as per detail design drawings. All cuttings and
fillings as per required level and profile including transportation/ disposal of
soil is included in the scope of this work.
Bidder shall ensure proper consolidation and stability of the pavement area
and its embankment suitable for plying loaded tippers. Toe wall, dwarf wall
or retaining wall, as required, to protect the embankment shall be provided
by the bidder. Side slopes will have boulder pitching with suitable drainage
channel.
The HFL, Bed level, water flow, etc. of the existing water courses, sub-soil
water table shall be taken into consideration while designing the structures.
Bidder shall undertake various remedial measures for protection of the
proposed CHP area from streams/water courses as per requirement.

• ARCHITECTURAL REQUIREMENTS
The structures in the whole CHP complex, under the scope of this contract,
shall have appropriate architectural look, with appropriate colour, shades
and structural networks. All the structures should portray architectural
excellence with due care to better utilization of space, service
requirements etc. and environmental issues. All visible surfaces shall be
painted properly foritslongevity and better appearance.
• LANDSCAPING AND ARBORICULTURE
The proposed CHP complex shall be designed keeping in view its proper
aesthetic appearance. The perspective view of the CHP with landscaping
shall be submitted. To provide better environment and arrest dust around
CHP, plantation of approved variety, should be done to form impervious
hedges around the plants and shall be maintained by bidder for the period
of one year after plantation.
• BOUNDARY WALL
The proposed CHP complex, as shown in the drawing, should be provided

with boundary wallhaving of 2.0m high brick wall above formation level with
concertina coil type fencing on top of the wall.Layout of boundary wall
indicated in the drawing is tentative and may change as per actual site
conditions and functional requirement. The final layout of boundary wall
shall be decided during detail engineering. Boundary wall shall be properly
painted.
Gate should be provided inthe boundary wall with main and pedestrian
gate as per functional requirements.
• FIREFIGHTING
Whole of the CHP shall be protected against fire. Automatic fire fighting
facilities shall be provided as per relevant IS codes and TAC norms.
Hydrants/spray nozzle shall be provided at suitable intervals all along the
proposed CHP as per technical requirement. Water tanks and pump house
is included in the scope of work. The capacity of the water tanks shall be
fixed as per relevant norms but shall not be less than those as mentioned
earlier.
Fire fighting points/hydrants shall be provided for entire proposed CHP

including truck receiving hopper complex, transfer points, drives houses,
conveyor, galleries, ground bunker, silo, switching stations and service
buildings etc. Fire hydrants shall be provided at an interval of 30m in the
entire plant. Necessary landing valves at all the floor of silo, switching
stations and at other places wherever necessary shall be provided.
The pressure of each hydrant shall be not less than 3.5 kg/cm2 when up to
four hydrants are used simultaneously.
• DUST SUPPRESSION AND EXTRACTION
Proper water supply arrangement for dust suppression and dust extraction
will be made at dust generating points so that all working space remain
free of dust. For dust suppression, water jets will have to be provided in
truck receiving hopper area, transfer points, silo and other places as per
requirement. For proper ventilation in all the working floors, arrangements
for installing exhaust fans/ventilation fans with ducting will have to be made
as detailed elsewhere in the tender document. All civil works pertaining to
dust suppression and extraction shall be as per system requirement. The
pumping sets for the dust suppression/control shallbeprovided with 100%
standby arrangement at each location.
• PLANT CLEANING
Water and compressed air pipe line network along with connection/tapping
points with control valves at suitable intervals shall be provided in the truck
receiving hopper floors, transfer and drive houses, conveyor galleries,
switching-stations, bunker, silo etc. for pressure cleaning of floor chutes,
walkways etc. Proper drainage arrangement will have to be made all along
the plant so that water or slush accumulation is avoided. At every probable
spillage point suitable arrangement will have to be made for a mechanized
or manual cleaning.
3.4.4.14 CONSTRUCTION, FABRICATION, ERECTION AND COMMISSIONING,

OVERHEADS AND SUPERVISION
• CLEARANCE OF SITE BEFORE START OF WORK
Site shall be handed over to the contractor in 'as it is' condition. Any site
preparation work including cleaning, cutting, filling, leveling, grading,
removal, etc. before start of the actual work shall be done by the contractor
to the full satisfaction of Engineer-in-charge.
The Contractor has to do their own arrangement for construction

water at site. One point for drinking water only, will be provided
within 100meterof the work site for which necessary temporary
storage arrangement may be made by the contractor.

• SITE CLEARANCE AFTER COMPLETION OF WORK

After the completion of work, the contractor shall remove scaffolding,
sheds rubbish and surplus materials except which are required for
rectification of defects. Contractor shall hand over the site in clean and tidy
condition after cleaning the total area including floor, drains etc. fit for the
use by the owner.
• LAYOUT AND LEVELS

The layout and levels of all structures, etc. shall be done by the contractor
at his own cost from the general grid of the plot and bench marks given by
the Engineer-in-charge for checking the detailed layout and correctness of
the layout and levels. But the contractor shall be solely responsible for
correctness of layout and levels.
• SPECIFICATIONS
The specifications should be intended for general description of the work,
quality and workmanship. The work shall be executed according to the
relevant Indian Standard codes of practices or to the recommendations of
relevant American and British Standard in cases where Indian Standard
codes are not available for such works.
As such the Contractor should plan the work and items in detail. Generally,
steps required towards the standardization to nearest higher rating of
equipment keeping in view of energy conservation, safety of men and
materials, better environment, shall be considered at any stage before or
during execution with due prior approval with no extra cost to MCL.
• CONSTRUCTION METHOD AND EQUIPMENT

The Contractor shall submit drawings and write ups indicating a broad
outline of how he intends to execute the work.
• INSTALLATION/ERECTION AND SUPERVISION
It shall be the contractor's responsibility to bring, receive and keep the

materials in safe custody in proper condition. Responsibility of handling the
materials during manufacturing, transit and handling at site rests with the
contractor.
All the equipment will have to be installed and fitted with accessories as
per approved drawing. Entire tools and tackles, manpower and any other
material required for successful installation will be supplied by the
contractor. The contractor shall furnish the list of engineers, supervisors
and other skilled personnel to carry out the job properly.
• COMMISSIONING
After installation, including electrical civil/structural items, the individual
equipment will be commissioned and put on no load trail run. Any defect

noticed will have to be rectified/replaced at contractor’s cost. After

commissioning all the equipment in the circuit individually on no load and
having satisfied the consultant/customer, the entire circuit shall have to be
put on load test and performance of individual equipment or its accessories
or the circuit as a whole, will be observed closely by a joint team of
engineers, drawn from consultant’s side, customer’s side and contractor’s
side. This test run on load will continue till the representatives of consultant
or customer is fully satisfied with the performance. The entire arrangement
of the trial run shall have to be made by the contractor at his own cost. The
contractor has to give intimation in advance in this regard to the
consultant/customers, so that run of mine coal can be supplied to plant for
load test. Any excuse on the part of the contractor will not relieve him from
the responsibilities of successful commissioning of plant to the best
satisfaction of consultant/customer. To carry out the job of commissioning
in the best possible way, the contractor shall have to co-ordinate with all
concerned agencies such as designer, equipment manufacturers,
consultant, customer, statutory bodies and other government or local
bodies as per requirement.
• INSPECTION AND TESTING
All the tests required for materials, quality of work and any other tests as
required/desired by the Engineer-in-charge shall be at Contractor's cost.
The frequency and mode of testing shall be as per latest relevant BIS
codes.
3.4.4.15 GENERAL REQUIREMENTS
a) Any other requirement related to construction and operation, whether

specifically indicated or not, but found necessary to be incorporated
at a later date for safe and efficient operation of the plant shall also be
deemed to have been covered within the scope of work of this tender.
b) Wherever required, dewatering shall be done by the contractor to

avoid damage of equipment, structural, etc. and timely completion of
work. This shall be carried out by contractor without any increase in
the cost.
c) If any certification or approvals are to be taken from electrical

inspector/statutory bodies, DGMS, the same shall be the
responsibility of the contractor.
d) As per system requirement envisaged in the NIT documents, various
parameters, specifications may undergo changes during detail
engineering stage. This shall be carried out by the contractor without
any increase in cost.
e) All safety regulations, labour laws, code of practices for power supply,
manufacturer, installation, erection, commissioning etc. envisaged by
the State Govt./Central Govt. or any authorities/bodies shall be strictly
complied without any increase in cost.
f) All Mines Acts and regulations will be followed during construction

stage.
3.4.4.16 OTHER ITEMS
• WEIGHT AND VOLUME CLAUSE
The quantities shall be within reasonable accuracy. Any variation in

quantities on higher side from quoted to during actual execution will not
entitle the contractor for any additional claim, while for short fall in the
quantity up to 10% no recovery/adjustment shall be made by the Owner.
However for shortfall in quantities beyond 10% during actual execution,
proportionate reduction in cost of contract for the relevant amount for
respective items of civil and structural works will be made. For example -
if the quoted quantity of the structural steel is 100 Te and as per actual
execution it comes to 85 Te, the proportionate reduction in cost against
structural steel will be 5% of the quoted price for structural steel. As such
the bidder should work out the quantities with utmost care.
All the bidders must furnish/fill up the respective column of the

weight and volume proforma enclosed with the “PRICE BID
DOCUMENT” at Vol-III, otherwise the bid will be treated as
cancelled.
3.4.5 TRAINING
The plant personnel responsible for operation & maintenance of the plant
and deputed by employer shall be properly trained whether in land or
overseas, so that the persons are fully conversant with the assembly and
sub-assembly of the equipment, detail circuit of the electrical control
system including, hydraulic system & operation and maintenance etc.
The plan personnel shall be in a position to rectify any defects of the
equipment developed during operation of the plant for efficient running
with minimum down time.
The Employer’s assessment of the minimum training requirement (in

terms of Employer’s personnel, periods and locations) is given in the
following table:

At Manufacturer’s Works At Site

Type of No. Period Total No. Period Total
Personnel
Engineer (E&M) 4 2 Weeks 8 Weeks 4 1 Weeks 4 Weeks
Engineer 1 2 Weeks 2 Weeks 1 1 Weeks 1 Weeks
(Electronics)
Mechanical 3 1 Weeks 3 Weeks 6 1 Weeks 6 Weeks
Supervisor
Electrical 3 1 Weeks 3 Weeks 6 1 Weeks 6 Weeks
Supervisor
Electronics 1 1 Weeks 1 Weeks 2 1 Weeks 2 Weeks
Supervisor
Mechanical Fitter 0 0 Weeks 0 Weeks 3 1 Weeks 3 Weeks
Electrician 0 0 Weeks 0 Weeks 3 1 Weeks 3 Weeks
Operator 0 0 Weeks 0 Weeks 12 1 Weeks 12 Weeks
Total 12 17 Weeks 37 37 Weeks
• DEFINITIONS :
Mechanical/Electrical/Electronics Engineer - Graduate Engineer

having basic knowledge
of the equipment.
Electrical/Mechanical Supervisor - Diploma Holder Engineer

having basis knowledge
of the equipment.
Mechanical Fitters/Electricians/Operators - Skilled
The Bidder shall assess the Employer’s assessment of training

requirement with due regard to the facilities offered, the maintenance and
operational requirement of offered equipment and level of expertise for
existing infrastructure and facility at the respective site(s).

ANNEXURE- III.1A
LIST OF CONVEYORS & BELTING
SL.NO. PARTICULARS Unit Qty

1 CONVEYORS
1 Extension of belt conveyor from existing LS
feeder breaker circuits to proposed
conveyors C1,
2 Conveyor C1A feeding from TH7 to TH6 NO 1
or Conveyor C1, Belt width 1200 mm,
Length as reqd., Cap 500 tph, Lift 5 m,
Speed 2 m/sec, Power 1X37kW
3 Conveyor C2A/B, Belt width 1600 mm, NO 2
Length as reqd., m, Cap 1800 tph, lift
3.5 m, speed 3 m/sec Power 1 x150kW
4 Conveyor C1, Belt width 1600 mm, NO 1
Length as reqd.,, Cap 1600 tph, lift 50
m, speed 3.5 m/sec Power 1 x500kW
5 Conveyor C3A/C3B, Belt width 1600 NO 2
mm, Length as reqd.,, Cap 2400 tph, lift
20 m, speed 3.5 m/sec Power 1
x450kW With CST Drive
Length as reqd.,, Cap 2400 tph, lift 0 m,
speed 3.5 m/sec Power 1x90kW
Length as reqd.,, Cap 2400 tph, lift0 m,
speed 3.5 m/sec Power 1x75kW
8 Tripper Conveyor C6A/B, Belt width NO 2

1600 mm, Length as reqd.,, Cap 2400
tph, lift6 m, speed 3.5 m/sec Power
1x250kW + 1x7.5kW
9 Reclaim Conveyor C7A/B, Belt width NO 2
tph, lift51 m, speed 4 m/sec Power
1x750kW+ 1x600kW with CST Drive
10 Bridge Conveyor C8A/B, Belt width NO 2
tph, lift0 m, speed 4 m/sec Power
1x90kW
2 BELTING m As per System
Belt widths of 1200mm, 1600mm, requirement
1800mm –N-N/Steel cord belting

ANNEXURE- III.1B
LIST OF MECHANICAL EQUIPMENT AND ACCESSORIES

SL.NO. PARTICULARS Unit Qty
1 EQUIPMEMT
1) Rapid loading system-4000 te capacity silo, Set 2
5000-6000 tph loading capacity, including, arch
breaker. Air cannon, Air compressor, hydraulic
system .test weights pipes & fittings with
electricals ,printer , display facility etc.
2) Pre weigh hopper for silo NO 4
3) Passenger lift NO 2
4) Rack & pinion chute gates NO 12
5) Electro mechanical vibro feeder cap.600 tph NO 12
6) Automatic coal sampling system Set 1
7) Plough feeder, capacity 0 - 3600 tph, complete NO 4

with electricals and in built dust extraction
system
8) Twin shaft sizer/ secondary roll crusher for NO 2
Secondary crushing, 1600 tph, Feed size (-
)250mm, product size (-)100mm, Material
R.O.M Coal ,power - 350 kW
9) Chain pulley blocks 10 t NO As required
10) Motorised hoist, cap-5t, lift-as reqd….M. NO As required
11) Manual hoist, cap-2t, lift-as reqd…….M. NO As required
12) In motion rail weigh bridge 100 t cap. With NO 4
printer, digital display etc.
13) Belt weigher NO 2
14) Magnetic separator for 1600mm belt NO 1+2
15) Metal Detector for 1600 mm belt NO 2
16) LS As required
Motorised flap gate
17) Belt cleaner. Set 16
18) Belt pulling device NO 1
19) Special tools & tackles As per
requirement
20) Vulcanizing M/c As reqd.
21) Chute assembly with liner NO As required
22) Dust suppression system with piping & other SET Adequate for the
accessories. plant
23) Ventilation system Adequate for the
plant
24) Safety & fire fighting system and Plant cleaning SET Adequate for the
system plant
25) Safety equipment As per
requirement
26) Misc equipment for any more left out item As per
required to complete requirement

ANNEXURE- III.2A
LIST OF ELECTRICAL EQUIPMENT AND ACCESSORIES
SUB-STATIONS
(TRANSFORMER, SWITCH BOARDS, MCCS, PF CORRECTORS, ETC.)
SL.NO. ITEM DESCRIPTION QTY
1 33 KV MAIN SUB-STATION ( AT EXISTING 33KV PROJECT S/S)
1.1 33 kV Power supply arrangement at existing substation 1 Lot
including switch yard structures, bays, tubular Aluminium bus
bars, GI structures, insulators, foundation etc.
1.2 33 kV outdoor type 630 amps, 750MVA, Vacuum Circuit 2 Nos
Breaker with indoor control panel
1.3 33/3.3 KV, 5000 KVA, ONAN, dy-11, Outdoor type power 2 Nos
Transformer.
1.4 33/0.415 KV, 200 KVA, Outdoor type Station Transformer. 1 No
1.5 30 kV Lightning Arrestor (GI Structure mounted) 2 sets
1.6 33 kV Isolator (GI Structure mounted) 1 No
1.7 33 kV Isolator with earth switch (GI Structure mounted) 2 sets
1.8 33 kV Isolator with earth switch & DO fuse (GI Structure 3 sets
mounted)
1.9 33 kV outdoor type CT (GI Structure mounted) 2 sets
1.10 33 kV outdoor type PT (GI Structure mounted) 2 sets
1.11 Neutral Grounding Resistor for transformer secondary neutral 2 Nos.
1.12 8-panel, 3300 volts, 1600/1250amps, 75 MVA indoor type 1 set
switchboard comprising 8 nos. of Vacuum Circuit Breakers
consisting of 2 nos. incoming, 1 no. coupler and 5 nos. of
outgoing VCBs including 1 no. spare.
1.13 415V switch board 1 set
1.15 Battery and battery charging set, DC DB etc. Ls
1.16 Misc. items including power and control cable for substation, LS
substation earthing , lightning protection etc.
2.0 Two sets. of 3.3 KV double circuit overhead lines (wolf Lot
conductor) on separate rail poles from 33kV substation up to
CHP & silo substations (one set up to 3.3kV Substation-I and
other up to 3.3kV Substation-III via 3.3kV Substation-II)
including DP/4 pole structures 3.3 KV isolator, lightning arrester
for power receiving arrangement at 3.3kV substations- I, II & III
and other accessories.
3.0 3.3 kV SUBSTATION– I

ANNEXURE- III.2A( contd.)
3.1 3 kV Lightning Arrestor (pole mounted) 2 Sets
3.2 3.3 kV Isolator (pole mounted) 2 Sets.
3.3 20- Panel, 3300 volts, 1250/630 amps, 75 MVA indoor type 1 Set
switchboard comprising 20 nos. of Vacuum Circuit Breakers/
Vacuum Contractor Panel consisting of 2 nos. incomer (VCB),
1 no. coupler (VCB) and 17 nos. of outgoing VCB / VCP (7 nos.
VCP for Controlling Conv. Drives and twin shaft crusher, &5
nos. VCB for power Trs, lighting Tr., Cap bank) including five
spare (2 nos VCB & 3 nos VCP).
3.4 Power transformer, indoor type, confirming to IS: 2 Nos
2026(current)
Rated kVA : As per design
Rated Voltage : 3.3 kV/ 415 V
3.5 415 V Motor Control Center (MCC-I) having required number of 1 Set
Air circuit breaker for incomer &sectionaliser and modules
having isolator with switch fuse unit, contactors, starter panel
etc with required protections for outgoing feeders with 10%
spare outgoing modules (minimum one) for each type of
modules
3.6 3.3 kV , 3X190kVAR capacitor with manual control panel 2 Set
3.7 415 V Power distribution Board (PDB-I & PDB-II) having 2 Sets
required number of module having isolator with switch fuse
unit, contactors and required protections for incoming and for
outgoing feeders having isolator with switch fuse unit,
contactors, starter panel etc with required protections with 10%
spare outgoing modules(minimum one) for each type of
modules
3.8 Lighting transformer, indoor type, confirming to IS: 1no
2026(current)
Rated kVA : 100
Rated Voltage : 3.3 kV/ 230 V (L-L)
3.9 Lighting Main Distribution board , 230 V(L-L) , 3 -Phase, indoor 1set
type consisting of MCCBs and HRC fuses of required number
as per design.(LMDB-I)
4.0 3.3 kV SUBSTATION– II

switchboard comprising 19 nos. of Vacuum Circuit Breakers/
Vacuum Contractor Panel consisting of 2 nos. incomer (VCB),
1 no. coupler (VCB) and 16 nos. of outgoing VCB / VCP (6nos
VCP for Controlling Conv. Drives & 5 nos VCB for power Trs,
lighting Tr. & Cap bank) including five spare (2nos VCB & 3
nos VCP).
2026(current)
4.5 415 V Motor Control Center (MCC-II) having required number 1 Set
of Air circuit breaker for incomer, sectionaliser& plough feeders
and modules having isolator with switch fuse unit, contactors,
starter panel etc with required protections for outgoing feeders
with 10% spare outgoing modules (minimum one) for each
type of modules

2026(current)
Rated kVA : 100
as per design.(LMDB-II)
5.0 3.3 kV SUBSTATION– III
switchboard comprising 10 nos. of Vacuum Circuit Breakers
consisting of 2 nos. incomer (VCB), 1 no. coupler (VCB) and 7
nos. of outgoing VCB (5 nos. of VCB for Power Trs, lighting Tr.
& Cap bank) including two spare (2 nos. VCB).
2026(current)

5.5 415 V Motor Control Center (MCC-III) having required number 1 Set
of Air circuit breaker for incomer &sectionaliserand modules
having isolator with switch fuse unit, contactors, starter panel
etc with required protections for outgoing feeders with 10%
spare outgoing modules (minimum one) for each type of
modules

2026(current)
Rated kVA : 100
as per design.(LMDB-III)
6.0 CABLE (POWER, CONTROL, COMMUNICATION, SIGNALING AND

SPECIAL CABLES)
6.1 3300 volts, 3 core XLPE power cables of different sizes with As per
aluminum conductor, suitable sheathed, single layer armored require-
and overall PVC sheathed having FRLS properties in outer ment
sheathing.
6.2 1100 volts grade, 3 /3 1/2 /4core power cable of different sizes, As per
aluminum conductor PVC sheathed single wire armored and require-
overall PVC sheathed having FRLS properties in outer ment
sheathing.
6.3 Single layer armored PVC insulated and sheathed control As per
cables of 2.5 sq.mm cross-section with copper conductor of require-
different no. of cores having FRLS properties in outer sheathing ment
with 10% spare core.
6.4 Cable for communication & signaling. As per
require-
ment
6.5 Cable trays/cable racks, binding materials, cable glands / Lugs As per
(separate trays shall be used for power and control cables) with require-
necessary cable trenches in switch yard and inside the ment
substation building.
6.6 Flexible trailing cables for traveling trippers, Plough feeder etc. As per
require-
ment


7.0 ILLUMINATION SYSTEM
7.1 Lighting Sub distribution board comprising of MCCB for As per

controlling incoming feeders and MCBs with back-up HRC fuse require-
for controlling out going feeders as per design having digital ment
clock based timer & contactor with all accessories for automatic
switching ON/OFF facility.
7.2 1x 40/ 2x40/ 4X20W watts fluorescent tube lights (with energy As per
saving chokes) with industrial/decorative, dust and vermin require-
proof type lighting fixtures ment
7.3 Luminaries with 70 W HPSV/ metal halide well glass type, dust As per
and vermin proof light fittings in the conveyor gantries as per require-
design. ment
7.4 Luminaries with 70/150/250 W HPSV /metal halide flood light As per
type fitting, dust and vermin proof fixtures for indoor lighting of require-
the plant as per design. ment
7.5 External lighting with luminaries with 150 W /250 W /400 W As per
HPSV/metal halide lamps in street light/ flood light type fitting, require-
dust and vermin proof fixtures with steel tubular poles, lighting ment
tower, bracket etc as per design.
7.6 External lighting through 15/20/30 m high lighting mast with As per
luminaries with 400 W HPSV/ metal halide flood light fitting , require-
dust and vermin proof fixtures etc as per design ment
7.7 1100 volts grade, 2 /3 1/2 /4core PVC insulated, PVC sheathed, As per
single wire armoured, aluminum conductor cables of different require-
sizes having FRLS properties on outer sheath. ment
7.8 650 volts grade PVC insulated PVC sheathed cables of As per
different sizes having FRLS properties on outer sheath. require-
ment
7.9 Misc. items such as junction boxes, cable tray, cable rack, As per
cable binders, clamps, lugs, flexible cables, PVC conduit pipes require-
etc. ment
8.0 WELDING SET & WELDING RECEPTACLES
8.1 Portable transformer welding set 2 nos.

8.2 1100 volts grade, PVC insulated, PVC sheathed, single wire As per
armoured, aluminum conductor cables of suitable sizes having require-
FRLS properties on outer sheath for power supply to welding ment
sockets.
8.3 Cable trays/cable racks, binding materials, cable glands / Lugs As per
etc. require-
ment
8.4 Dust and vermin proof plug sockets with switches along the As per
conveyor, in drive houses, transfer houses, hoppers floor Silo require-
floors, Bunker etc for feeding power to welding cable/holder as ment.
per design.

9.0 EARTHING
9.1 Required number of Ground electrodes, earthing mat etc. as As per

per IS 3043 (latest) around the substation building, yard, require-
substations, control room, along the conveyor, drive house, ment
pump house, Hopper house Ground bunker, silos, Lightning
arresters, transformer neutral & body etc.as per design.
9.2 Galvanized iron earthing strips/wires for main earthing, sub As per
earthing of building and structures, light fittings, dust proof require-
welding sockets, pull chord switches, belt sway switches, zero ment
speed switches, all electrical equipment etc. as per design.
10.0 LIGHTNING PROTECTION SYSTEM
10.1 Spikes and interconnecting strips on the substation As per

building/Substations, Silo, Ground Bunker, drive houses etc as require-
per design. ment
10.2 Required number of Ground electrodes, earthing mat etc. as As per
per IS 3043 (latest). as per design. require-
ment
10.3 Galvanized iron earth strips / wires, nuts, bolts etc as per As per
design. require-
ment
11.0 CONTROL AND MONITORING SYSTEM
11.1 Auto remote and auto sequence control of plant with control As per
desks, mimic panels, annunciation panels, micro processor require-
based PLC with hot standby, audio-visual signaling, UPS, ment
computer, printer, VDUs etc. complete in all respect for CHP
and Rapid Loading system
11.2 UPS with battery back up As per
require-
ment
12.0 COMMUNICATION
12.1 Telephone sets to be wired to a common junction box and Lot

connected to project communication system as described in
system description at para no 2.3.11
13.0 PRESSURIZATION AND AIR CONDITIONING
13.1 Pressurization for Switchgear rooms of 3.3 kV Substation- I, II As per

require-
& II
ment

13.2 Split Type Air conditioners for Silo Control room, PLC room , As per
Engineer-in-charge’s room require-
ment
14.0 OTHER ITEMS
14.1 Suitable aluminum portable telescopic ladders 1 no.

14.2 Miscellaneous items such as measuring & testing equipment, As per
electrical firefighting equipment for substations. require-
ment
14.3 Safety equipment as per relevant Indian Standards & Indian As per
Electricity Rules, for control room and 33kV Main require-
ment
Substation&3.3kV Station buildings
14.4 Signaling system near truck unloading hopper as per design. As per
require-
ment
14.5 Exhaust and ceiling fans As per
require-
ment
14.6 Insulating mats as per IS for 33kV substation & 3.3kV sub- As per
station I & II, III, MCC and control rooms etc. require-
ment
14.7 Aviation Light at Silo Tops As per
require-
ment

LIST OF ELECTRICAL TESTING EQUIPMENT
ANNEXURE- III.2B
1.0 ELECTRICAL TESTING EQUIPMENT
1.1 Portable Transformer oil testing equipment 0-75KV range 1 No.
1.2 Cable fault locating machine 1 No.
1.3 Bridge megger

1 No
5000 Volt
1000 Volt
1.4 Tong Tester( 1000/600/400 A, 600 V ) 1 No
1.5 AVO meter 1 No
1.6 Tachometer 1 No
1.7 Soldering Kit 2 set
1.8 IC Soldering Kit 1 set
1.9 Rubber Hand gloves having insulation level 15 KV 10 pairs
1.10 Crimping tool with dies, hydraulically operated 1 set
1.11 Relay testing equipment with testing board 1 set
1.12 Vacuum cleaner 1 No
1.13 Earth Tester 1 No
1.14 Lux meter 1 No
1.15 Self supported trolley mounted telescopic ladder 1 No.

ANNEXURE- III.2C
LIST OF ACCESSORIES AND FACILITIES
PARTICULARS Quantity
Gas cutting set 3
Portable welding set (it should be 3-phase) 4
Portable compressor for plant cleaning 30 cfmcapacity
2
6 kg/cm² Pressure
Belt vulcanizing machine-hydraulic type Suitable for 1
belt width up to 1800 mm for N-N / ST belting
Special tools and tackle As received along with
the equipment
supplied
Consumables for start up including first and second fill
As required
of lubricant
Noise abatement measures to reduce noise level As required
Measures to control vibration so as to keep its level
As required
within ISO limit
Items/accessories not specifically mentioned but As required
needed for successful commissioning/operation of the
plant
Belt replacing equipment 2

ANNEXURE- III.3A
LIST OF MANDATORY SPARE PARTS (MECH)
Sl. Description of spare part. Quantity

No.
1. Gearboxes. 1 of each of every type included in
the Plant and Equipment
2 Motors (LT and HT) 1 of each of every type for
conveyorsystem, Plough feeder, RLS.
3. Couplings (Fluid and Other) 1 of each of every type included in

4 Pulley 1 of each of every type included in
5 Cleaner 1 of each of every type included in
6 Load cells for pre weigh- hopper One set for each hopper.
7 Bearings of gate. 1set for each type.
8 Cylinders 1set for each type

ANNEXURE- III.3B
LIST OF ELECTRICAL SPARE PARTS
SL. NO ITEM QUANTITY

1 3.3 kV Motor
1.1 One set of Bearing for each type and size of Motor As required
2 Low Voltage Motor
2.1 One set of Bearing for each type of Motor As required
3 HT and LT Switch Gear
3.1 Vacuum interrupter 3 sets
3.2 Spring charging motor for VCB 2 nos
3.3 Closing coil for VCB 3 nos.
3.4 Breaker control switch 3 nos.
3.5 Tripping coil for VCB 3 nos.
3.6 Over current relay 3 nos.
3.7 Directional over current relay 3 nos.
3.8 Under voltage relay 1 no
3.9 Pilot lamp (Green) with holder 10 sets
3.10 Pilot lamp (Red) with holder 10 sets
3.11 Pilot lamp (White) with holder 10 sets
3.12 Pilot lamp (Orange) with holder 10 sets
3.13 Control fuse 2A, 4A, 10A 12nos. each)
3.14 CT each rating 1 set
3.15 PT each rating 1 sets
3.16 Fuse for vacuum contactor (each rating) 3 sets
3.17 Auxiliary relay 10 nos.
3.18 Ammeter selector switch 3 nos
3.19 Voltmeter selector switch 3 nos
4 Transformer
4.1 HT bushing each type 1 set
4.2 LT bushing each type 1 set
4.3 Silica gel each type 1 set
4.4 All size of gasket each type 1 set
5 Control and Instrumentation
5.1 Each type of interface module 1 set
5.2 Each type of digital input module 2 sets
5.3 Each type of digital output module 2 sets
5.4 Each type of analogue input module 1 set
5.5 Each type of analogue output module 1 set
5.6 Each type of power supply unit 2 sets
5.7 Each type of limit switches 2 nos.
5.8 Pull chord switch with accessories 5 nos
5.9 Belt sway switch 5 nos.
510 Local stop push button 2 nos
5.11 Zero speed switch 2 nos
5.12 Emergency push button 2 nos
5.13 Alarm hooter 2 nos
5.14 Continuous level monitor 1 set
5.15 Resistance thermometer PT 100 2 nos

ANNEXURE- III.4
LIST OF TOOLS AND TACKLES(MECH)
No. Nomenclature Quantity

1. Hydraulic jack - 100.Te 1No.
2. Pull lift .M/c - 1.5t 1No.
3.. Pull lift M/c - 3.5t 1No.
4.. Pull lift M/c - 5t 1No.
5. Drill Electric (1-1/2”) 1No.
6.. Aluminium ladder (3M) 1No.
7.. Telescopic Aluminium ladder (7M) 1No.
8.. Marking punches 1No.
9.. Vice Grip 1No.
10.. Three legged tripod (fixed height) 1 No.
11. Hydraulic cable jointing kit suitable up to 240 sq. 1 set
mm cable size
12. Spirit level 1No
13. Feeler gauges 2 sets
14. Scriber 1 No.
15. Dial gauges (alignment) 2 Nos.
16. Steel tape (15.M) 2 Nos.
17. Vernier caliper (Internal and External) 2 sets each
18. Steel scales 2 Nos.
19. Hack saw frame with blade 4 Nos.
20. Tri square 2 Nos.
21. Plumb bobs 1 No.
22. Bucket volume grease gun Tecalamite make(30L) 2 Nos.
23. Oil can (1/2.litre) 4 Nos.
24. Files 10”, flat rounded half rounded bastered fine 4Nos each
filesetc
25. Micro metre(Inside, outside) 2each
Torque wrenches (2”, 4”,8”)of suitable torque
26. 1No each
capacity

ANNEXURE- III.4(contd.)
27. Standard ring spanners (up to 30 mm) 4 Sets
28 Standard DE spanners (up to 30 mm) 4 sets
29 Tabular box spanners 4 sets
30 Socket box spanners 4 sets
31 Circlip extractors, bearing extractors and oil 1 set
seal extractors
32 Belt puller (Motorised winch type with 200mm rope 1 No.
capacity 1.5 Te)
33 1.5 Te capacity rope pull tackle manual without 1 No.
34 Four inch dia wheel, AC motor driven portable 1 set
grinding machine and flexible grinder
35 Vacuum cleaner for control room, sub-station and 2 Nos.
MCC rooms suitable for system requirement
36 Any other type of spanners/tools required for 1 set each
operation and maintenance of equipment as per
Manufacturer’s recommendations.
37 Engineers level gauge 1 No.
38 Cabinet 2’ x 4’ with 2 Nos. carrying trays 1 set
39 Bearing puller (SKF make) for up to 250 mm dia 1 set
40 Bearing puller 3 legged 2 Nos.
41 Sound level meter 2 Nos.
42 Vibration meter 2 Nos.
43 Temperature monitor meter (sec.)
44 High potential test kit 1 No.
45 Adjustable wrench 8”. 2 sets
46 Wire rope slings with eye bolt and D-shackles for 2 sets each up to
1 ton, 5 ton, 10 ton, 50 ton and 100 T lifting 10 Te & 1 set
capacity each for 50 Te &
100 Te.
47 Adjustable wrench 10” 2 sets
48 Adjustable wrench 12” 2 sets
49 Slip joint pliers 6” 3 sets
50 Slip joint pliers 8” 3 sets
51 Rib glove pliers 10” 3 sets
52 Diagonal pliers 6” 3 sets
53 Long nose pliers 6” 3 sets

ANNEXURE- III.4(contd.)
54 Chain nose pliers 8” 3 sets

55 Side cutting pliers 8” 1 set
56 Vice Slip joint pliers 6” 2 sets

57 HD pipe wrench 10”/14” 2 sets
58 Socket (1/4”, 5/16”, 11/32”, 3/8”, 7/26”, ½”, 1”/1-1/2”). 3 sets
59 Extension bar 5”,6” 2 sets

60 Speeder handle 2 sets
61 Ratchet spanner 3 sets
62 Universal joint 2 sets

63 Sliding ”T” handle 2 sets
64 Deep socket 2 sets
65 5 pcs screw drive set (-) 4 sets

66 5 pcs screw driver set (+) 4 sets
67 Plastic hammer, 1 kg 3 sets
68 Ball point hammer, 500 g 3 sets
69 Wire tripper 4” 3 sets
70 Steel compass 300 A 2 sets
71 Spring divider 300 A 2 sets
72 Tool box with set of spanner 3 sets
73 Straight edge 3 m length 3 sets
74 Motorised oil filling pump and motor set (As per 1 set
system requirement)
75 Motorised blower 220 V 3 Nos.
76 Stop watch 2 Nos.

77 Portable air compressor As per Clause 8.2 d
78 Pipe wrench (chain type) for 4”and 6” pipe 2 each
79 Pass meter (for measuring inside bore) 1 set

80 Sledge hammers 3 Nos.
81 Pulley block for manila ropes 3 Nos.

82 Pneumatic wrench 1 No.
83 Automatic filling / emptying system for lubrication 1 No.
in crusher lubrication tank, gearboxes etc.
84 Spot vulcaniser (12”) 1 No.
85 Motorised belt reeling drum for belt 3 Nos.
laying/replacement

APPENDIX “A”
LOCATION FOR INSTALLATION OF ELECTRIC HOISTS & CHAIN PULLEY

BLOCKS
SL NO LOCATION ELECTRIC HOIST MANUAL HOIST

1 RECIVING PIT ‐ 2
2 TRANSFER HOUSE1 1 1
3 CRUSHER HOUSE 1 2
4 TRANSFER HOUSE3 1 ‐
Take up & DRIVE HOUSE ON
9 C7A/7B 1 2
10 TRANSFER HOUSE 8 1 1
13 ABOVE BUNKER FOR TRIPPER 2 ‐
IN MAINTENANCE BAYS FOR
14 PLOUGH FEEDER 4
15 SILO TOP 2 2
16 SAMPLER HOUSE 1 1
TOTAL 20 15
Note: The requirement of hoists indicated is minimum. The capacity of

Electric Hoist/ Chain Pulley Block shall be 25% more than the heaviest
assembly/ component to be lifted. At the same time, the rating of Electric
Hoist/ Chain Pulley Block shall be standardized to minimize inventory for
maintenance and inter changeability. The nos . indicated above are
tentative and minimum. The quantity may vary during detail engineering as
per requirement.
.

APPENDIX “B”
I. APPROVED VENDORS LIST FOR MECHANICAL EQUIPMENT
(Last date of Updation : 30/06/2011)
The makesof various equipment are listed out hereunder. It is essential

that bidder/ contractor shall source its equipment from any of the makes
listed against that particular equipment in the list. In case the bidder/
contractor intends to add any particular make of equipment by a make
other than that listed hereunder, he shall clearly bring out the same in his
bid along with justification and indicate the alternative makes offered by
him. Only those names of vendors should be included who have supplied
such equipment (which are successfully operating for more than two
years) in similar capacity bulk handling plant operating in Mines/ Power
Plants /Ports. It would be the prerogative of the Employer to accept or
reject the alternative makes so offered.
SL. ITEM DESCRIPTION NAME OF APPROVED MANUFACTURERS

NO.
CONVEYOR COMPONENTS
1. CONVEYOR IDLERS : ELECON / TRF/ KALI / MBE / THYSSEN-KRUPP /
HINDUSTAN UDYOG LTD./ BENGAL TOOLS LTD./
NEWALL INDUSTRIES/ VISHWA.
2. CONVEYOR PULLEYS : ELECON / TRF / KALI/ MBE / THYSSEN-KRUPP /
HINDUSTAN UDYOG LTD./ BENGAL TOOLS LTD.
/NEWALL INDUSTRIES/ VISHWA.
3 GEAR BOX : ELECON / PREMIUM / FLENDER/ GEARS INDIA /
ALLEN BERRY / MACNEILL GEARS / DAVID
BROWN / ALLEN RANK / RADICON / BENGAL
TOOLS/ VULCAN GEARS/ BALDOR ELECTRIC.
4 COUPLING : ELECON / NAW / FENNER / HI-CLIEF/ WELLMAN-
(FLEXIBLE/GEARED) BIBBY / ESBI HI- FLEX PVT. LTD.
5 FLUID COUPLING : VOITH / PEMBRIL / FLUID DRIVE / FLUIDOMAT/
ELECON
6 BELTING (NN, EP) : MRF / SEMPERTRANS NIRLON / PHOENIX /
NORTHLAND RUBBER MILLS / ORIENT RUBBER /
FORECH / HINDUSTAN RUBBER/ NEELKANTH
RUBBER MILLS/ JOHNSON RUBBER INDUSTRIES/
NRC INDUSTRIES.
7 STEEL CORD BELTING : PHOENIX / BANDO, JAPAN / CLOUTH, GERMANY /
IMAS, GERMANY / DUNLOP/ MARUBENI, JAPAN /
SIG, ITALY/ FORECH.

APPENDIX “B”(contd.
8 ACTUATORS : TECHNO-MECH. ENGINEER/ ACTUATORS INDIA /

INDIAN ENGG. WORKS
9. ROTARY PLOUGH : LOUISE INDIA / TRF / THYSSEN-KRUPP / ELECON
FEEDER / L & T/ MBE.
10. SIZERS /ROLL MMD/ FFE/ STAMLER OLDENBURG(UK)/
CRUSHERS THYSSUN-KRUPP/ DBT MINERAL PROCESSING
Gmbh, GERMANY
11. RAPID LOADING : STRATEGIC WEIGHING SYSTEMS / MERIT
OUTFITS TECHNOLOGIES/ RAMSEY/ Schenck Process India
Ltd./Essae Digitronics (Kanawha RLS).
12. BELT WEIGHER : JHONSON & NICHOLSON / POWER BUILD/
AUTO MEASUREMATIC / GILLANDERS / KIS
TELEMORSE/ Schenck Process India Ltd.
13. CHUTE LINER : TEGA / KAVERI /DEVI-RUBBER / WEAR
RESISTANT TECHNOLOGIST / DURAWELD
WEARPLATES.
14. CHAIN PULLEY BLOCK : INDEF / TRACTEL TIRFOR / GREAVES COTTON /
BATLIBOI / TURBO FURGUSON / ELEMECH HOIST
/ GRIP ENGINEERS / REVA ENGG./ KANUBHAI / /
SUREKA/ ARMSEL
15. MOTORISED FLAP : TECHNO-MECH/ ACTUATORS INDIA/
GATE PRECISION/ MERIT TECHNOLOGIES.
16. PUMPS : MATHER & PLATT/ KIRLOSKAR/ GREAVES
COTTON / JYOTI / MAMC /HUMBOLDG WEDAG /
DORR-OLIVER / HYD. IND. / KSB/ BEACONWEIR
17. BUNKER LEVEL : UPTRON / ENDRESS & HOUSER/ NIVO
INDICATOR CONTROLS / AUTO MEASUREMATIC / MONITOR
CONTROLS / EPI INSTRUMENTS / HEIN-
LEHMANN/ EIP BULK CONTROLS/
KISTLERMORSE
18. ELECTRIC HOIST : HOIST-O-MECH/ GREAVES COTTON/ ELEMECH
HOIST/ POWER BUILD/ KANUBHAI/ INDEF/
BATLIBOI/ BRADY/ TRACTEL TRIFOR / HITECH/
TURBO-FURGUSON/ GRIP ENGG,/ SWIFT
(GREAVES)/ KM ENGG./ SUREKA/ ELITE STEELS/
ELECTROMECH MHS.
19. FIRE FIGHTING : MINI-MAX/ THERMAX/ VIJAY/ F.HARLEY/APC/
SYSTEM TECHNO FAB/ STEELAGE /TECHNO INDIA/
PROJECTS AND CONTROL

APPENDIX “B”(contd.)
20. VENTILATION SYSTEM : FLAKT INDIA/ C.DOCTOR & CO./ MAMC/ VOLTAS /
BATLIBOI / ABB INDIA / ANDREW YULE/ DUST VAN/
PROJECTS AND CONTROL/ INDVENT FANS/
ARGOSY INCORPORATED / ALSTOM/ APC/ NELSON
21. DUST SUPPRESSION : BATLIBOI/ F. HARLEY/ GEC/ VENDON INDIA LTD. /
THERMAX / ANDREW YULE/APC/ PROJECTS AND
CONTROL/ Kavery Ultra Polymers
22. DUST EXTRACTION : FLAKT INDIA / ANDREW YULE / GEC / THERMAX/
DUVANT/ ABB INDIA / DUST VAN/ PROJECTS AND
CONTROL/ INDVENT FANS / ARGOSY
INCORPORATED / ALSTOM/ APC / NELSON
23. FREIGHT-CUM- : OTIS /MITSHUBISHI, JAPAN /KONE/ THYSSEN-
PASSENGER LIFT KRUPP
24. BELT VULCANISER : NILOS / SHAW ALMEX / CHANDA & CO.(ENGG.) PVT
LTD.
25. AIR BLASTER : TECHNOFAB/ LINEMANN HALFLO, U.K. / DSI/ TEGA /

MM FABRICATOR / KAVERY ULTRA POLYMERS
26. SAMPLING SYSTEM : RAMSEY/ ADVANCE SYSTEM / EASTMAN CRUSHER
/MERIT TECHNOLOGIES.
27. METAL DETECTOR : POWER BUILD/ ELECTROMAG/ MAGNET INDIA/

M.R.EQUIPMENT/ AUTOMATIC CONTROLS/ ERITZ,
UK / ELECTRO ZAVED/ KRUPP, GERMANY/
ELECTRO MAGNETIC INDUSTRIES/ MAGNETIC
CORPORATION OF INDIA / MAGNET
INDUSTRIES(CAL) PVT. LTD.
28. CROSS BELT : PBL/ ELECTROMAG/ STEARNS MAGNETIC/
MAGNETIC SEPARATOR MAGNET INDIA / ERITZ, UK / ELECTRO ZAVED/
KRUPP, GERMANY/ ELECTRO MAGNETIC
INDUSTRIES/ MAGNETIC CORPORATION OF INDIA /
MAGNET INDUSTRIES(CAL) PVT. LTD.
29. OVER HEAD : PBL/ ELECTROMAG/ STEARNS MAGNETIC/
SUSPENDED TRAMP MAGNET INDIA / ERITZ, UK / ELECTRO ZAVED/
IRON MAGNET KRUPP, GERMANY/ ELECTRO MAGNETIC
INDUSTRIES/ MAGNETIC CORPORATION OF INDIA /
MAGNET INDUSTRIES(CAL) PVT. LTD.
30 WEIGH BRIDGE : SCHENCK PROCESS INDIA LTD./ RICE LAKE
WEIGHING SYSTEM (INDIA) LTD./ AVERY.
ELECTRO MECHANICAL TRF / IC / ELECON / MBE / HYDIND / ORIEN /
31
VIBRO FEEDER SAYAJEE / KRUPP INDUSTRIES / L&T

APPENDIX “B”(contd.)
II. APPROVED VENDOR LIST FOR ELECTRICAL EQUIPMENT
Sl. ITEM DESCRIPTION NAME OF APPROVED MANUFACTURERS

No.
1 MOTOR (L.T.) : KIRLOSKAR/ BHEL/ SIEMENS/MARATHON ELECTRIC
MOTORS/ JYOTI/ NGEF/ ABB/ CROMPTON
GREAVES/ BHARAT BIJLEE/ INTEGRATED ELECTRIC
COMPANY LTD/ LAXMI HYDRAULICS PVT. LTD./
BALDOR ELECTRIC
2 MOTOR (H.T.) : KIRLOSKAR/ BHEL/ SIEMENS/ MARATHON
ELECTRIC MOTORS/ JYOTI/ NGEF/ ABB/ CROMPTON
GREAVES/ BHARAT BIJLEE/ INTEGRATED ELECTRIC
COMPANY LTD. / LAXMI HYDRAULICS PVT LTD/
BALDOR ELECTRIC
3 POWER : KIRLOSKAR/ BHEL/ BHARAT BIJLEE/ GE
TRANSFORMER INDUSTRIAL/ CROMPTON GREAVES/ ANDREW
YULE/ SIEMENS/VOLTAS/ ABB/ NGEF/ Transformers &
Electricals/ Tesla Transformers Ltd./Pan-electro Technic
4 LIGHTING : KIRLOSKAR/ BHEL/ BHARAT BIJLEE/ GE
TRANSFORMER INDUSTRIAL/ CROMPTON GREAVES/ ANDREW
YULE/ SIEMENS/VOLTAS/ ABB/ NGEF/ L &T / POWER
MASTER ELECTRICAL PVT. LTD/ TRANSFORMERS &
ELECTRICALS/ TESLA TRANSFORMERS LTD.
5 CONTROL : L&T/ SIEMENS/ JYOTI/ GE INDUSTRIAL/ NGEF/
TRANSFORMER KIRLOSKAR/ BHARAT CUTLER HAMMER
6 VACCUM CURCUIT : KIRLOSKAR SYSTEMS/ BHEL/ JYOTI/ MEI/ SIEMENS/
BREAKER/ ABB/ GE INDUSTRIAL/ ALIND /NGEF/ ANDREW
SWITCHGEAR YULE/ ASEA / SOUTHERN SWITCHGEAR (SSG)/
ELECTRO TEKNICA/ MEDITRON/ SAIT Mine
Line/BIECCO LAWRIE/ APE POWER PVT. LTD./
MEGAWIN SWITCHGEAR/ MEDITRON/ AMIYA
INDUSTRIES.
7 VACCUM : GE INDUSTRIAL / JYOTI/ UNIVERSAL ELECTRICAL/
CONTACTOR BHEL/ ANDREW YULE/ SIEMENS/ CROMPTON
GREAVES/ MEGAWIN SWITCHGEAR/ AMIYA
INDUSTRIES/ ELECTROTEKNICA SWITCHGEARS .
8 LT SWITCH BOARD : NGEF/ L&T/ ANDREW YULE/ GE INDUSTRIAL / JYOTI/
PANEL/ MOTOR SIEMENS/ BHARATIA INDUSTRIES LTD./ ABB/ EASUN
CONTROL CENTRE/ ENGG/ CROMPTON GREAVES/ KIRLOSKAR
AIR CIRCUIT SYSTEMS / SCHNEIDER/ CONTROL & SWITCHGEAR
BREAKER / MCCB / COMPANY/ MINILEC(INDIA) PVT LTD/ STANDARD/

No.
MCB / RCCB ELECTRICALS LTD/ JOLLY ENGG./ TRANSGIETZ/
MEGAWIN SWITCHGEAR/ MEDITRON/ AMIYA
INDUSTRIES/ ZENITH CONTROLS/ HPL
INDIA./PRAYAS AUTOMATION/ AC POWER SYSTEM.
9 P.F.CORRECTION : ABB/ MADHAV CAPACITOR/ GE INDUSTRIAL /
EQIPMENT VOLTAS/ YESHA/ KHATAU JUNKER/ BHEL/ UNISTAR/
NGEF/ BHARATIA INDUSTRIES LTD./ EPCOS.
10 POWER CABLES & : CABLE CORPORATION/ FORT GLOSTER/
CONDUCTORS UNIVERSAL CABLES/ NICCO/ PREMIER CABLES/
HINDUSTAN CABLES/ INCAB/ ASEAN / HAVELLS/
RADIANT/ LASER CABLES/ SKYTONE/ LUMINO/
SIECHEM / RAVIN CABLES LTD./KEI INDUSTRIES
11 CONTROL CABLES : CABLE CORPORATION/ FORT GLOSTER/ NICCO/
ASEAN/ UNISTAR/ HINDUSTAN CABLES/ K.D.K./
RAJNIGANDHA CABLES/ HAVELLS/ RADIANT/ LASER
CABLES/ SKYTONE/ SIECHEM/ RAVIN CABLES LTD./
KEI INDUSTRIES
12 COMMUNICATION : HINDUSTAN CABLES/ DELTRON/ TOSHNIWAL/
CABLES INCAB / VINDHYA TELELINK LTD/ SIECHEM.
HT TRAILING CABLES : UNISTAR/ INCAB
13
14 COMMUNICATION : ITI/ PHILIPS / MOTWANE/ TATA TELECOM / UPTRON/
SYSTEM/ GE INDUSTRIAL / ECIL/ CROMPTON GREAVES
EQUIPMENT
15 LIGHT FITTINGS : PHILIPS/ CROMPTONS/ GE INDUSTRIAL / BAJAJ/
ECE / GLOLITE /ANCHOR
16 RELAYS : GEC ALSTOM/ L&T/ UNIVERSAL ELECTRIC/
SIEMENS/ KIRLOSKAR SYSTEMS/ A.V.K.-S.E.G.
CONTROLS LTD./ BCH / EASUN REYROLL / ABB
/ANDREW YULE/ TELEMECANIQUE/ / BHARATIA
INDUSTRIES LTD. / CONTROL & SWITCHGEAR
COMPANY LTD/ MINILEC(INDIA) PVT LTD / SAIT Mine
Line. / MEGAWIN SWITCHGEAR/ Amiya Industries.
17 PLC : L&T/ SIEMENS/ ALLEN BRADLEY/ KELTRON/
UPTRON/ TTS SYSTEMATIC PVT. LTD./ ABB/
MITSUBISI/ SCHNEIDER/ GE FANUC/ BHARATIA
INDUSTRIES LTD/ MINILEC(INDIA) PVT LTD/
HONEYWELL/PRAYAS AUTOMATION
18 CT'S & PT'S : ELECTRIC POWER EQPT./ EASTERN SWITCHGEAR/
AUTOMATIC ELECTRIC/ POLYCRETE LTD. / KAPPA/
ABB /CONTROL & SWITCHGEAR COMPANY LTD. ./


No.
MAX ENERGY PVT. LTD./ APE POWER PVT.
LTD./MEGAWIN SWITCHGEAR/ Electroteknica
switchgears.
19 L.T. CONTACTOR : SIEMENS/ L & T/ BHARATIA INDUSTRIES LTD./ GE
INDUSTRIAL / ANDREW YULE/ JYOTI / HAVELL'S/
KIRLOSKAR SYSTEMS / ABB / TELEMECANIQUE
20 PUSH BUTTON; : L&T/ SIEMENS/ ESSEN/ BCH/ BHARATIA INDUSTRIES
INDICATING LAMP LTD/ RASS CONTROLS.
21 CONTROL SWITCHES : L&T/ KAYCEE/ JYOTI/ ESSEN/ SIEMENS /HAVELL'S
22 ISOLATING : SIEMENS/ L&T/ BHARATIA INDUSTRIES LTD./
SWITCHES/ SOFT ANDREW YULE/ GE INDUSTRIAL/ JYOTI/ CROMPTON
STARTERS GREAVES/ HAVELL'S/ TELEMECHANIQUE / ABB/
CONTROL & SWITCHGEAR COMPANY / MINILEC
(INDIA) PVT LTD /STANDARD ELECTRICALS LTD./
Danfoss Industries Pvt Ltd./PRAYAS AUTOMATION
23 CONTROL CONSOLE : L&T/ SIEMENS/ JYOTI/ NGEF/ GE INDUSTRIAL/
WITH COMPONENT KIRLOSKAR SYSTEM/ ANDREW YULE/ APLAB/ ABB/
ALLEN BRADELY/ BHARTIA INDUSTRIES LTD/
MINILEC (INDIA) PVT LTD/ SKYTONE/ ZENITH
CONTROLS
24 BATTERY & BATTERY : CHLORIDE/ STANDARD/ AMCO
CHARGER
25 (a) LIGHTENING : ICE/ OBLUM/ IGE (I) LTD./ WS
ARRESTER INSULATORS/CROMPTON GREAVES/ SATCOM
ELECTRONICS
(b) EARTHING SATCOM ELECTRONICS
SYSTEM
26 WELDING : ADVANI OERLICON/ INDIAN OXYGEN/ PHILIPS/ ESAB
TRANSFORMER/ MG
WELDING SET
27 LIMIT SWITCH, PULL : R.K.ELECTRICALS/ ESSEN/ SIEMENS/
CORD SWITCH, BELT TECHNOCRAT/ PHOTO CONTROL/ JAYSHREE
SWAY SWITCH, ELECTRONICS/ BHARTIA INDUSTRIES LTD/ SAIT
CENTRIFUGAL MINE LINE/ PROTOCONTROL INSTRUMENTS./
SWITCH etc.
28 TIMER : BCH/ TELEMECANIQUE/ L&T/ SIEMENS/ GE
INDUSTRIAL / ABB/ MINILEC(INDIA) PVT LTD.
29 ELECTRO MAGNETIC : ELECTROMAG/ PBL/ INDUSTRIES SYNDICATE / BCH
BRAKE
30 METERS : AEP/ IMP/ HPL INDIA


No.
31 SELECTOR SWITCH : L&T/ SIEMENS/CROMPTON/ BHARTIA INDUSTRIES
LTD/ RASS CONTROLS.
32 HRC FUSE : GE INDUSTRIAL / L&T/ SIEMENS/ STANDARD/ ABB/
CONTROL & SWITCHGEAR COMPANY LTD/
STANDARD ELECTRICALS LTD./MEGAWIN
SWITCHGEAR.
33 HOOTERS : TULLU/ NATIONAL
34 AIR CONDITIONER : ACCAIRE/ BLUE STAR/ VOLTAS/ GODREJ/ CARRIER
35 C.I. Earthing Pipes- : KAPILANSH DHATU UDYOG
ELECTRODE

3.5 IMPORTANT NOTE:

Plant and Equipment supplied within the country shall be from approved
vendors as listed in “Approved Vendor List” In case the bidder intends to
supply P&M from vendors not listed in approved vendor list, written
approval of the employer shall be taken as per proforma given at 7.5.3.1.
The customer after evaluating the eligibility and qualification of such
vendors, may choose to include them in approved vendor list. Bidder in his
bid shall furnish information for evaluation and qualification of each such
vendor. The criteria and formats for evaluation of vendors are given.
For plant and equipment supplied from vendors abroad, information for
evaluation and qualification of each vendor shall be furnished in the bid
and the written approval of employer for approved foreign vendors shall be
taken.
APPENDIX “C”
FORMAT FOR VENDOR EVALUATION
PART – I GENERAL
1.0 Name of the company
2.0 Nature of the company

(Proprietary / partnership / Private / Public
Limited)
(Attach photocopy of articles of
association/
Registration/Partnership/Deeds etc.)
3.0 Registered office address
4.0 Works address
5.0 Name of chief executive
6.0 Name of the person to be contacted for
this bid
(Furnish photocopy of authorization)
7.0 OFFICE :
• Telephone no :
• Fax No:
• E-mail :
• Web site, if any
8.0 WORKS :
• Telephone no :
• Fax No:
• E-mail :
9.0 Total area of the factory
• Covered
• Uncovered
• Factory layout
10.0 Total number of employees

• Managerial
• Technical
• Administrative
11.0 Organisation chart
12.0 Range of products manufactured
(Enclosed all relevant technical
catalogues and literatures)
13.0 Year of commencement of manufacture
PART – II TECHNICAL
1.0 Details of major products manufactured

• Type
• Size
• Description
• Annual production for preceding three
years
2.0 Has your product been tested by any
agency? If yes, indicate details, copies of
qualification approval, test certificates),
test reports etc.
3.0 Foreign Collaboration ( if any)
• Products covered
• Name and address of collaborator
• Status of collaboration
• Scope of involvement and responsibility
with respect to this bid, if any.
• Proof in support thereof
4.0 Details of plant and machinery
• Include list of major items of plant and

equipment relevant to the products
under considerations.
5.0 Have you supplied the product similar to
product under consideration to other
customers? If yes, furnish name of such
firm(s) & details of such product.
6.0 Quality Assurance
• How is the quality assurance function
carried out ? Give its organization and
linkage with the Chief Executive.
• Are there written procedures for all
quality related activities?
• If the firm is ISO 9000 certified
company, then please attach a copy of
the certificate showing range of product
covered & its validity.

7.0 Do you have an R & D Department?

• If so, furnish details of its infrastructure
and laboratory test facilities.
8.0 How is quality control of raw materials,
purchased items exercised ? If goods
coming in are inspected, provide following
details :
• Test equipment and facilities available
in factory
• Assistance from external agencies
• Description of test (s)
• Name of the agency carrying out the
tests (s)
9.0 • Inspection and quality control of
finished products
• Test equipment and facilities available
in factory
• Assistance from external agencies.
10.0 Principal customers
• Name and address
• Product indication there operating
parameters
• Sales for last two years
• User’s performance certificates
11.0 Future Expansion
• Programme
• Installation of new machinery
• Any other information you would like to
provide
11.0 Process plan / flow chart of product
under consideration
12.0 Product brochures
13.0 Details of BIS licence, if any
14.0 Outsourcing activities for product under
consideration (if any)
• Activities to be outsourced
• List of out sourcing agencies for each
activity and their official address
• List of P&M & testing facilities available
with outsourcing agencies
• List of products manufactured by
outsourced agencies
• List of client of outsourced agencies
• Attach copy of order received from
client for outsourcing agency and
performance certificate , if any
• Any other information about outsourced
agencies (whether ISO certified, BIS
licence holder etc.)

PART – III COMMERCIAL
1.0 Name and address of banker(s)
2.0 Value of current assets as on date
3.0 Value of current liabilities as on date
(Attach balance sheets for last three
years)
4.0 Net fixed assets
5.0 Value of total sales during the previous
years
6.0 Value of orders in hand, enclose copy of
supply order
7.0 Value of total capital employed
8.0 Audited Balance sheet of last year
9.0 Source of finance
10.0 Borrowing limit as sanctioned by bank, if
any
11.0 Are your products covered by warranty, if
so, state
• Period
• Scope of warranty
Is after sales service provided ? If so,

12.0
furnish details in respect of availability of
adequate spare parts and distribution
network for spare parts, trained
personnel, for servicing, special tools and
tackles and test equipment as may be
required for servicing
Any other information that the bidder may
13.0
like to furnish in support of their capacity
and capability
I certify that the information supplied herein, including all pages
attached, is correct to the best of my knowledge
SEAL
SIGNATURE :
NAME :
DESIGNATION :
PLACE:
DATE :

TENDER DOCUMENT FOR DESIGN, SUPPLY, ERECTION, COMMISSIONING AND TESTING OF COAL
HANDLING PLANT & SILO (16.0 Mtpa) NEAR LINGARAJ OCP
CHAPTER - IV
DETAILED TECHNICAL SPECIFICATIONS
4.1.0 MECHANICAL
4.1.1.0 BELT CONVEYOR (MECH-01)
Complete conveyor system consisting of 16 nos. of belt conveyors shall be

manufactured based on the detailed specification to be read in conjunction with
different drawings and conveyor data sheet (Annexure-IV-1) forming part of this
tender specification. It shall, inter-alia include, the following:
i. Drive unit complete with electrically driven motor, Gear-boxes/ CST

drive with inbuilt hold back devices, pulleys and couplings, bearings
and Plummer blocks, drive base frame etc.
ii. Idlers – carrying, return, impact, self-aligning, transition with frames.
iii. Conveyor frames and stools for supporting conveyor frames.
iv. Decking plates
v. Skirt plates
vi. Belt cleaning devices
vii. Electro-magnetic brakes
viii. Pull chord switches
ix. Belt sway switches
x. Zero speed switch/Belt sequence switch
xi. Hold back device
xii. Take up device
xiii. Guarding
xiv. Traveling tripper arrangement with travel rails wherever applicable.
xv. Any other accessories which the supplier considered necessary for
successful operation of the conveyor.
All the necessary calculations/ designs shall be submitted for approval.
4.1.2.0 DUTY CONDITION
The conveyors shall normally operate 18 hours per day and 330 days a year. It
shall however, be designed and constructed for round the clock continuous
operation for 365 days in a year.
It shall be suitable for operating in adverse working in conditions such as highly

dusty surroundings, exposure to open sun and rain and temperature variations
from 5o to 50oC and relative humidity from 5% to 95%.
The conveyors shall be able to start in full load condition. The minimum tail end
height shall be 1200mm and head end height shall be 1500 mm or as per
system requirement.
Job No: 730176 IV - 1

4.1.2.1 DRIVE UNIT
The drive unit consisting of Drive Pulley Assembly completes with motor,
Reduction Gear Boxes with in built hold back device, high speed and low
speed couplings motors and other components shall be mounted on a
combined rigid base frame. The unit shall be robust and compact. The design
shall be modular so that individual components can be taken out and replaced
for repair and overhaul. The removal and dismantling of unit should not call for
dismantling of adjacent units. Suitable designed replaceable couplings guard
shall also be provided. The Hydrovicous-clutch operated reducer gear drive
(HVC drive) for high torque/high inertia load conveyor belt has been provided
for the motors above 200 kW. Such drive has been envisaged for conv. C1,
C3A, C3B, C6A/6B, C7A & C7B etc.
As far as possible standardization should be attained, i.e., the units shall be so

built as to be easily interchangeable and to facilitate dismantling into sub
assemblies and reassembly at site.
4.1.2.2 BASIC COMPONENTS OF DRIVE FRAME, BASE FRAME AND

FOUNDATION ARRANGEMENT
The base frame for drive unit shall be fabricated of heavy structural steel
sections and plates and suitably braced, so that the unit in operation is
vibration free. It shall be of bolted and welded construction. The pulley
mounting structural members shall adequately long to accommodate the
chutes. Both sides of the pulley supporting members shall be connected by
adequately sized channels.
The motor, reduction gear box, couplings and drive pulleys shall be properly
aligned in the works of the manufacturer before the supply is affected. Dowel
pins shall be provided with gear box, motor and Plummer blocks for proper
alignment. The frame shall be provided with machined plates at necessary
places to install the motors, reducers and Plummer blocks, etc. The combined
drive base frame shall be bolted to the foundations through adequate size
foundation bolts. At least 4 nos. of bolts/ inserts shall be provided for each
supporting leg as per the System requirement.
For drive power snub and tandem drive shall be used. For tandem drive belt
wrap shall not be less that 450o. Arrangement details have been mentioned in
conveyor data sheet (Annexure-I). It shall be in conformity with drawings
enclosed with this tender document.
4.1.2.3 REDUCTION GEAR BOX
The gear box rating shall be minimum 1.6 times the motor power.
The reduction gear box shall be helical gear type / bevel helical with
parallel/perpendicular shaft completely enclosed running in oil bath (Splash
lubrication). It shall be of low weight compact design type. The gears shall be
machined & rated for service factor (not less than 1.6 on motor power) in
Job No: 730176 IV - 2

accordance with IS: 7403 (Code of Practice for Selection of Standard helical
gear boxes). The gear box shall have inbuilt hold back device.
The steel gears shall be machine cut and case hardened and shall be in
accordance with relevant Indian Standards.
The high speed shaft shall be so designed to accommodate electro magnetic
brakes and hold back devices.
Suitable oil level indicator, Magnetic drain plug and Metallic breather shall be
provided.
The gear box housing made from grey cast iron shall be so split as to enable
easy maintenance. It shall be of vibration damping device.
Gear shafts shall be supported on suitable bearings of ample capacity and
dimensionally conforming to relevant Indian Standards.
The selection of gear box shall preferably be done on the basis of natural
cooling only. Fan cooled gear box may be offered only for 300kW and above.
The gear box shall have a minimum rated life of 50,000 working hours.
The conveyors drives for C1, C3A, C3B, C6A/6B, C7A & C7B should have
controlled Start Transmission (CST) drive as in a 2 in 1 gear box which
combines a planetary gear reducer with an integral wet clutch system. The
service factor for CST drive shall be minimum 1.2 times of motor power and
shall have following capabilities:
• Field adjustable ‘S’ shaped velocity ramp of the conveyor belt. The belt
velocity ramp time to be adjustable from 40 to 300 secs.
• Field adjustable creep speed. The Min. creep speed shall be adjusted
15~20% of design speed under no load conditions.
• Field adjustable Maxx. Power (torque) limit for each drive to protect
conveyor component (belt, pulleys. Idlers, bearings) and the drive
components (gears, bearings) from shock and excessive loads. The HVC
drive shall send a fault signal to controls when power exceeds the Max.
Power set limit.
• In multiple drive configurations, true load share among the drives subject
to the condition that the kW signals from MCC for each motor is accurate.
kW load share regulation shall be within ±2% under full load conditions.
• The main motor starting will be controlled by drive PLC controller or
remote monitoring SCADA system. In multiple drive configurations, the
motors will be started in a staggered sequence of 5 sec interval. For short
stoppage of Conveyor belt, the motors need not be turned off, the drive
may simply be de-clutched.
• In a multiple drive configuration, if any one of the drive fails, it should be
possible to disable that drive from the PLC controller soft-touch monitor
screen and the belt should be restarted with remaining drives on reduced
load.
• Five full load starts within one hour, equally spaced (12 minutes apart).
• The local PLC controller shall have built-in diagnostics and menu driven
troubleshooting screens. The controller shall have hierarchical security
system to prevent unauthorized adjustments.
Job No: 730176 IV - 3

4.1.2.4 COUPLINGS
Suitable flexible couplings shall be used between Gear box and drive pulley for
low kW motors (less than 200 kW). The flexible coupling shall preferably be of
gear type. The hub and sleeves of the couplings shall be forged carbon steel
and bolts shall be alloy steel.
For all conveyors suitable fluid coupling shall be used between motor and gear
box. The size / type shall be selected in accordance with the drive power
requirement.
In case of fluid couplings suitable arrangement shall be provided to contain the
fluid and collect it without escaping out and injuring the work men.
Both the coupling shall be provided with protective guards made of sheet steel
and flats.
4.1.2.5 PULLEYS (DRIVE, DISCHARGE, TAIL, TAKE UP, BEND & SNUB)
The pulleys shall conform to IS: 8531 (Specification of pulleys for belt
conveyors). The matching tolerance of individual parts of pulley assembly shall
conform to IS – 919 (current).
The face width shall be belt width +200mm for all types of pulleys.
Tolerance on finished pulley face width prior to lagging shall be 16mm.
The pulley diameter shall be one of the following (No account shall be taken of
the pulley lagging): (mm) 500, 630, 800, 1000 and 1250. The diameters shall
be maintained within tolerance as specified in IS 8531-1977.
The pulley diameters shall not be less than the values specified in enclosed
conveyor schedule.
The diameter of the pulleys shall be maintained within the tolerances given
below:
Diameter of Pulley Tolerance
Up to 630 mm + 12 mm
- 3 mm
Above 630 mm + 15 mm
- 3 mm
The out of roundness shall be within in 0.5% of dia prior to lagging.

The pulleys shall be manufactured from mild steel conforming to IS: 2062
(Specification for structural steel) (Standard Quality).
For pulley fabrication, the welding procedure shall conform to IS: 823 (Code of
procedure for manual metal arc welding of mid steel).
All pulleys shall be statically balanced.
The pulley shell thickness shall be suitable for taking bending and other loads
on the pulley. This shall be clearly indicated in the offer for all the pulleys and
shall not be less than 16 mm for drive, discharge and 12 mm for tail pulleys and
10 mm for other pulleys. However calculation support with respect to shell
thickness shall be submitted during detail engineering.
Job No: 730176 IV - 4

For pulleys a middle disc shall be fitted to prevent deflection of rim at the
centre. In case of pulleys of face width 1600 mm or more, two such discs shall
be provided. The end cover shall be of disc type welded to the rim before
machining. Ring feeder lock sets will be provided on all pulley connections.
The pulley shaft shall be designed for combined bending and torsion stresses.
The shaft dia at bearing shall be selected from the following sizes keeping in
mind standardization:
60, 80, 100, 120, 130, 140 .160, 180, 210, 240 & 320 mm
Drum shafts shall be of EN-8 steel as per BS 970 (Current) or C-40 steel as
per IS 1570 (Current). The pulleys shall be connected to the hub through ring
feeder/ equivalent keyless shaft to hub connections.
All the drive pulleys shall be lagged with 16 mm thick rubber. The lagging shall
be bonded on the pulley by hot vulcanizing. The lagging shall be in Chevron/V-
type herring-bone or diamond pattern. The depth of groove shall be 6 mm
minimum with 6 mm minimum thickness of material under the bottom of the
groove. Alternatively, herring bone profiled wear resistant rubber bars molded
with a aluminum reinforcement shall be used. The hardness of rubber on drive
pulleys shall be 55 to 60 shore durometer hardness – A scale.
4.1.2.6 BEARINGS AND PLUMMER BLOCKS
Self-aligning double row spherical roller bearing dimensionally conforming to

relevant Indian Standard and selected for adequate capacity depending on the
load per bearings shall be used. The minimum design rated life of bearing shall
not be less than 50,000 hours. Cast steel Plummer blocks with provision of
easily accessible grease nipples for lubrication shall be used. Bearings shall be
protected against ingress of dust and moisture by multi labyrinth / rubber seal
and other effective dust sealing devices.
The bearing housing centers shall be 2300mm for 1600mm belt and 2500mm
for 1800 mm belt.
4.1.2.7 CONVEYOR FRAME
The conveyor frame and supporting stools shall consist of stringers made from
a minimum size of ISMC 150 channel conforming to relevant IS. N type
bracings minimum of ISA 50 x 50 x 6 shall be provided between two stringers
of 3000mm length for stability. Individual section shall be of such length so as
to facilitate easy assembly at site without any match marks and having any
reference to left and right of the conveyors. At the same time top and bottom
idler frames when assembled on the stringer shall have their position at right
angles to the longitudinal axis of the conveyors.
The conveyor frame shall be complete with stools for supporting stringers.
Holes for fixing the supporting stools shall be drilled on stringer channel for
intermediate structures. Stools for support of conveyor frame shall consist of
vertical supports with base plate to enable fixing of stools on foundation.
However, the support stools shall be welded to the stringers after erection.
There shall be an expansion joint at suitable interval to take up the expansion
Job No: 730176 IV - 5

of the structures during summer season.

The height of the stools shall be such as to give clearance between return roller
and ground of at least 500 mm. The plates of the stools shall be suitably drilled
for grouting. However, a minimum conveyor height of 1.2m is to be considered
for the design of intermediate structures.
4.1.2.8 IDLERS
The carrying and return idler and idler sets shall conform to IS: 8598-1987
(Idler and Idler sets for belt conveyors).
Diameter of idler, shell thickness and bearing size for carrying, and return
impact idlers shall be clearly mentioned in the offer. Idler’s rollers of diameter
less than following shall not be used.
Carrying & return Impact
• OD of steel tube (mm) 152.4 114.3 For 1200/1600

mm belt
• OD of steel tube (mm) 168.3 114.3 For 1800 mm
belt
• Tube thickness (mm) 5.40 5.40
• OD of Rubber disc (mm) 0.00 190.00
Steel tubes used in the manufacture of idler and idler set shall conform to IS:
9295 (steel tubes for idlers for troughed belt conveyors) and shall be preferably
ERW tubes.
4.1.2.8.1 IDLER SPACING (MAXIMUM)

In normal circumstances idler spacing shall be as under:
Belt Width Carrying Idler Return idler Impact idler

(mm) (mm) (mm) (mm)
1200/1600/ 1000 3000 500

1800 1000 3000 500
Suitable seize resistant deep grove ball bearings with C3 clearance and heavy
duty type dimensionally conforming to relevant Indian Standards and selected
according to bearing manufacturers recommendation for rated life of at least
30,000 guaranteed working hours shall be used. The minimum bearing bore
dia shall be as under:
Belt width Minimum bearing bore (mm)

(mm) Carrying & return rollers Impact rollers
1200 25 30
1600/ 1800 35 40
Job No: 730176 IV - 6

4.1.2.8.2 IDLER SHAFT
Idler shaft shall be made of steel not inferior to EN-8 / C40 conforming to
relevant IS standard.
4.1.2.8.3 IDLER ARRANGEMENT
O CARRYING IDLERS
The carrying idler set shall consist of three rollers of equal length. The
troughing angle shall be as specified and shall be of the value 35o / 450, for all
the conveyors with respect to capacity requirement irrespective of belt width.
o THE ANGLE OF TILT
i. The angle of tilt of side idlers shall be function of troughing angle and
belt speed and shall be as small as practicable and shall in no case
exceed 2o.
ii. The angle of tilt of side idlers shall be in the direction of belt run for
the unidirectional conveyors.
iii. The direction of belt travel shall be marked on the frame by an arrow
head.
O RETURN IDLERS
The return idlers shall be of single roll type.
O IMPACT IDLER/PAD
At loading point impact pad/idlers shall be provided. The impact pad shall be of
composite design comprising of top layer of UHMWPE (having hardness of
65+/- 50 shore A) of 10 mm thickness, middle layer of soft rubber (having
hardness of 55-65 shore A) of minimum thickness 45mm and bottom layer of
non-corrosive aluminum reinforcement. All three layers shall be moulded in
single operation and cured for proper bonding. Fastening of clamp shall be
sliding type. The length of pad shall not be less than 1000 mm. The pad shall
be designed for heavy duty operation and shall be provided with heavy duty
bolted frame.
o SELF ALIGNING IDLERS
On the carrying side two sets of self aligning troughing idlers shall be placed at
5 meter spacing from head and tail pulleys. The spacing of intermediate self
aligning troughing idler set shall be 15 meters. On the return side two sets of
self aligning return idlers shall be placed at 10 meter spacing from head & tail
pulleys. The spacing of intermediate self aligning return idler set shall be 30 m.
Self aligning idler set shall also be provided near the drive and take-up pulleys.
In case of short conveyors at least two set of self aligning idlers shall be
provided on the carrying and return run.
Job No: 730176 IV - 7

o TRANSITION IDLERS
Transition idlers shall be used adjacent to head and tail pulleys to permit
gradual transition from fully troughed section of belt to a flat faced eliminating
high stress concentration in belt. The transition length and the number of
transition idlers shall be selected depending upon the tension, type and size of
belt, number of plies and other necessary governing factor. However, there
shall be a minimum of nos of idlers shall be provided with 5o, 10o, 20o troughing
angles before the head and tail pulley.
4.1.2.8.4 BEARING HOUSING & LUBRICATION
The bearing housing for all types of idler rollers shall be charged with an
adequate quantity of good quality grease and shall not be less than 10cc on
either side of each roller capable of remaining free from hardening and
separation consistent with the sealed for life design. Idler bearings shall be
provided with suitable labyrinth seal on outer side and felt seal on inner side.
Bearing should be of 'seize resistant' type.
Clearances gaps etc. for all types of idlers shall confirm to latest version of
IS:8598-1977. Lengths of individual rolls shall conform to IS:1570 (latest)
Eccentricity / ovality of the idler shall be minimum and shall be mentioned
specially for all types and it shall not exceed 0.8mm at any point.
The bearing housing of idler roller shall be made of pressed steel and shall be
press fitted and shall be completely welded with idler tube. The details of this
shall clearly be furnished in the offer.
The radial run out of the idler shall be minimum. The full indicated movement
pertaining to eccentricity of the idler at any point along its length when rotated
on its axis shall not exceed 0.8 mm.
The idlers shall be made of ERW tubes of the specifications mentioned
elsewhere.
4.1.2.9 IDLER BRACKETS
The brackets for the carrying idlers shall be of rigid frame construction to
withstand shock loads resulting from large lumps. It shall be made from formed
steel sections of thickness not less than 4mm.
The fixing arrangement of carrying and return idlers shall be such as to permit
adjustment of the idler sets for purposes of belt training. Allowance for such
adjustments shall be provided on both sides of the conveyor and the play shall
not be less than to 5 mm on either side.
The idlers shall be of drop-in type to enable easy installation and replacement.
The allowable friction factor shall not be more than 0.03.
4.1.2.10 DECKING PLATE
Formed steel sheet decking plates to protect the bottom belt against spillage
shall be provided through out the length of the conveyor. The thickness of
decking plate shall not be less than 3.15 mm. The decking plate design shall be
such that there will not be any gap between the adjacent decking plates. Each
Job No: 730176 IV - 8

section of decking plate shall have 2 nos of pressed "V" type projection
(inverted) for strength. Preferably carrying idler fixing bolts shall be used for
fixing the decking plates.
4.1.2.11 SKIRT PLATE
Skirt board shall ensure centralized loading of conveyor belt to avoid coal
spillage. Suitable ‘Skirt Plates’ of 7.5 meters length shall be provided at each
feeding point of conveyor. The width of the Skirt Boards shall be two-third the
conveyor belt width. The gap between the bottom of the Skirt Board and the belt
shall be made to increase uniformity in the direction of belt travel. The height of
skirt board shall be sufficient to contain the material volume as it is loaded on the
belt and shall not be less than 600mm. In addition a covered hood of suitable
height shall be provided to contain dust pressure. The segmented rubber curtains
shall be hung from the top of the hood at regular intervals in segmented manner.
End of the skirt board shall be provided with rubber curtain. At the tail end, a
sealing box shall be provided which shall be minimum 750mm long and 500mm
high. At the tail end/ rear side also, skirt sealing shall be provided. To prevent
material spillage at conveyor transfer points, skirt board sealing systems
consisting of rubber which tail into each other to provide a continuous sealing
strip, will be provided. The fixing of skirt board rubber block shall be press-fit type
between adjacent rubber to avoid leakage of dust. Equally spaced guides shall be
provided for smooth vertical movements. The clamp shall be serrated type to
ensure uni-directional motion of the rubber block towards the belt. The shore
hardness of rubber block shall be 55±50 shore A.
The clamps and fixing bolts shall be galvanized for longer life.
4.1.2.12 BELT CLEANING ARRANGEMENT
Constructional Features of Belt Cleaning System:

The belt cleaner shall be of two parts:
a) Pre cleaner
b) Secondary cleaner
The pre-cleaner shall remove most of the material sticking to the belt and leave
only a thin skim of fines.
The pre-cleaner shall be installed on the face of the head pulley just below the
trajectory of the material leaving the belt to remove the carry back material
sticking to the belt.
The secondary cleaner shall be positioned after the tangential line where return
belt leaves the head pulley to remove remaining material i.e. the sticky fines
which have passed under the pre-cleaner blades. This is to ensure that all the
fines return to the main flow of the product.
Belt scraper shall be segmented type and multiple sets of scraping elements
shall be provided to cover maximum width of the conveyor belt. Each scraping
element should have individual spring action. Each scraping blade shall be
suitably mounted to give spring action to individual blade. Blade shall be of
150-200 mm wide and shall provide overlapping design.
The blade segments assembly shall be such that it can be fitted easily even in
confined areas of most head chutes and should be outside the chute wall with
Job No: 730176 IV - 9

provision of adjustment if required from outside so that minimum down time is

required for installation and replacement of parts.
All bolts and nuts for fixing the belt Scraping system, adjustment of belt scraper
and for the attachment of blades shall be of stainless steel only and all other
steel items shall preferably be galvanized.
Deflector plate of non sticking polymer should be provided on both sides of
each segment not to allow the scraped material to deposit and allow falling in
the chute below the scraper.
The blade tips should be superior abrasion resistant material. The design of
each blade, deflector plate and elasto mount should have provision to replace
the tip portion only.
The blade assembly should be supported on both sides with “elastomount”
having special torsion rubber spring to facilitate easy adjustment against blade
wear.
The scraper shall have safety device to prevent over travel of blade against
wear.
The angle and inclination of blades should be maintained against the direction
of the belt to ensure minimum tracking pressure with maximum cleaning.
Suitable internal belt cleaner of V plough type shall be provided on return belt
near the tail pulley. In conveyors using loop / vertical gravity take up, V type
plough belt cleaner shall also be provided near the bend pulley forming part of
take up unit to prevent material spilled on return belt, from damaging the belt at
the take up pulleys
All the conveyors shall be provided with a self cleaning type rubber disc return
idler located near the head pulley for cleaning
4.1.2.13 HOLD BACK DEVICE
Suitable hold back device shall be provided on all the conveyors to prevent
reverse movement of the belt in case of power failure or breakdown. These
devices shall be an integral part of the gear box and shall be fail safe design
4.1.2.14 ELECTRO-MAGNETIC BRAKES
Necessary electro-magnetic brakes shall be provided with all the conveyors

after calculating the coasting time. If required, necessary fly-wheels can also be
used for smaller conveyors. The coasting time calculation shall be submitted
for approval.
4.1.2.15 ACCESSORIES
4.1.1.15.1 PULL CHORD SWITCHES
For stopping the conveyor from any point along the conveyor length, pull chord
switches shall be provided on the walk way side of the whole conveyor length.
This shall be totally enclosed, dust and vermin proof, cast metal unit with trip
and reset levers mounted along the main walkway side at regular interval of 30
meters. The pull chord rope shall be of PVC sheathed GI wires. In addition, one
emergency ‘stop’ push bottom switch shall be provided at drive end. The
conveyors frame shall be provided with suitable brackets for carrying the pull
Job No: 730176 IV - 10

chord.
4.1.1.15.2 BELT SWAY SWITCH
Totally enclosed dust and vermin proof belt sway switches shall be provided on
both side along the conveyor length at a regular intervals of 50 meters. Belt
sway switches shall also be provided near discharge pulleys, tail pulley and
drive pulley. These switches shall be auto reset double contact type, one for
advance indication of excessive belt sway and the other for tripping the
conveyor.
4.1.1.15.3 ZERO SPEED SWITCH/ BELT SEQUENCE SWITCH
One number belt speed monitoring switch for conveyor shall be provided which
will stop the conveyor in case of slipping or snapping of the belt or in case belt
speed falling below 80% of the rated speed. These switches shall also serve as
belt sequence switch for the proceeding conveyor.
Suitable overload protection switches, chute blockade switches and over-speed
switches shall also be provided.
4.1.2.16 SAFETY REQUIREMENTS
All safety requirement as specified in IS-7155-Latest (code of practice for

conveyor safety) shall be followed in the selection, design and operation of
conveyors.
4.1.1.16.1 GUARDINGS
All moving parts of conveyors except rollers shall be suitably guarded by

guards made of structural steel and expanded metal conforming to IS 412
(Latest). Similarly the tail pulleys and drive arrangement shall have removable
protective guards. Similarly all couplings shall be provided with sheet metal
guards of adequate thickness and end M.S.flats.
The minimum clearance between the guards and moving parts shall be as
follows:
Size of opening (mm) Minimum Clearance (mm)
Not exceeding 10 25
Over 10 upto & including 15 65
In case of traveling tripper conveyor, the following sub clause shall also apply :
Job No: 730176 IV - 11

4.1.1.16.2 ACCESSES
Where there is danger of trapping a person between the moving tripper

conveyor and any fixed object, other than its track, there shall be a minimum
clearance of 500 mm.
4.1.1.16.3 GUARDS
Provision shall be made to prevent any trapping between the traveling wheels
& the rails, Slots 30 mm wide suitable reinforced may be provided in guards for
insertion of bars for cleaning. The minimum distance between any moving parts
of the conveyor and the slot shall be 300 mm.
Guards shall totally enclose all parts as far as practicable in order to, prevent
access to the part i.e. for an running belt. The guard around which an operator
can put his arm shall extend at least 900 mm from the belt.
4.1.1.16.4 HAND RAILS
Hand rails shall be provided all along the walkway and cat way along the
conveyor up to the bunker and other zones of conveyor length wherever they
are required.
4.1.2.17 TRAVELLING TRIPPER
Tripper shall be traveling self sustaining type as specified. Traveling tripper

shall be of motor propelled type, capable of reversing. Tripper shall be provided
with two way type discharge chute as specified in system drawing.
The traveling tripper shall reverse its direction of travel automatically and travel
back and forth continuously or be manually stopped for continued discharge at
desired locations.
The tripper frame shall be made of structural steel, welded construction,
designed to withstand maximum belt tension, providing ruggedness and
resistance to shock. A suitable operator’s platform of chequered M.S. plate
shall be provided over the tripper. A cross over ladder shall also be provided on
the discharge side of the tripper. The operator’s platform shall have protective
railings.
Traversing mechanism shall be complete with motor, reduction gear box,
couplings and brakes etc. The electric power shall be supplied through suitable
cable arranged in festoon, incorporating for both local and remote control.
All operating levers and handles as well as the lubricating points shall be within
easy and safe reach of the operator's platform.
Adequate and safe means for locking the tripper to the rails in a stationary
position must be provided. Provision must be made so that locking device can
not be operated while the traversing mechanism is in operation or vice-versa.
The traversing and locking mechanism shall be electrically operated and
suitable for both local and remote control.
Suitable belt cleaner shall be provided on tripper discharge pulley as has been
described elsewhere.
Job No: 730176 IV - 12

Frame of traveling tripper shall be mounted on flanged cast steel wheels with
antifriction bearings housed in Plummer blocks with grease nipples for external
lubrication.
The tripper shall be moving on adequately sized rail tracks rigidly fixed to the
supporting structures. The tripper travels shall be limited by the provision of
end buffers on both ends of the rails.
4.1.2.18 INSPECTION & QUALITY CONTROL BEFORE DISPATCH
Apart from the inspection and testing requirements stipulated in general

conditions for supply of equipment, the following test shall be carried out.
4.1.1.18.1 SPECIAL MATERIALS
In addition to the prescribed inspection and quality control measures, adopted

by conveyor manufacturers/contractors during raw materials purchase, sub-
assembly and final assembly stages the manufacturers / contractor should be
prepared to furnish without extra charge, test certificates covering mechanical
properties and chemical composition for the material is used (eg. materials for
idler or drum shafts). This certificate shall be from approved testing laboratories
such as CMERI, Durgapur, NPL, New Delhi etc. Samples of such materials are
to be selected as per relevant latest Indian Standards and Codes.
4.1.1.18.2 TEST RIG FOR IDLERS AFTER ASSEMBLY
The idlers based on approved drawing after assembly shall be tested for no
load run on a suitable test rig capable of running idlers at a suitable speed
higher than rated speed for a given time. This test rig speed shall not exceed 3
to 4 times the rated speed. Similarly the idlers shall be tested for ingress of
dust and water. These tests shall have to be carried out at manufacturers’
works as desired by MCL / their consultants.
4.1.1.18.3 BEARINGS
A certain percentage of anti-friction bearing, to be selected at random, will be

checked for boundary dimensions keeping in view the permissible tolerance as
per accepted standards. Further, the selected bearings shall be rotated at
about 1600 RPM and checked for abnormal noise.
4.1.1.18.4 NO LOAD TEST RUN OF CONVEYORS DRIVE HEAD
The conveyor drive head comprising of motor, reduction gear box, coupling
driving drum etc. mounted on a composite rigid base frame shall be subjected
to a no-load test run for few hours to check for abnormally high temperature or
abnormal conditions including too much noise. The conveyor manufacturer
shall furnish a test certificate in duplicate for the above no-load tests.
The following additional tests may also be carried out, at the option of the
customer and all facilities for carrying out such tests shall be extended by the
supplier at their own cost.
Job No: 730176 IV - 13

a) Dimensional checking of all items

b) Material test certificates for material of construction.
c) For idlers the following tests shall be carried out
i. Friction factor test
ii. Idler running test at high speed
iii. Test for dust proof and water proof
iv. Ovality test of finish idler.
v. Alignment and co-axiality test of idler set assembly.
d) For pulleys following test shall be carried out
e) Checking of out of roundness
f) Static balancing test
g) Test of bought out items
All tests shall be carried out in terms of relevant IS and upto date engineering
practices.
4.1.2.19 POWER UNIT
POWER SUPPLY
415 / 3300 volt, 3-phase, 50 Hz.
4.1.1.19.1 MOTOR
TEFC induction motor of squirrel cage type ( double cage ), synchronous

speed - 1500 rpm, insulation-class ‘F’, high torque, foot mounted integral type,
with IP-55 protection as per IS:4961.
The motor shall be capable of giving rated out put without reduction in the
expected life span when operated continuously in the system having the
following particulars:
i) Rated terminal voltage : 3300 volts, 3 phase

above 90kW
ii) 90 kW & below : 415 V: 3-phase
iii) Variation in voltage : +5% for 415 volt
±10% for 3300 volt
iv) Frequency : 50 Hz, +3%
The motor shall be suitable for full voltage DOL starting. This shall be capable
of starting and accelerating to the rated speed along with the fully loaded driven
equipment without exceeding the acceptable winding temperature even when
the supply voltage is 80% of rated voltage throughout the starting period.
The locked rotor current shall not exceed six times the rated full-load current
subject to tolerance as given in IS: 325.
Space heater suitable for 240 V, 50 Hz, single phase supply system shall be
provided for motor above 30 kW capacity. For rating below 30 kW space heater
shall be provided if required if it is meant for specific use in damp areas.
Suitable temperature detector for detection of winding and bearing temperature
shall be provided for all 3300 volt motors. These shall be installed at locations
where high temperatures are expected during operation. The indications shall
Job No: 730176 IV - 14

be carried to the control desk.

Power terminal blocks shall be suitable for receiving 3300/1100 volt grade
aluminum conductor single layer armored cross linked polyethylene
insulated/PILCSWA/PVCA insulated cable.
Two independent earthing points shall be provided in accordance with IS:3043
on opposite sides of the motor for bolted conditions.
The design, manufacture, installation and performance testing shall conform to
the latest revisions of the Indian Standards equivalent to IEC standard for the
applicable motor type and rating, latest Indian Electricity Act, Indian Electricity
Rules and IS:325.
Job No: 730176 IV - 15

TENDER DOCUMENT FOR DESIGN, SUPPLY, ERECTION, COMMISSIONING AND TESTING OF COAL HANDLING PLANT & SILO (16.0 Mtpa) NEAR
LINGARAJ OCP
SCHEDULE OF CONVEYORS ( Annexure IV-I )

C6A/B
SL No Particulars Unit C1A C1 C2A/B C3A/B C4A/B C5A/B C7A/B C8A/B
(Tripper)
270.00/ 428.00 / 76.00 132.00 176.00/
1 Tentative Conveyor Length (Horizontal) m 29.50 371.00 493.00 31.00
269.00 425.00 /80.00 /139.00 174.00
2 Belt Width mm 1200 1600 1600 1600 1600 1600 1600 1800 1800
3 Belt Speed m/sec 2.00 2.50 3.00 3.00 3.00 3.00 3.00 4.00 4.00
4 Rated Capacity tph 500 1600 1800 2000 2000 2000 2000 3600 3600
5 Lift m 5 42 3.5 20 0 0 7 51 0
6 Quantity No 1 1 2 2 2 2 2 2 2
1x250+ 1x750+
7 Drive Power kW 1x37 1x450 1x150 1x450 1X90 1X75 1x90
1x11 1x 600
8 Type of Drive Normal CST Normal CST Normal Normal CST CST Normal
9 Material to be carried Coal Coal Coal Coal Coal Coal Coal Coal Coal
10 Bulk density of material of Coal t/m3 0.8-1.2 0.8-1.2 0.8-1.2 0.8-1.2 0.8-1.2 0.8-1.2 0.8-1.2 0.8-1.2 0.8-1.2
11 Troughing angle Degree 35 35 35 35 35 35 35 45 45
12 Max Lump Size mm 200 200 100 100 100 100 100 100 100
Plough
13 No of Loading Points No 1 5 6 2 1 1 1 feeder 2
loading
14 Preferred type of Take-up G Tup G Tup HG Tup G Tup G Tup G Tup G Tup HG Tup Screw
Minimum diameter of drive / discharge

15 mm 630 800 630 800 800 800 800 1000 630
pulley
Minimum diameter of Tail / take up

16 mm 500 630 500 630 630 630 630 800 500
pulley
17 Minimum diameter of other pulley mm 400 500 400 500 500 500 500 500 400
Steel Steel Steel Steel
18 Type of belting N-N N-N N-N N-N Steel Chord
Chord Chord Chord Chord
Job No: 730176 IV - 16

4.1.2.0 CONVEYOR BELTING NYLON-NYLON (MECH-02)
4.1.2.1 SCOPE
This specification covers the supply of conveyor belting of required size and
length with Nylon-Nylon carcass for surface use and shall be read in
conjunction with relevant references.
4.1.2.2 CARRYING MATERIAL
a) Coal / Shale :(-) 100 mm/ (-) 200mm as per

requirement indicated
b) Percentage of shale / sand stone :20-30%
c) Percentage of inherent moisture :7.2-8.1%
(15 % in rainy season)
d) Bulk density : 0.8-1.2 t /m3
e) Condition of material : Dry/wet /Sticky /Acidic /
Alkaline
4.1.2.3 DUTY CONDITIONS
The belting shall be of heavy duty type and suitable for round the clock
continuous operation i.e. 24 effective working hours and 365 working days
per year.
This shall be suitable for installation over conveyor system having 35o
troughing angle.
The belting shall be suitable for extreme environmental conditions i.e.
exposure to open sun and rain, temperature variations from 5o to 50o C and
relative humidity from 5% to 100%.
4.1.2.4 CONSTRUCTIONAL FEATURES
The belting shall have Nylon-Nylon carcass. The fabric shall be evenly firmly
woven and shall be free from foreign matter and such defects as knots,
lumps etc.
The belting shall be of straight ply (full with ply), skim coated plies, open
ends and edge protected construction.
Minimum cover thickness and cover grade of belting shall be as specified
and conform to IS 1891 (Part-I whenever applicable).
The belt shall have sufficient strength to give required tension at 10 (ten)
factor of safety and 80% tension utilisation.
The belt shall have sufficient lateral flexibility for adequate troughing of
empty belt on troughing idlers of specified troughing angle.
The belt shall have sufficient longitudinal flexibility so that it can easily flex
around different pulleys of conveyor and shall provide necessary load
support without excessive sagging between idler sets.
The belt shall have sufficient impact resistance to withstand impact at
loading points.
Job No: 730176 IV - 17

4.1.2.5 COMPLIANCE WITH STANDARD AND TESTING
The belting shall conform to relevant Indian/International standards, all

applicable codes.
4.1.2.5.1 INSPECTION AND QUALITY CONTROL
Before dispatch the finished material shall be subject to inspection by the

authorities / representative of the purchaser. The inspection shall be carried
out in presence of the manufacturer in terms of up to date engineering
practices and relevant Indian standard / International standards in this
respect, for which all facilities shall be provided by the manufacturer at his
own cost. This shall, inter alia, include the following:
4.1.2.5.2 RUBBER COVER TEST (TOP/BOTTOM)
• Tensile strength of cover ( kg / cm2 )

• Elongation at break (%)
• Adhesion between ply to ply
4.1.2.5.3 FULL THICKNESS BELT TEST
• Breaking load (kg / cm2 )for warf and weft

• Elongation under load ( % )
• Elongation at break ( % )
4.1.2.5.4 PHYSICAL DIMENSION CHECK
O FLEXIBILITY TEST
The manufacturer shall also make available to the purchaser’s inspecting

personnel all the relevant standards and codes of practices for manufacture,
inspection and testing of the material. He will also make available a set of
meters and gauges etc. as may be required for testing and inspection of the
material. All relevant type test certificates shall have to be produced prior to
inspection / supply.
o TESTING FACILITIES, RE-TEST & REJECTION
• The vendor shall, at his own cost, supply all labour and appliance for
the tests. In the absence of facilities at his own premises for carrying
out the testing, the test shall be carried out by an approved authority
at the cost of Vendor.
• Re-Test & Rejection Should any sample (drawn in accordance with
IS: 1891, Part-I) fail to comply with the test requirements, two
additional samples shall be drawn and tested at the cost of the
vendor. In the event of either of these two samples failing to comply
with test requirements, the supply shall be rejected.
Job No: 730176 IV - 18

o MARKING
The belting shall be marked at intervals of 5 to 10 meters on the

surface with the maker's name, the trade mark if any and the
manufacturer's identification code including quarter and year of
manufacture.
o GUARANTEE
The tenderer shall give guarantee that the belting offered shall meet
the ratings and performance requirements stipulated in this
specification. The guarantee shall be for a minimum period of 12
months from the date of commissioning or 24 months from the date
of receipt, whichever is earlier.
4.1.2.6 DETAILS AND LITERATURE
The following information shall be included in the offer :
• General description with supporting literature and leaflets, sectional

views giving details of construction.
• Specification sheet completely filled in as per enclosed proforma.
Failure of supplier to comply with this requirement may result in
rejection of offer.
• Inspection and test reports shall be submitted before the delivery.
• Instructions for storage, installation, jointing, operation and
maintenance of belting shall be given along with supply.
• The supplier shall give necessary information regarding his
manufacturing, executive and financial capabilities along with
following details of past supplies.
• Name and address of installation / organisations that are using
similar belting & type of material being carried.
• Year of supply with order number and date (minimum three different
orders to be indicated).
• Manufacturing capability of the manufacturer.
• Quality control and R&D facilities available with the manufacturer.
• User's performance certificate, if any.
Job No: 730176 IV - 19

4.1.3.0 CONVEYOR BELTING STEEL CORD (MECH-03)
4.1.3.1 SCOPE OF SUPPLY
This specification covers the design, manufacture, construction features,

performance requirements for supply and installation of steel cord belting
along with splicing and vulcanizing material.
4.1.3.2 APPLICABLE STANDARDS AND CODES
The belting shall be designed and manufactured, unless otherwise

specified, in accordance with the latest revision of ‘DIN-22131’ standard and
other associated ISO, DIN and other relevant international standards.
4.1.3.3 DUTY REQUIREMENTS
The belting shall be heavy duty type , capable of handling lumpy coal
containing shale and suitable for round the clock operation in marine
environment laden with dust as well as humidity . The conveyor may be
semi covered or uncovered. The belting shall, therefore, be suitable for
extra environmental condition variation from 4 degree to 50 degree Celsius
and relative humidity upto 100%. The basic parameters of the conveyors
are given in the Technical Data Sheet of Conveyor Belting’ (Appendix-B) of
this document.
The belting shall be designed and constructed such that it gives smooth
service under the stipulated working conditions. The belting shall primarily
consist of one layer of longitudinal steel cords embedded in rubber
compound. The whole belt shall be fused or vulcanized together in
accordance with the best manufacturing practice, The belt edges shall be
completely sealed against ingress of moisture.
To protect the belt against longitudinal slits, the belt shall have rubberized
steel insertion strips/ polyamide fiber reinforcement in traverse direction at
regular intervals. The spacing of the reinforcement shall be designed
keeping in view the duty requirement, belt strength and the material being
handled and to inhibit longitudinal cuts. Belting shall be provided with rip
and impact protection by layer of traverse synthetic cord located between
top cover and steel cord as well as bottom cover and steel (full width & full
length).
The belt shall have sufficient strength to give required tension at 10 (ten)
factor of safety and 80% tension utilization
The belting shall have the following features.
Job No: 730176 IV - 20

4.1.3.4.1 STEEL CORD
Steel cord used in the belt shall be manufactured from high grade carbon
steel to provide high flexibility for increased fatigue resistance, less elasticity
and permanent elongation .The steel cord shall be coated with adequate
quantity of zinc to protect the steel from corrosion and to assist adhesion
between the wire and rubber.
The steel cords used shall be of reputed make as indicated in the vender
list.
4.1.3.4.2 BELT LENGTH
The total length of belting shall be not less than the specified length. The
length in the individual roll shall be within (+) 2% and (-) 0.5%.
4.1.3.4.3 BELT WIDTH
The width of the belting shall be within (+) 1.5% and (-) 0% of the specified
nominal belt width.
4.1.3.4.4 BELT EDGES
At each edge of the belting the distance between the edges and the outer
cord shall be not less than 15mm.
4.1.3.4.5 BELT THICKNESS
The mean overall belt thickness shall be within (+) 1.5 mm and (-) 0.5 mm of
the specified nominal belt thickness. The difference between any two
measurements taken shall not exceed 10% of the mean belt thickness.
4.1.3.4.6 COVER THICKNESS
The specified cover thickness shall be within (+) 1.5 mm and (-) 1.0 mm of the
specified nominal cover thickness . The specified cover thickness shall include
any transverse reinforcement.
4.1.3.4.7 CORD PITCH
The cords shal be evenly spaced across the width of belting and shall lie in
one plane subjected to the following tolerance:
- 95% of all cord pitches shall be within (+/-) 1.5 mm of the specified
nominal pitch.
- The distance between the centers of the two outer cords of the belting,
when measured along the cord pitch, shall be within (+/-) 1.5% of the
figure calculated by multiplying the number of pitches in the belting by
the specified nominal pitch.
- The steel cords of the belting shall lie in one plane. The permissible
dislocation of cord vertically shall be within (+/-)1.00 mm.
Job No: 730176 IV - 21

4.1.3.4.8 CORD DIAMETER
The tolerance on the specified cord diameter shall be within (+/-) 5%.
4.1.3.4.9 JOINTS IN CORD
Cord joints shall be avoided, as far as possible. In any length of finished

belting the number of individual spliced cord joints permitted shall be as
follows:
• Not more than one joint in any one cord;
• Not more than one cord joints per 10 metre of belting;
• Not more than one cord joint in belts containing upto 50 cords;
• Not more than two cords joints in belts containing 51 to 100 cords;
• Not more than three cord joints in belts containing over 100 cords;
4.1.3.4.10 FREEDOM FROM DEFECTS
The belting shall be straight when rolled out flat. The surfaces and edges of
finished belting shall be free from blisters, pitting and other surface defects
and shall be completely sealed against the ingress of moisture.
4.1.3.4.11 TENSILE STRENGTH OF BELTS AND CORDS
The breaking strength of the belt shall be calculated from the breaking
strength of the cords. The measured cord strength shall not be less than the
minimum cord strength as stated by the manufacturer. The bidder shall submit
cord manufacturer’s Quality Assurance Certificate for the steel cord breaking
force.
Belt strength KN/meter of belt width shall be calculated as follows:-

= Cords strength (KN) X No. Of cords
Belt width (m)
4.1.3.4.12 ADHESION
i. CORD PULL -OUT STRENGTH
The adhesion between rubber and steel cord shall be determined by pull-out
force as per ISO-7623. The values of pullout force shall not be less than rhe
values specified in DIN 22131.
ii. COVER ADHESION
The mean adhesion strength between cover and bonder/core rubber shall not
be less than 12 N/mm of belt width (as per ISO-8094).
Job No: 730176 IV - 22

4.1.3.4.13 BONDING / CORE RUBBER
Bonding /Core Rubber used between rubber and steel cord shall provide high
strength bonding between steel cords and rubber and also flow into the
interstices of the cord during the vulcanizing process.
The tensile strength of the bonding rubber shall be not less than 18 N/sq. mm
(as per DIN -53504). The elongation at break (as per DIN-53504) shall be not
less than 350%. The tearing strength (as per DIN-53507) shall be not less
than 12 N/mm².
4.1.3.4.14 COVER RUBBER
The cover rubber shall be made of natural/ synthetic rubber as main material
so that it is excellent in abrasion, impact and flexing resistance and make it
suitable for surface operation.
The cover rubber shall be of FRAS (Fire resistant Anti-static) type. The tensile
strength of the cover rubber shall be not less than 25 N/sq. mm (as per DIN-
53504). The elongation at break (as per DIN-53504) shall be not less than
350%. The tearing strength (as per DIN-53507) shall be not less than 12
N/mm². The abrasion of cover rubber shall not exceed 120 cu.mm (as per
DIN-53516).
4.1.3.4.15 MARKING
The belting shall be clearly marked on the carrying side. The character height
shall be not less than 80 mm , the marking shall be repeated a maximum
longitudinal spacing of 10 metres, at approximately 80 mm from the left and
right edges of the belting alternatively. The marking shall be sufficiently
durable.
The following identification marks shall be applied on the carrying side of the
belting:
- Manufacture’s identification
- Belt type
- Cover thickness of carrying and running side
- Cover grade
- Mark /batch number
- Month and year of manufacture

4.1.3.4.16 QUALITY ASSURANCE SYSTEM

The manufacturer shall establish and maintain a quality assurance system to
the satisfaction of the purchaser. The system shall ensure that the
manufactured products meet the requirement of this specification. The bidder
shall submit the quality assurance plan along with the bid.

Job No: 730176 IV - 23

4.1.3.5 SAMPLING AND TESTING SYSTEM

4.1.3.5.1 SAMPLING
Depending upon the length of conveyor belting of the same characteristics

(i.e. type, width etc.) the sample shall be drawn in accordance with following
table given below:
Length No. of samples
Up to 500 m 1
501 m to 1000 m 2
1001 m to 2000m 3
2001m to 3500m 4
3501 m to 5000m 5
5001 m to 7000 m 6
7001 m to 10000 m 7
The sample shall not be tested within two days after the manufacture of the
belting.
4.1.3.5.2 TESTING
Following tests shall be performed in the presence of purchaser or his
authorized representative:
- Belt width;
- Belt thickness
- Cover thickness
- Cord diameter, number of cords and cord pitch
- Breaking force of the steel cord from the belt
- Cord pull-out strength
- Cover adhesion
- Tensile strength , % elongation at break , abrasion resistance and
hardness of cover rubber ( for as manufactured as well as artificial
ageing).
In case the purchaser is not in a position to witness the tests the supplier shall
maintain adequate records of having carried out the tests and forward the test
reports as specified elsewhere in this document.
Job No: 730176 IV - 24

4.1.3.5.3 RETEST AND REJECTION
In case the sample fails to comply with the specified requirements, additional
two samples shall be drawn and tested to check compliance with the specified
requirements at the cost of the supplier. In the event, any sample fails to
comply with the specified requirements, the supply shall be rejected.
4.1.3.5.4 TEST AND INSPECTION
The purchaser shall have the right to carry out inspection during
manufacturing. Such inspection shall not, in the event of any defect noticed
later , entitle the supplier to plead that inspection has been done by the
purchaser and absolve themselves of the obligation . Necessary facilities
shall be provided by the supplier to the purchaser top carry out such
inspection.
The test and inspection shall be carried out in the presence of the purchaser,
as per DIN- 22131 and other relevant BS, DIN, ISO and international
standards, for which all facilities shall be provided by the manufacturer at his
own costs. All costs for sampling, testing and inspection shall be borne by the
manufacturer.
The manufacturer shall also make available to the purchaser’s inspecting
personnel all the relevant standards and codes of practices for manufacturer,
inspection and testing of the material / product equipment. The manufacturer
shall also make available a set of meters, gauges, instruments, testing
equipment etc. as may be required for testing and inspection to check that the
products are in compliance with this specification.
Job No: 730176 IV - 25

SCHEDULE OF BELTING
(Annexure II)
SL. Belt Type Length Type Designation Cover Top cover Bottom cover
NO width (m) grade thickness(mm) thickness(mm)
(mm)
1 1200 N-N 140 Heavy 800/4 M24 5 3

Duty
2 1600 N-N 2100 Heavy 1750/5 M24 6 3
Duty
2 1600 Steel 3350 Heavy ST 2000 8 6
chord Duty
4 1800 Steel 2200 Heavy ST 2500 10 8
chord Duty
Job No: 730176 IV - 26

4.1.4.0 MECHANICAL VIBRO FEEDER (MECH – 04)
4.1.4.1 INTRODUCTION
The vibratory Feeder will be installed below the truck receipt hoppers to
reclaim coal from the hopper and load on to the belt conveyor C2A & C2B.
4.1.4.2 SCOPE
The scope shall cover design, manufacturing, testing before dispatch, delivery
at site, installation at site. This shall be read in conjunction with the
specifications described below. The scope of supply shall consist of the
following:
¾ Mechanical vibratory Feeder consists of deck, vibrating mechanism,

shock absorbing devices, drive unit etc.
¾ Special tools and tackles.
¾ First fill oil and grease.
¾ Maintenance, operation manuals, spare parts catalogue.
¾ Drawing showing the dimensions, foundation details, load data etc.
4.1.4.3 DUTY
The vibratory Feeder will normally operate for 15 to 18 hours in a day however
it will be designed and constructed for round the clock operation.
The vibratory feeder shall operate in the range of 4-50 degree centigrade
ambient temperature, up to 100% relative humidity and dusty environment.
It shall be able to receive coal from the hopper. It shall be able to start at full
load and meet the required duty requirement.
4.1.4.4 TECHNICAL PARAMETERS FOR DESIGN

i. Rated capacity - 600 tph
ii. Material to be conveyed - Crushed ROM coal mixed
with shale sand stone,
small quantity of clay, soil
iii. Bulk density of coal - 0.8t/cum.
iv. Largest lump size/ minimum
lump size - (-)100 mm/fines
v. % of largest lump size - 80%
vi. Compressive strength of coal - 500 kg/sq.cm.
vii. Hardness of coal - 50 HGI
viii. Abrasively of coal - slightly abrasive
ix. Presence of clay - small quantity
x. Presence of tramp iron - small quantity
xi. Method of feeding to the feeder - from hopper.
xii. Water will be added - small quantity will be
Job No: 730176 IV - 27

4.1.4.5 CONSTRUCTION FEATURES

The vibratory feeder shall be robust in construction, requires minimum head
room, requires minimum maintenance gives uninterrupted operation with
minimum down time.
The vibratory feeder shall have long stock and low frequency of vibration with
provision of slope adjustment feature. The feeder shall be adoptable to
manual, remote of automatic control system and shall have provision to
achieve variable feed rate.
The vibratory feeder shall mounted on coil springs and floor mounted. The
feeder shall be able to absorb the impact due to free fall from the hopper.
The drive force may be supplied by ratting eccentric weights or any other
method so that required duty parameters can be achieved.
The feeder shall have quick starting smooth stopping feature and shall
operate at low noise level. The noise level shall be under 80 db within one
meter of the unit with the tray empty.
4.1.4.6 DECK
The frame shall be rigid and shall be rigid and shall be made from thick steel
plates. They shall consists of steel plates. The deck plate and side plate will
be provided with replaceable wear resistance plates of minimum 10 mm thick.
The wear resistance plate shall be fitted with counter sunk bolts or any other
method the wear resistance plates shall be sections to facilitate for easy
transportations.
4.1.4.7 COUNTER WEIGHTS

Counter weight will be mounted on a shaft made from forged steel without
cracks. The shaft shall be of one piece and made of high tensile steel and
properly machined. The shaft shall be mounted on heavy duty spherical roller
bearings. Timing gears shall be of single helical design made from heat
treated steel have a long service life under heavy loading. The gears and
bearings shall be housed in a casing having automatic oil splash lubrication
with adequate heat dissipation arrangement to ensure low bearing
temperature. Suitable seals shall be provided to prevent the oil leakage.
4.1.4.8 SUPPORT
The supports of feeder shall be capable of carrying the entire load and prevent
the vibrations being transmitted to the surrounding structures. The base frame
on which the feeder is mounted shall be of rolled steel sections of suitable
size. Suitable size machine drilled holes shall be provided in base frame for
fixing it on foundations.
4.1.4.9 DRIVE UNIT

The vibratory feeder shall be driven by an electric motor or adequate capacity
through ‘v’ belts or cordoned shaft. No chain drive is acceptable.
Job No: 730176 IV - 28

4.1.4.10 MOTOR
The motor shall be squirrel cage, induction motor, foot mounted, high torque,
TEFC enclosure, IP54 protection, DOL starting, continuously rated, class ‘B’
insulation, synchronous speed 750/1000 RPM, suitable for 415V, 3 phase 50
Hz supply, suitable to withstand +/- 10% voltage variation, +/- 6% frequency
variation, cable end boxes shall be suitable for PVC insulated PVC sheathed
cables of three core wit copper conductors of suitable size. The motor shall
conform to IS 325, IS 1231. This shall be of reputed make.
4.1.4.11 BELT DRIVE

A suitable multiple ‘V’ belt drive or flat belt drive may be used for reduction of
speed. The transmitting capacity of belt shall be as per relevant standards.
4.1.4.12 LUBRICATION
Proper lubrication arrangement shall be provided. The grease nipples etc. if
provided shall be easily accessible.
4.1.4.13 GUARDING
All the rotating parts shall be provided with guards as per relevant Indian
Standard.
4.1.4.14 PAINTING
The entire surface exposed to weather shall be thoroughly cleaned and
applied with two coats of signal red lead primer over which two coats of gray
color paint shall be applied. These shall conform to relevant Indian standards.
Job No: 730176 IV - 29


4.1.5.0 ROTARY PLOUGH FEEDER (MECH-05)
4.1.5.1 BASIC PARAMETERS
• Qty : 4 Nos.
• Location :Over reclaim conveyor no.C7 & C8
• Capacity :3000 TPH
Design :1800 to 3600 TPH (Variable)
• Material to be handled : Crushed coal containing
shale/sandstone up to 30%
• Bulk Density : 0.8 to 1.2 t/m3
• Material size : (-) 100 mm
• Maximum inherent : 8% moisture content
• Travel length : Bunker length +
Length of maintenance bay
4.1.5.2 DUTY CONDITIONS
The Rotary Plough Feeder shall be suitable for continuous duty to reclaim coal
from self-flowing semi ground bunker of 15000 t. Capacity. The m/c shall be
capable of reclaiming simultaneously from two shelves. The plough feeder
shall be installed over the slit opening running along the length of the bunker.
The feeder shall be capable of handling slurry material in rainy season,
traversing continuously, reversing or positioning at any point along the entire
length of the reclaim shelves for maximum flexibility. The equipment shall be
required to operate 20 hours a day and 330 days a year; but the design shall
be such that it can be operated 24 hrs. a day and 365 days a year. The
surrounding may be quite dusty and surface temperature may vary from 4°C
to 50°C and relative humidity up to 100%.
The rotary plough feeder mechanism shall consist of curved arms revolving on
a vertical axis to discharge the material from shelves on to a belt conveyor
through a traveling chute, skirt board and adjustable dust seal etc. and shall
have the following specific features.
4.1.5.3.1 DISCHARGE WHEEL
This shall consist of six (6) radially displaced discharge arms spaced equally
round the central hub of the discharge wheel. The discharge arms shall be
easily replaceable from the driving hub.
The discharge arms shall be made of wear resistant alloy steel and shall be
hard faced by welding.
Job No: 730176 IV - 30

4.1.5.3.2 DISCHARGE WHEEL DRIVE
Smooth and infinitely variable control of the discharge wheel speed shall be
provided by a hydraulic drive system. The prime mover shall be single speed
non reversing, flame proof/explosion proof induction motor suitable for
operation at 415 V, 50 Hz, 3 Ph. A.C. supply. Maintenance free safety facilities
shall be provided against overload, jammed arms etc. Speed of the discharge
wheel shall be capable of remote automatic control as well as manual
adjustment at local panel.
4.1.5.3.3 MACHINE TRAVEL DRIVE
The rotary plough feeder shall traverse in either direction (forward and
reverse) along its entire length by means of a 415 V, 50 Hz 3 phase reversible
motor, fluid coupling, reduction gear units. The travel drive shall be
constructed as 4 wheel drive. The travel shall be fully automatic and self-
reversing by means of heavy duty travel limit switches/ anti-collision switches
mounted on the machines.
The machine travel shall also automatically reverse travel direction in case, the
feeder trespasses the predetermined operating zone of the other feeder. The
machine shall also be capable of operating on 1% sloping travel rail.
4.1.5.3.4 MAIN HOUSING
All the bearings, shafts for the discharge wheel drive as well as the machine
travel drive shall be housed in a single totally enclosed split sealed housing of
heavy duty construction. The housing shall have provision for inspection and
maintenance including a float switch and sight-glass for protection and
observation of gear box oil level. Lifting eyes shall be provided. The travel
drive housing shall be provided with seals against ingress of dust and
moisture.
The main housing shall be also support the discharge chute. This shall be
made from 8 mm thick mild steel plate, suitably stiffened and lined with wear
resistant rubber or equivalent lining material. The discharge point shall be
completely dust tight.
4.1.5.3.5 MOVABLE DUST COLLECTING SYSTEM
The plough feeder shall incorporate movable dust extraction system suitable
for operation in slit type bunker. The movable dust collector unit shall be
complete with all necessary accessories like radial ventilator, bag filter, valves,
motors and electrical controls etc. Separate price should be quoted for this.
Job No: 730176 IV - 31

4.1.5.3.6 LUBRICATION
All gear assemblies shall be filled with commercial quality oil and the hydraulic
system with hydraulic oil of best quality. Other parts needing lubrication shall
be provided with centralized lubrication system.
4.1.5.4 PLOUGH FEEDER DISCHARGE CHUTE
BASIC PARAMETERS
• Qty : 4 Nos.
• Location : Over reclaim conveyor no.C7A &
C7B
• Capacity : 3600 TPH
Design : 1800 to 3600 TPH (Variable)
• Material to be handled : Crushed coal containing
shale/sandstone up to 30%
• Bulk Density : 0.8 to 1.2 t/m3
• Maximum inherent : 8% moisture content
• Travel length : Bunker length up to slot openings
4.1.5.4.1 CHUTE FITTINGS
The chutes shall be fitted below the rotary discharge wheel of plough feeder.
The chute shall be constructed of Mild steel plates of adequate thickness (Min.
8 mm) and suitable braced and stiffened to withstand the loads imparted. It
shall have a minimum slope of 55° to the horizontal. The chutes shall be
provided with easily replaceable wear resistant polyurethane liner, of suitable
thickness. Painting finish shall be in accordance with IS: 1477 (current) and
three coats of approved paint shall be applied. Chute discharge opening shall
be 1000 mm x 1000 mm minimum. Anti clog nozzle for atomized water spray
shall be fitted on chute body at suitable location.
4.1.5.5 HYDRAULIC SYSTEM
4.1.5.1 HYDRAULIC POWER PACK
Hydraulic system shall be supplied for operation of the rotary discharge wheel.
The system shall provide for maximum reliability. The rating of all hydraulic
equipment/ component shall be well above the duty for operation in tropical
climate and dusty atmosphere. The system shall be operative for three shift
working.
Hydraulic system shall have its own power pack unit. The power pack unit
shall incorporate hydraulic pump set with electric motor. Fluid supply tank fitted
with necessary pressure and control equipment, continuous filtration package,
pipe work etc. and mounted on steel skid shall form integral part of the system.
All equipment shall be rated for continuous duty in the range of climatic
Job No: 730176 IV - 32

conditions prevailing at the site.

Fluid supply tank shall have ample capacity appropriate to its duty. It shall be
fabricated in mild steel and provided with flanged connections for the supply
and return pipes. Provision for complete drainage shall be made and flanged
apertures for sludge removal shall be incorporated. All components internal to
the tank shall be easily accessible to facilitate cleaning and maintenance.
All pipes returning fluid to the tank shall terminate at a level sufficiently below
the fluid surface to prevent aeration. Suction pipe shall be fitted with a highly
efficient filter positioned well below the fluid surface to prevent vortex
formation. Preferably the pump may be provided with positive suction head by
elevating the tanks above the pumps. The piping system shall be completed
with shut off valves, valves, flow control valves & flow dividers as necessary.
The tank shall be equipped with the following gauges.
• Sight glass giving clear visual indication of fluid level.

• Low fluid level device with visual and audible alarms.
• Temperature sensing device with visual and audible alarms.
• Pressure gauges
• Breather assemblies.
All hydraulic pipe / hose work shall follow the shortest practicable route in neat,
straight runs, readily accessible for maintenance (ease of disassembly and
replacement) yet sited in a position which presents least risk of mechanical
damage).
Pipe-work in unavoidably exposed position shall be effectively protected and
all pipe work shall be adequately supported. All pipe fittings to be used in
construction of power unit shall conform to relevant IS specification. The
complete equipment shall be designed to operate at the lowest possible
pressure to minimize leakage and maximize equipment life. Electronic motor
shall be squirrel cage induction motor suitable for 415 ±5% volts, 3 phase, 50
± 3%Hz operation of suitable rating.
The power-pack shall incorporate an oil cooler with continuous filtration circuit.
In view of the high ambient air temperature, prevailing at the site, it may be
necessary to provide water cooling. The auxiliary filtering package shall
consist of a pump with an adequate rating motor and filter assembly.
The hydraulic system shall be controlled from the central micro-processor
based control system located in the control room. Provision is to be made for
the system to react to operating signals from this control room and to return
system status information for display on the control panel. Control and
adjustment for local panel shall also to be incorporated.
Hydraulic seals shall be suitable selected to prevent ingress of dust and
moisture and to provide for longer life.
The hydraulic power pack system shall be mounted suitable on the machine.
Job No: 730176 IV - 33

4.1.5.6 DUST CONTROL
A sufficient number of precision and antic log nozzles made of brass/stainless

steel shall be fitted at suitable places at the plough feeder discharge chute for
suppression of dust during reclaiming operation. The nozzles shall provide
high-pressure atomised sprays of water for effective suppression of coal dust.
Water is to be atomised by compressed air and in the resonance zone of
nozzles, the wetted dust particles are to be agglomerated and suppressed at
the source. The formation of mud and crust shall have to be avoided.
The technical component shall include water and compressed air filters, air
compressor, piping & mounting system with pressure regulating valves /
panels & nozzles. The moisture charge shall be in the range of 1-2% only.
The dust suppression system shall be so interlocked that it operates only when
the reclaiming operation is on.
Festoon type piping arrangement for supply of compressed air & dirt free clean
water to nozzle units are to be incorporated in the system.
4.1.5.7 MAINTENANCE MONORAIL HOISTS AND CHAIN PULLEY BLOCKS
Necessary monorail electric hoist and chain pulley blocks of adequate capacity
at suitable locations shall be provided.
4.1.5.8 COMPLIANCE WITH STANDARDS
The design, selection, construction of equipment, component and material

shall conform to relevant Indian Standard Specifications and Codes of
Practices incorporating latest revisions or any other equivalent International
Standards.
4.1.5.9 ELECTRICAL
4.1.5.9.1 GENERAL
Electrical equipment shall be suitable for operation at 415 volts, 3 phase, 50

Hz.Power supply to the equipment and other facilities will be made available
through 1.1 kV grade cable feeders which will be laid in trench from MCC
room. These cables will be terminated at four points at the extreme ends of the
bunker.
4.1.5.9.2 MOTORS
The TEFC squirrel cage induction motor(double cage type) will be fitted to
each plough feeder. These motors shall be suitable for operation on a 415
volts 3 phase, 50 Hz supply with variation of 5% on voltage and 3% on
frequency. It shall be foot mounted type with dimensions as per relevant IS.
The motors shall be of flame proof construction and tested to IS: 2140 and
class of insulation shall be 'F' conforming to IS: 1271.
Job No: 730176 IV - 34

4.1.5.9.3 ELECTRICAL CONTROL SYSTEM
The electrical power distribution system for the rotary plough feeder shall
include the following:
POWER CIRCUIT
This shall incorporate all the necessary isolating switches, protection

circuit breakers, contactors, fuses, protection relays, single phasing
preventor, timers etc. housed in enclosure of dust and damp proof
construction confirming to protection class of I.P. 55. The cubicle will be
installed in a separate room at the end of the bunker.
CONTROL CIRCUIT
The control circuit shall be provided for following machine operation.
o To delay the start up of the travel motor until the discharge wheel
has commenced to rotate.
o To automatically stop and reverse the direction of machine travel
at each end of the bunker and via anti-collision switches on the
machine and proximity and/or lever roller operation limit switches.
o Automatic travel reversal in case of jamming of discharge wheel
due to compact material, tramp material or otherwise.
o Manual adjustment of discharge wheel speed for variation in
output.
o Reclaiming of material without machine travel.
o Indication of various machine operating conditions like faults,
machine running etc.
o Automatic stop in case of electrical or hydraulic faults.
o Audio/visual alarm in the control room for reclaim conveyor TPH
going beyond 10% of rated capacity.
o Motor protection relay and earth leakage relay.
LOCAL CONTROL PANEL
Manual operation shall be accomplished by the use of a local panel.

The enclosure shall have the following operational controls and
other emergent conditions requiring urgent attention.
PUSH BUTTON
o Emergency stop
o Start push button for discharge wheel
o Reset ( to reset flasher in fault advising)
o Discharge wheel speed adjustment (Increase-Decrease)
o Machine travel speed adjustment (Faster-Slower)
o Machine travel with constant speed.
Job No: 730176 IV - 35

SWITCHES
o Travel Drive - On/Off

o Travel Drive - Left/Right Only Local
o Remote-Local to select local panel or remote panel
ANNUNCIATOR LAMPS (LOCAL)
o Low level of oil gear box

o Low level of oil hydraulic
o High oil pressure
o Hydraulic oil temperature
o Discharge wheel motor – overload
o Machine traverse – overload
o Servo motor –overload
o Maintenance mode
o Local mode
o Remote mode
o Travel left
o Travel right
INSTRUMENTS
o Ammeter for discharge wheel drive

o Speed selector dial
o Speed indicator
It shall also be possible to perform all the functions in remote mode from the
coal handling plant control room.
CATENARY CABLE SYSTEM

GENERAL
The rotary plough feeder shall be supplied with a catenary cable system
designed to supply for power and control to the machine and back to the
control room.
CABLE
FLEXIBLE CABLE FESTOONING ARRANGEMENT
The flexible power and control cables of 1.1 kV grade of adequate size shall
be supplied in sufficient quantity to cater for the machine travel distance of
bunker section plus maintenance bay. The cables shall be VIR insulated, fire
resistant conforming to relevant IS (latest revision).
Job No: 730176 IV - 36

CABLE TROLLEYS
The flexible cables shall be supported by means of cable trolleys of the swivel
type, designed to enable the cables to be stacked in a minimum space.
The trolleys shall be complete with cable clamps and steel wheels fitted with
ball bearings with life sealed greasing arrangement.
TERMINAL BOX
Terminal boxes shall be supplied complete with terminals for catenary cable
system and shall be designed to receive customer’s power supply cables,
power supply cable to rotary feeders and control cables.
4.1.5.10 INSPECTION AND QUALITY CONTROL
4.1.5.10.1.SPECIAL MATERIAL
The manufacturer should furnish during inspection, without extra charge test
certificates covering mechanical properties and chemical composition for
special raw materials used including that of liners.
The certificates should be from the approved testing laboratories like CMERI,
Durgapur, NPL, New Delhi etc. If considered necessary, samples for such
material and components may be selected as per IS:1548(current) by the
customers representative from amongst the raw materials and manufactured
components of equipment and got tested in the approved laboratory. In case,
samples so selected fail to meet the standard specifications, the whole lot of
the manufactured components will be rejected and disqualified for use again
for any CIL supplies.
4.1.5.10.2.STAGE INSPECTION
The customer reserves the right for carrying out inspection at any stage of the
process of manufacturing and assembling for which all facilities shall be
provided by the manufacturer. Before carrying out such inspection, necessary
advance information shall be given to the manufacturer.
4.1.5.10.3.AVAILABILITY OF STANDARD SPECIFICATION METERS, GAUGES,

ETC. FOR TESTING & INSPECTION
The manufacturer will maintain all relevant standards and codes of practices
for manufacture, inspection & testing of components of the equipment ordered.
He will also maintain a set of meters and gauges etc. as may be required for
testing and inspection of components.
Job No: 730176 IV - 37

4.1.6.0. RAPID LOADING SYSTEM (MECH-06)
4.1.6.1. BASIC DATA
• Number of Silo : 2 (Two)

• Capacity of Silo(live) : 4000 t
• Bulk Density : 1.2 t /m3(For load calculation)
: 0.8 t/m3 (For cap. calculation)
• Silo side slopes : 70o to the horizontal
• Number of outlet at Silo : 2 (two) nos. above the each Pre
weigh discharge hopper
• Inside diameter of : 18 Meters
the silo
• No. of Pre: weigh hopper : 2 (Two) in each Silo
• Loading capacity : 5500 - 6000 tph
• Type of loading chute : Swing chute
• Construction material details : R.C.C. (Refer civil section)
• No. of holes to be provided : As required for pneumatic arch
breaker
• Silo liner material : Ref. Civil section
• For any other relevant details : Ref. Civil section
4.1.6.2. GENERAL FEATURES
The silo shall be of R.C.C. construction and designed to take all the loading as
required for the system. Necessary RCC / structural work shall also be
provided to house, the arch breaker access platform, freight cum passenger
lift, staircase etc. The structural work shall also include necessary platforms,
cross over, ladders / stairs etc. as elaborated elsewhere and as may be
required for efficient working and maintenance of the system.
The silo shall be designed on the basis of mass flow concept so that chances
of arching and bridging, rat holing at silo outlet is minimized. However,
because of wide fluctuations in the condition of the coal being fed into the silo
and due to seasonal impurities etc. there may be possibility of arching or
bridging. To overcome the situation, pneumatic arch breaking device (as
elaborated elsewhere) shall also be included. Adequate number of holes shall
be provided around the silo at suitable locations. The holes shall be fitted with
discharge tubes and flanges for quick and easy mounting of pneumatic arch
breaker. The sloping sides of the silo shall be at minimum 70o to the horizontal.
Below each outlet of the silo, a rolling slide type maintenance gate which is
operated by hand pump operated power pack. A rolling double bladed over
lapping slide gate will be mounted below this maintenance gate named
discharged gate. Below this discharge gate there will be Pre weigh hoppers
from which Unit Load Swing Chutes Cum Flow Control Gates will be
assembled.
Job No: 730176 IV - 38

4.1.6.3. LEVEL INDICATION INSIDE SILO
The level indicators provided shall monitor the following:
• Continuous level of coal in the silo.

• Predetermined high coal level in the silo which will automatically stop
the silo in feed conveyors. This should ensure that coal in the highest
position will not touch structures on top of the silo.
• Pre determined intermediate level.
• Predetermined low level in the silo which will automatically close the
silo outlet gates. It may be just above the RCC conical portion inside
the silo. This is to prevent damage to any R.C.C. work and the silo
outlet gates.
The gate shall remain closed and in operative until predetermined intermediate
level of coal is reached. The equipment shall be ultrasonic type complete with
sensors, transducer and limit controllers together with audiovisual signaling
system for different levels. In addition to the direct reading device/ comparator
shall also be incorporated to detect excessive differential levels across the silo
which may occur in the event of certain adverse flow conditions. This shall
indicate as audiovisual alarm to alert the supervisor and enable him to initiate
necessary measures. Suitable accesses for maintenance for level sensor are
to be provided.
4.1.6.4. PNEUMATIC ARCH BREAKERS
The arch breakers shall be compressed air operated. Separate air compressor
shall be supplied for operation of the arch breakers.
The arch breakers shall be designed to suit the duty requirement and shall
discharge air into the coal with sufficient energy to break the arch and shall be
located around the perimeter of the silo in two levels. In order to ensure trouble
free material flow from the coal silo, min. 28 numbers of Air Cannons shall be
provided at each silo. The Air Cannon shall be complete with air vessel, dryer,
mountings, accessory package and inter connecting piping etc
The location of 28 Air Cannons shall be as given below:
a) 20 Nos.(min) Air Cannons of minimum 625 litre capacity shall be

mounted on the concrete portion of the silo in two levels.
b) Location and firing sequence, however, is to be designed by the
tenderer and submitted for approval.
Each air blaster shall consist of a reservoir tank to store air under pressure
with external discharge valve assembly. On command through a
programmable electronic controller emerging solenoid valve, a given quantity
of air should suddenly be injected into arch formation to help material flow.
Air blaster vessel shall be fabricated from boiler quality MS plates as per
Job No: 730176 IV - 39

relevant IS code IS: 2002. It shall be designed conforming to IS: 2825. The
vessel shall be painted with corrosion resistant epoxy paint on inside surfaces
over one coat of epoxy primer and one coat of red oxide primer followed by
two coats of synthetic enamel over external surfaces.
The discharge valve assembly shall be made of carbon steel with chrome
plating inner surface and must be mounted externally to the vessel for ease of
maintenance. Size of discharge opening shall ensured free flow.
Air shall be directed from the blaster to the inside of the silo through special
deflectors or diffusers. All air blaster shall have an air release time of about 0.5
seconds and shall be complete with connections sets through tubes to silo,
firing and discharge solenoid assemblies, plug socket assembly, safety valve,
ball valve, check valve, air filter, air lubrication and connecting hoses.
Compressed air shall be supplied to the blasters by a suitable pipe from the air
compressors situated in compressor room. Air blasters shall be suitably
supported from the outside of the silo walls and shall have proper access.
Suitable lifting frame shall be provided over each air blaster for maintenance
purpose Compressed air shall be made available at a pressure of
approximately 7 Kg/cm2.
Necessary sequential control, interlocks, required for the operation of
(individual or all) air blasters shall also be provided for both manual as well as
automatic operation. The operation of air blaster be initiated by supervisor key
switch only. The timer shall be LED display to indicate individual circuit fired
condition.
4.1.6.5. AIR COMPRESSOR
For charging of air blasters 4 nos. air compressors (2 nos for each Silo) are to
be installed in compressor house. The compressor shall have adequate rating
as required both for quickly filling of the tanks of air blasters at a discharge
pressure of 7 kg/cm2, and feeding compressed air to nozzles for dust
suppression.
The compressor shall be stationary reciprocating lubricated double stage type,
preferably air cooled and shall be complete in all respects with electric motor
drive, air receiver of suitable capacity, inter cooler and after cooler with
moisture separator and trap, intake filter with silencer, pressure gauges, safety
valves, non return, valves, oil pressure switch, pressure reducing valve, other
accessories as may be required for smooth operation of the complete system
and all inter connecting pipe work. The operation of air compressor to charge
the arch breaker and also to feed the nozzles for dust suppression shall be
from the control room.
The compressor drive shall be with direct flanged motor. Lift track slots in the
base frame shall be provided for ease of installation.
The compressor shall be fitted with electro pneumatic regulator for three step
(full load, half load and no load) automatic operation.
A fail safe switch shall be provided to stop the compressor set if the oil
pressure drops below a safe limit. Compressor shall be suitable for continuous
multi shift operation.
Job No: 730176 IV - 40

4.1.6.6. MAINTENANCE GATE
Nos : 8 for each Silo

Size : 1525mm x 1525 mm
Automation : Manually operated hydraulic double bladed rolling
slide gate.
Rolling double bladed over lapping slide gate having a opening of 1525mm x
1525mm, operated by two heavy duty hydraulic cylinders will be fitted on the
1525mm opening flanges at the bottom of the overhead loading hopper. This
gate blade shall be made of 25mm mild steel with a 12mm plug welded
abrasion resistant steel liner (SAIL hard or equivalent). This gate shall be
mounted on and friction rollers of the needle type re-greasable cam rollers.
4.1.6.7. DISCHARGE GATE
Nos : 8 for each Silo

Size : 1525mm x 1525 mm
Automation : Hydraulic operated double bladed rolling slide gate.
Rolling double bladed over lapping slide gate having a opening of 1525mm x
1525mm operated by two heavy duty hydraulic cylinders will be fitted on the
1525mm opening flanges at the bottom of the overhead loading hopper. This
gate blade shall be made of 25mm mild steel with a 12mm plug welded
abrasion resistant steel liner (SAIL hard or equivalent). This gate shall be
mounted on and friction rollers of the needle type regreasable cam rollers.
4.1.6.8. SPECIFICATION OF PRE WEIGH HOPPERS:
Nos : 2 Nos for each Silo
i. Pre weigh bin shall be designed to have a nominal flush capacity of 115
m3 to give a live capacity of 90 m3. This is to be located below the silo
and mounted on four nos of compression type load cells [single beam,
double ended shear beam] of capacity but not less than 60 t. Controlled
filling of the weigh bin will be by means of four hydraulically operated
horizontal rolling slide gates positioned immediately above the hopper
but separate from the swing gate at the bottom of the weigh bin used for
emptying. Flexible seals boot type shall be provided between the silo
discharge gates and top of the weigh bin to prevent any interference with
the weighing. The remaining portion on the top of the weigh bin shall be
covered by means of reinforced mild steel plates. The weigh bin shall be
provided with two air vent ducts of flexible pipes connected to the silo.
There will be one outlet for each pre weigh bin. This outlet shall be
controlled by flow control gates located at the bottom of the swing chute.
ii. Lifting points shall be provided for use during the initial erection of the
weigh bin. Jacking pockets shall be incorporated adjacent to each load
cell for lifting of the weigh hopper and removal of load cells for routine
maintenance. The deflection of the weigh bin supporting beam shall be
Job No: 730176 IV - 41

less than 0.5mm. The lifting of the weigh bin will be by means of
hydraulic cylinders.
iii. The weigh bin shall be made of 10mm thick mild steel plates provided
with corner angles and RS section members of adequate size and
thickness to stiffen the plates as necessary and to cater for all
conditions of loading. The weigh bin shall be lined with replaceable
8mm stainless steel (409M) plates and plug welded. The sloping sides
shall be at minimum 70 degree to the horizontal for better flow ability.
Inspection / service manhole shall be provided with weather tight
covers. Adjustable check rods shall also be provided. The corners in
the weigh bin shall be provided with heavy duty steel liner plates to
avoid building of materials.
iv. Under each silo two nos. of weigh bins will be provided.
4.1.6.9. SPECIFICATION OF CALIBRATION WEIGHT SYSTEM:
i) One set of test weights of 25000 kg shall be supplied with each pre
weigh bin for weigh bin calibration. These weights shall be integrally
mounted in the weigh bin system and could be activated by hydraulic
cylinders from the control room located at a remote place.
ii) The certified calibration weights shall be in the form of a number of cast
iron weights placed symmetrically on a spreader bar on either side of the
weigh bin. They shall be removed from/applied to the weigh bin by
hydraulic power pack operated from control room.
iii) The test weights shall be certified and stamped by the Indian weights and
measures department, and shall be constructed from a material such as
cast iron. Certification of the calibration weights will be fully bidder
responsibility.
iv) The electronic check of the weighing instrumentation shall correct any
drift of zero or gain irregularity due to damage of ambient temperature
and this check shall be carried out prior to each train loading as part of
the automatic initialising procedures.
v) Weight calibration is to be carried out on a regular weekly basis
immediately before train loading and shall be completed in 30 minutes
maximum. The frequency of calibration may require to be varied by
circumstances and by experience build up, once system is in operation.
4.1.6.10. SWING CHUTE
Size : 1525mm x 1525 mm

Quantity : 2 nos for each Silo
The swing chute will have a nominal size of 1525mm x 1525mm size opening,
and this will have the following features. 12mm thick IS: 2062 plate will be
used as chute side walls, with 12mm thick abrasion resistant steel plate liner
(SAIL hard plates). This chute will swing in the direction of the train travel. The
swinging action of the chute will ensure control over the positioning of chute.
Chute will have necessary replaceable urethane based seal to minimize the
dust. Chute will have a shear cum crushable section at the lower part of the
Job No: 730176 IV - 42

chute. In case of a roll back by the locomotive or tall wagon and, if the chute is
not retracting in time the shear section will get isolated from the chute and fall
on the locomotive/wagon.
Chute will be activated by a single heavy duty hydraulic cylinder which is
cushioned at both the ends.
4.1.6.11. FLOW CONTROL GATE
This gate shall be located at the bottom of the above chute and shall have a
nominal 1525mm x 1525mm internal opening and shall be of proper non
jamming type design. It shall have the following specific features:
The gate wall shall be of 12mm thick mild steel plates with 12mm thick
abrasion resistant steel liner (Triscal or equivalent) plug welded.
The gate shall be made of 25mm thick mild steel plate with 5mm thick type 304
stainless steel top liner.
The gate shall pivot on a shaft supported by two flange bearings with external
lubricant fittings.
Actuation of flow control gate shall be by two hydraulic cylinders.
The gate opening can be varied between fully close and fully open position, if
requires. The gate position feed back shall be provided by position indicator
connected to the gate blade pivot sheet. On the slides of the chute, skirt plate
of soft rubber shall be provided to ensure that coal does not spill over the side
of the wagons during loading operation.
The operation of the chute & gate has to be controller from the console in the
proposed control room.
4.1.6.12. HYDRAULIC SYSTEM
4.1.6.12.1 HYDRAULIC POWER PACK
Hydraulic system shall be supplied for operation of the silo outlet gates, swing
chute and the flow control gates system. The system shall provide for
maximum reliability. The rating of all hydraulic equipment / component shall be
well above the duty for operation in tropical climate and dusty atmosphere. The
system shall be operative for three shift working.
Hydraulic system shall have its own power pack unit. The power pack unit shall
incorporate two numbers hydraulic pump sets with electric motor of which one
will act as stand bye. Fluid supply tank fitted with necessary pressure and
control equipment, continuous filtration package, pipe work etc. and mounted
on steel skid shall form integral part of the system.
The complete system shall be sized to provide sufficiently rapid action at all
cylinder to achieve the required opening/closing times. These times must
satisfy the fastest duty cycle which is likely to occur when the coal is in its best
state for flow and the rake is over speeding to the maximum tolerance allowed.
All equipment shall be rated for continuous duty in the range of climatic
conditions prevailing at the site.
Fluid supply tank shall have ample capacity appropriate to its duty. It shall be
fabricated in mild steel and provided with flanged connections for the supply
and return pipes. Provision for complete drainage shall be made and flanged
Job No: 730176 IV - 43

apertures for sludge removal shall be incorporated. All components internal to

the tank shall be easily accessible to facilitate cleaning and maintenance.
All pipes returning fluid to the tank shall terminate at a level sufficiently below
the fluid surface to prevent aeration. Each suction pipe shall be fitted with a
high efficiency filter positioned well below the fluid surface to prevent vortex
formation. Preferably the pump may be provided with positive suction head by
elevating the tanks above the pumps. The piping system shall be completed
with shut off valves, valves, flow control valves & flow dividers as necessary.
The tank shall be equipped with the following gauges:

• Sight glass giving clear visual indication of fluid level.
• Low fluid level device with visual and audible alarms.
• Temperature sensing device with visual and audible alarms.
• Pressure gauges.
• Breather assemblies.
All hydraulic pipe/hose work shall follow the shortest practicable route in neat,
straight runs, readily accessible for maintenance (ease of disassembly and
replacement) yet sited in a position which presents least risk of mechanical
damage.
Pipe work in unavoidably exposed position shall be effectively protected and
all pipe work shall be adequately supported. All pipe fittings to be used in
construction of power unit shall conform to relevant IS specification. The
complete equipment shall be designed to operate at the lowest possible
pressure to minimize leakage and maximize equipment life. Electric motor shall
be squirrel cage induction motor suitable for 415 ± 5% volts, 3 phase, 50 ±3%
Hz operation of suitable rating.
The power pack shall incorporate an oil cooler with continuous filtration circuit.
In view of the high ambient air temperature, prevailing at the site, it may be
necessary to provide water cooling. The auxiliary filtering package shall consist
of a pump with of adequate rating motor and filter assembly.
The hydraulic system shall be controlled from the central micro processor
based loading control system located in the control room. Provision is to be
made for the system to react to operating signals from this control room and to
return system status information for display on the control panel.
The hydraulic power pack system shall be mounted on a steel skid.
4.1.6.12.2 HYDRAULIC ACCUMULATOR
The hydraulic system shall also incorporate hydraulic accumulator. The

accumulator system shall act in conjunction with the hydraulic pump during
normal loading operation. In the event of power failure, or emergency
operation shutdown, or pressure failure, closing of flow control gate and
retrieving of the chute to the stored position can be achieved with the help of
these accumulators. The accumulator shall have sufficient capacity for a
normal open/close/position of rolling slides gates, of flow control gate & chute
retractor. The accumulator system shall include necessary hydraulic / electric
control with audiovisual alarms. Pressure at accumulator shall suit the required
duty requirement.
Job No: 730176 IV - 44

4.1.6.12.3 HYDRAULIC CYLINDERS
These shall be of suitable bore and stroke double acting cylinders with
cushions at each end of the stroke. The rods shall be chrome plated high
strengthened steel. Hydraulic seals shall be suitably selected to prevent
ingress of dust and moisture and to provide for longer life. These shall be
designed for twice the normal operating pressure.
4.1.6.13. SPECIFICATION OF HIGH TEMPERATURE DETECTION
Thirty temperature sensors shall be embedded in each silo inside walls at

three levels to detect any local heating and to give a warning in the loading
control room and at the main control room. In the event of over heating being
detected, the system will provide audible and visual warning to enable the
loading supervisor or control room operator to take preventive action before a
major fire occurs. The system shall have battery back up to operate even in
the event of power shut down or failure and be of proven type for similar duty
application.
4.1.6.14. SPECIFICATION OF PASSENGER LIFT
4.1.6.14.1 GENERAL
An Industrial duty freight cum passenger lift shall be manufactured, supplied
and erected as per IS: 14665 current. The lift will be used near silo for carrying
the men and materials required at various floors in the silo complex. The lift
will be with cage and counter. The various floors to be served are control room
floor, floor at which emergency gates operate, floor at which the air cannons
are installed, top of silo and any other floors or levels if felt necessary at the
time of detailed design stage for efficient plant maintenance and operation. All
the materials shall conform to the relevant Indian Standards. The machine
room will be located at the top of the lift shaft.
4.1.6.14.2 DESIGN PARAMETERS

i) Capacity 1200 kg. freight or 15 persons
ii) Speed 0.5 m/s
iii) Lift size 1700 mm wide, 2000 mm deep, 2200
mm clear height
iv) No. of floors to be As per system requirements served
covered
v) Total travel As per system requirement
vi) Control system As per system requirement
vii) Gates at each floor Collapsible gates
viii) Duty requirement As specified elsewhere in the document
Job No: 730176 IV - 45

4.1.6.14.3 SCOPE OF SUPPLY

The scope of supply shall mainly consists of the following:
i) Lift car of 1700 mm wide, 2000 mm deep, 2200mm height
along with fan, light, gate, wheels, frame etc.
ii) Modular C.I. blocks as counter weights
iii) Steel guides along with brackets for movement of lift car and
counter weights
iv) Collapsible iron gates at each landing level / floor, car door
along with locking devices
v) Safety gears for counter weights and lift car
vi) Spring buffers in the bottom of the well
vii) Suitable rope for suspending the car and counter weight
along with rope tensioning devices
viii) Required sheaves and pulleys
ix) Driving mechanism
x) Controllers and operating devices
xi) Indicating devices at each landing floor and inside the car
xii) Required limit switches
xiii) Lifting/Hoisting beams and hoist blocks in the machine room
xiv) Any other materials for the efficient operation of the lift
4.1.6.14.4 CONSTRUCTIONAL FEATURES

The lifts shall conform to IS: 14665 current
The details are as given below
i. LIFT CAR FRAME
The car frame shall be constructed from structural steel, generally consisting of
interconnecting cross beams, upright and plank members which supports the
car platform and provided on each of guide rails with upper and lower guide
shoes attached to the frame.
The car frame shall generally be made of rolled or formed steel. Cast iron shall
not be used for any parts which are subjected to tension, torsion and bending.
Cast iron can be used for guiding supports, guide shoes and anchorages for
compensating rope. Connection between members of car frame shall be
riveted/bolted /welded. Suspension ropes will be attached to steel hitch plates
or structural steel shapes connected to the car frame.
Lift cars shall be enclosed on all sides by means of car body, gates. A solid
roof capable of supporting 4 persons that is 4 x 68 kg will be provided. The car
floor shall be of flat, non-slip surfaces. The inside walls and roof will be
provided with elegant stainless steel surface of suitable thickness.
Each lift car shall be fitted with adequate no of suitable lighting fixtures
provided with on: off switches.
Job No: 730176 IV - 46

The lift car shall be provided with a suitable capacity fan. Ventilation openings
shall be provided in the enclosure above1.8 m level and below 0.15 m level.
The total area of openings shall be not less than 0.035 m2 for each square
meter of area of the car floor. The openings shall be equally divided between
the top and bottom level.
The car enclosure and doors, including their tracks of a lift car shall with stand
a thrust of 345 N applied normally at any point, excepting any vision panel
without permanent deformation.
A three pin plug socket with switch for hand lamp shall be fitted on top of the
lift car for use by persons working there.
Lift car platforms shall be of formed construction and designed on the basis of
rated loads evenly distributed. The minimum factor of safety shall be 5.
Every lift car shall be provided with battery operated emergency light and
emergency alarm. The emergency light shall automatically come into
operation in case of failure of normal power supply.
A separate circuit with control shall be provided in the machine room for fan
and light to permit switching off power to lift without switching off power to light
and fan.
Glass shall be used only for the following:
i) As covers for certificates
ii) For lighting fixtures
iii) For vision panels and mirrors
iv) For appliances used in connection with the operation
of car
ii) COUNTER WEIGHTS

The counter weights shall be of modular construction and made of cast iron
minimum two numbers of tie rods shall be provided to keep the counter weight
sections in place and prevent displacement. These tie rods shall pass through
all sections and properly secured. The factor of safety of steel frame members
and tie rods shall not be less than 5. The counter weights shall with stand the
impact of buffer impact. At least four replaceable guide shoes with renewable
lining or steel roller guides shall be provided, two at the top and two at the
bottom of the counter weights. Suitable capacity counter weights shall be
provided.
iii) GUIDE RAILS
The car and counter weights shall be guided by at least two rigid steel rails
for each unit. The rubbing surfaces shall be machined properly. The guide
rails shall be of standard lengths as far as possible and joined together by
means of welding at site. The strength of guides, their attachments and joints
shall be sufficient to withstand the forces imposed due to the operation of
safety gear and deflections due to uneven loading of car. The fixing of the
guides to their brackets and then to the building shall permit compensation,
Job No: 730176 IV - 47

either automatically or by simple adjustment, effects due to the normal settling

of the building or shrinkage of concrete. A rotation of the attachments by
which the guide could be released shall be prevented.
The building construction forming the supports for guide rails and brackets
shall be of such design as to safely withstand the application of car or counter
weight when stopping the car along with rated load or the counter weight.
Guide rail brackets shall be secured to their supporting structure by means of
bolts/rivets.
iv) GATES AND THEIR CONTROLS

The car and landing openings at various floor/platforms shall be provided
with gates for safety. The gates shall be manually operated collapsible
gates. The collapsible gates (Horizontally sliding) shall be of close picket
type and opening between the two vertical members shall not be more than
5.5cm in width when they are fully extended. The distance between the lift
well side of the car door and lift well side of the landing door shall not exceed
13cm. The distance between the car and landing sills shall not exceed
30mm (shall be properly sealed) the opening for the landing doors shall be
not wider than that of the width of lift car. The minimum height of the door
will be 2m. The landing doors shall be properly secured.
The doors shall be made of steel. These doors shall be of over hang type
properly guided both at top and bottom and shall run on over head track
secured rigidly by suitable means. The doors shall not be sprung from their
guides or tracks in normal service. Arrangement shall be provided for opening
of gates manually.
v) SUSPENSION
Minimum three numbers of independent suspension ropes will be used for car
or counter weight. The car and counter weight shall be attached at two ends
of the rope. The diameter of ropes shall be suitable for the load condition with
a factor of safety 10 and shall not be less than 10mm. The car and counter
weight ends of suspension ropes shall be properly fastened as specified in the
Indian Standards.
Chains shall not be used for suspension. Means shall be provided to equalize
the load on the individual suspension ropes.
Job No: 730176 IV - 48

vi) SHEAVES AND PULLEYS

All the sheaves and pulleys shall conform to Indian Standards and made of
cast iron. These shall be free from cracks, blow holes and injurious defects.
The dia. of the sheaves and pulleys shall be as per IS: 14665 but not less than
40 times rope dia. The grooves shall be machined and dimensions shall be as
per IS: 14665. The sheaves and pulleys shall be supported as per relevant
Indian Standards.
vii) WIRE ROPE

The type of the rope shall be one of those given in IS:46665. The rope shall
conform to relevant Indian Standards. The rope shall be of fiber core type.
The dia. of rope shall be as specified elsewhere in the document. The rope
shall give sufficient life. No rope shall be used with splicing. The car and
counter weight ends of the suspension ropes shall be properly fastened.
viii) SAFETY GEARS FOR CAR AND COUNTER WEIGHT

Every lift car and counter weights shall be provided with a safety gear located
preferably at the lower part of the car and counter weight and capable of
operating in downward direction. It shall be able to stop the car carrying the
rated load/ counter weight at the tripping speed of the over speed governor,
even if the suspension devices break, by gripping the guides, and of holding
the car/ counter weights. The safety gear shall be of instantaneous type. The
safety gear of the car shall be tipped by its own over speed governor. The
safety gear shall be able to be released by lifting car /counter weight. The
over speed governor and its driving mechanism shall be as per IS:14665.
ix) SAFETY BUFFERS :

Safety buffers will be provided in the lift as a final emergency device to bring
the descending lift car or counter weight to rest by absorbing kinetic energy
motion should the car or counter weight pass the normal downward limit of
travel. Energy accumulation type of buffers (springs) will be provided. The
buffers shall be suitable for supporting a minimum static load of twice the load
weight of the loader car or counter weights. The stroke length of the spring
shall be as per IS: 14665. The springs shall comply with the requirements
given in IS: 7906.
x) DRIVE ARRANGEMENT
The driving machine may be either Drum type or traction type. The drive
arrangement will consist of a motor, starter, coupling, gear box, brake, base
frame etc. The motor shall be of lift duty, suitable for 120 starts and stops in
an hour, TEFC, IP54 protection, class B insulation, 750/ 1000 RPM, foot
mounted, DOL starting of suitable rating. Other specifications will confirm to
the specifications mentioned elsewhere in this document. The speed reducer
Job No: 730176 IV - 49

may be of worm type. The transmitting capacity of the gear box will be min.
1.6 times motor rating. Facility shall be provided for hand winding to adjust for
compensation over wind and under wind. The connection between the speed
reducer to the driving sheave will be of suitable type as specified in the IS:
14665. Brake shall be provided to prevent the rotation of the lift motor when
there is no power supply to the lift. The brake may be either electromagnetic
type or thruster type of suitable capacity. The brake shall conform to the
requirements specified in the IS: 14665.
Controllers and operating devices, limit switches – shall conform to the
requirements specified in IS: 14665.
xi) INDICATING LAMPS, CONTROL SWITCH BOARD:

At each floor i.e. near the lift gate and inside the lift indicating lamps showing
the location of lift with up and down arrows shall be provided.
Inside the lift a switch board housing the buttons to operate the lift, light, fan
etc. shall be provided.
Job No: 730176 IV - 50

4.1.7.0 SECONDARY ROLL CRUSHER (MECH-07)
Secondary crusher / sizer - To reduce lumps from 250mm to (-)100mm

(Nominal) with capacity of 1600 tph. It will be installed separately as indicated
in the enclosed plan.
In general the crusher shall have the following features:
4.1.7.1 SCOPE
This specification covers manufacture, testing before dispatch, delivery at site

and commissioning of secondary roll crushers / sizers and shall be read in
conjunction with enclosed “General conditions for supply of equipment”
The scope of supply includes:
i) Crushers in required quantity complete with electric motor, pulleys and

V-belts (if required) and accessories required for safe and efficient
operation.
ii) Starter for motor (price to be quoted separately).
iii) Tools and tackles for dismantling, assembly and maintenance.
iv) Spare parts.
v) First fill of oils, grease and lubricants.
vi) Drawings and documents.
The crusher shall normally operate for 15 to 18 hrs. per day. It shall however,
be designed and constructed for round the clock continuous operation.
It shall meet stipulated performance parameter with type of coal mentioned.
It shall be able to start in full load condition and shall be robust enough to take
import of coal from a height in the region of 2 to 3m.
It shall allow passage of tram iron, timbers and other uncrushable debris.
In general, the crusher shall have the following features :
4.1.7.3.1 BASE FRAME
The base frame shall be rigid in construction and fabricated from heavy steel
plates and structural sections to withstand heavy shocks and loads. Suitable
holes shall be provided in the base frame for fixing the crusher on
beams/columns by foundation bolts. The bearing pads shall be machined for
high accuracy of alignment and for easy location of shaft, bearings and gears.
Job No: 730176 IV - 51

4.1.7.3.2 HOUSING FRAME
The housing frame shall be fabricated from heavy steel plates to withstand
heavy shocks and loads. End frames are machined from solid frame. Side
members shall be spigotted and bolted to end plates forming a very robust
assembly capable of containing any dynamic forces created by sizer while in
operation. The sections shall be easily removable for ease in maintenance.
4.1.7.3.3 ROLLER ROLL
The shaft and timing gears are fully machined from solid one piece forging of
high carbon steel/Alloy steel and are slotted to accept crushing segments.
The shaft bearing shall be spherical roller and of heavy duty type and shall be
selected for rated life of at least 40,000 ltrs at full load. The timing gears shall
be oil lubricated. The tooth profile shall be designed suitably to meet the duty
conditions and produce minimum of fine generation not exceeding 5%. In
order to minimise fine generation the roll speed shall be minimum and should
not exceed 40 rpm.
4.1.7.3.4 LUBRICATION
All bearings gears and pinions shall be oil lubricated. Non drive end shaft
bearings shall be lubricated from manual fill oil baths. Oil levels should be
checked by slight glasses.
4.1.7.3.5 WEAR PLATES
The crusher shall be fitted with wear plates completely covering the inside of
body and crushing chamber. These plates shall be made from high wear
resistant steel and shall be doweled and bolted to units allowing easy removal
when required and positive secure long term location.
4.1.7.3.6 CRUSHING TEETH
The crushing teeth shall be designed to slip into splined shaft without
removing the shafts from the main frame. These teeth shall be held firmly in
the drums by clamp plates and each row shall be individually tightened by
tensioning bolts.
4.1.7.3.7 DRIVE ARRANGEMENT
The rolls shall be driven through one/two motors depending upon duty
requirement, input coupling, gear box and output coupling etc. The coupling
shall be geared coupling/fluid coupling. The gear box shall be
helical/planetary type with a minimum service factor of 2.5.
Job No: 730176 IV - 52

4.1.7.3.8 MOTORS
Unless otherwise specified, the motor shall be foot mounted, totally enclosed,
fan cooled spuirrel cage direct on line starting type with torque characteristics
matching with the fluid coupling(if any) and shall conform to enclosed
specifications.
4.1.7.3.9 STARTER
This shall be DOL type suitable for the duty requirement and shall conform to
enclosed specification.
4.1.7.3.10 PAST PERFORMANCE

The tenderers are required to furnish the following details in support of their
successful past experience in manufacturing of this equipment.
• Name and address of organizations who are using similar make, type
and capacity of crusher.
• Material handled including maximum feed size and product size.
• Year of supply of crusher, with order number and date. (Minimum three
different orders to be indicated).
• User’s performance certificate if any.
• Capability of the firm in manufacturing of such equipment with annual
turn-over for last 3 years.
• Various facilities available for such work.
• Inspection and quality control facilities available with the firm.
Job No: 730176 IV - 53

4.1.8.0 ELECTRIC HOIST (MECH-08)
This will be of mono block type and fitted on rollers traveling on suitable I
sections. These shall be located in drive houses, transfer points and bunker
and shall be installed suitably to lift the heavy weights during
installation/maintenance.
The unit will have two geared motors one for lifting and lowering and other for
traversing forward and backward on I section.
The gear unit shall consist of helical gear and pinion. There shall be a limit
switch at highest and lowest positions of hook so that the hoist is protected
from any damage due to over travel of the hook. The drum shall be of
fabricated steel construction having very high tensile strength. The drum
should be provided with smooth machine cut grooves. The hoist motor shall be
fan cooled rotor brake motor conforming to international standards. The
movement of electric hoist shall be based on the location of hoist block /
monorail.
This device will be floor operated and will be placed over the overhead
structures so that it covers the whole floor.
The lifting height, traversing distance, lifting speed and other technical
parameters will be selected to suit the system design. The supply will include
complete hoisting unit including power supply, travel mechanism and structural
traveling monorail portion.
4.1.9.0 ELECTRONIC BELT WEIGHER ( MECH- 09)
4.1.9.1 BASIC PARAMETERS
The following basic parameters are to be taken into consideration while

making appropriate technical proposal:
• Nos to be supplied : 2 Nos.

• Conveyor belt width (mm) : 1800 (Conv. C7 & C8)
• Belt speed m/sec : 4.0 m/sec
• Conveyor troughing angle : 35o
• Conveyor capacity :
Peak TPH : 3600
Operation :
Continuous/Intermittent : Continuous
Working hours/day : 18
Working days/year : 330
Material Handled
Type : Crushed ROM coal
Maximum lump size : (-)100 mm
Bulk density: : 0.8 to 1.2 t/m3
Inherent surface
moisture content (max.) : 8%
Angle of repose : 35o (when in motion)
Inclination of belt conveyor : 11o(max.) at the place of equipment
installation
Job No: 730176 IV - 54

• Power supply : 415V 3 phase 50Hz

Working condition : Dusty and moist
The equipment is to be installed on incline/horizontal portion of a belt conveyor

and it shall record the weight of coal moved through the conveyor system
within permissible accuracy of ±0.5%. The weight measured shall be
displayed and also printed on cards. The equipment should have inherent
design features to work in dusty condition and fluctuating quantity of material
coming through the belt conveyor system. The belt weigher should have
facilities like digital luminous display board, daily chart recorder for rate of flow,
feed rate indicator, TPH and totaliser for automatic recording and displaying of
total material handled.
In general, the equipment should be robust in nature and have inherent design
features so as to give satisfactory performance in adverse loading condition
also. It shall be complete with all accessories required for its successful
operation in the stipulated duty conditions. It shall have, inter-alia, the
following specific features:
4.1.9.4 WEIGHING FRAME & SENSORS
Sufficient care should be taken in the fabrication and alignment of the weigh-in
frame, which is to be supported using anti-friction ball bearings, so as to
facilitate a smooth movement of the weighing frame in vertical plane. It shall
have strain gauge type load cell and speed sensing device of proper design to
ensure satisfactory result.
4.1.9.5 SIGNAL CONDITIONER
This forms the inter-face between the sensors and the control console. This
incorporates necessary circuitry for the generation of speed signal to excite
the load cell and for the conversion of load cell out-put into a current signal.
The information about the speed of the conveyor is obtained speed sensing
device which is directly proportional to the belt speed. Since the control
console is usually located at a place far away from the conveyor belt, it is
desirable to transmit the load cell outputs after processing as a current signal
rather than as a voltage signal.
4.1.9.6 RATE INDICATOR
The rate indicator is an automatic null balance type potentiometric servo

indicator capable of accepting D.C. Signals. This signal is further processed
by necessary accessories and finally indicated by final position of pointer of
the potentiometer which gives a measure of voltage produced by transducer
and which is indicated as rate of flow.
Job No: 730176 IV - 55

4.1.9.7 TOTALISER
This is a real-time integrator. Sufficient care should be taken in designing of

integrating element and the time function generator since the long-term
accuracy of the equipment depends upon the quality of the integrating element
and the stability of the time function generator. This performs the function of
totalising the quantity of material passed through it, during a particular period
of time and the same can be recorded and numerically displayed.
4.1.9.8 CALIBRATION SET-UP
This is a set-up for checking the operational accuracy of the system which
incorporates all the functional blocks, in terms of a 'number' usually know as
'cal-figure'. Initially, immediately after commissioning the system, the cal-figure
could be evaluated and re-corded. So, the cal-figure displayed at later date
could be compared with initial figures and the necessary adjustment effected
to bring back the system to the original condition. In the proposal, provision of
this system should be elaborated in detail.
4.1.9.9 DISPLAY & OPERATOR CONTROL CONSOLE
The control console and display unit shall be housed in a control room
normally provided near the loading point. The weight indicator shall be visual
digital type and should be fully self-indicating. The indicator shall be enclosed
in dust and moisture proof housing and it should show at a glance the weight
of material conveyed and also the rate at which material is being conveyed.
The letter height should be such that it could be easily read from a distance.
All the electronic circuitry of the weigher, as far as possible, should have
printed card modular feature for easy replacement of defective control parts
ensuring minimum down-time of the equipment.
Job No: 730176 IV - 56

4.1.10.0 TRAMP IRON MAGNET / MAGNETIC SEPERATOR (MECH-010)
Inline Magnetic separator will be electromagnetic type, with oil cooled design.
All equipment will be totally enclosed. Magnet Circuit comprising of insulated
aluminum adequately impregnated with epoxy resin making it impervious to
moisture will be provided. Magnetic Separator will provide for continuous and
automatic extraction and discharge of tramp metal (magnetic pieces) from
Coal being discharged from the given belt conveyor (refer Data Sheet).
The magnetic separator unit will be suitably mounted from structural member
from the top. The required turn buckle arrangement to facilitate the necessary
adjustments during operation will be provided. The unit will be complete in all
respects including all electrical ancillaries, viz. local control panel, ON/OFF
control push buttons and indicating lamps etc. The material of chutes and
trolley associated with each magnetic separator will be of non-magnetic
material in the magnetic zone. Magnet core material will be of pure annealed
iron or equivalent having high magnetic permeability. The coil will be of
aluminum wire with Class `H’ insulation. Dimensions and shape of the core
and side poles will be optimized to obtain wider, deeper field ensuring large
force index to effect higher lifting capacity over wide area. Magnetic Separator
will be located such that it picks up tramp iron from coal trajectory after it has
been discharged from head pulley. Magnetic pieces picked by magnetic
separator will be discharged via tramp metal chute into mobile trolley located
suitably.
Suitable arrangement will be provided in the magnet for keeping the coil of
magnet dry from atmospheric condition when the magnetic separator is not in
use.
The other mechanical components of the Magnetic Separator like pulleys,
bearing blocks, drive, belt etc. will be liberally designed to ensure trouble free
operation. The motor and gear reduction unit for driving the belt will be
adequately sized .
The separator belt will be designed to withstand high temperature at the
bottom of the magnet and also to withstand impact of the sharp edges of the
tramp iron pieces. The belt will be provided with suitably spaced built in ribs.
All the equipment and accessories will conform to the relevant Indian
Standards wherever applicable. The Idlers and the pulleys supporting the belt
will be manufactured to the best engineering practices and will conform to
relevant Indian standard (IS).
Each magnetic separator will be suitable to lift the following tramp iron piece
from the given belt.
MS cube of 20 mm size
50 Kg. M.S. / Brake Shoe
MS round bar of 50 Kg with L/D ratio not exceeding 5.
Job No: 730176 IV - 57

4.1.10.1 DATA SHEET:
INLINE OVERBAND MAGNETIC SEPARATOR:
1.0 Type of Magnetic Separator: Inline Over band Magnetic Separator.

Oil cooled type electromagnet with self
cleaning arrangement complete with
local panel.
1.1 Equipment Qty. : 2 Nos.

1.2 Belt Conveyor Details : C1 & C3A/3B
1.3 Location of Magnetic
Separator w.r.t Pulley : ILMS above drive cum discharge pulley
of Conv.
1.4 Operating Height

(approx.) : 400 mm for ILMS
1.5 Flux Density
(Minimum) : 1000 Gauss at operating height specified
above
1.6 Force Index : Minimum 100000
1.7 Magnet Core
Material : Pure annealed iron or equivalent having
high magnetic permeability, IS 4491
1.8 Coils : Aluminum wounded coils with class “H”
insulation
1.9 Rectifier : 3 ph., full wave bridge using Silicon
Diodes forming rectifier set
1.10 Tramp Metal Chute : Suitable tramp metal chute (5 mm thk
M.S.) with mobile trolley will be provided
for magnetic separator
1.11 Non‐Magnetic
Idlers/Pulley : Non‐Magnetic Pulley will be provided.
1.12 Separator Belt : EP Type of F.R‐Grade complete with
built – in ribs and zero speed switch.
4.1.11.0 METAL DETECTOR (MECH-011)
The function of this unit will be to detect nonmagnetic substances like

manganese steel, brass, aluminum or any other metal that may come along
with R.O.M. coal.
It will be installed after the magnetic separator in the direction of coal flow.
Metal detector will consist of a very highly sensitive search coil which can
sound an alarm and stop the conveyor whenever any nonferrous metals or
bigger pieces of iron or any magnetic substance pass with the coal. The
detector should also be able to show by indicator the position of the piece of
Job No: 730176 IV - 58

metal. The indicator may be in the form of colored powder or sand or saw dust.
The metal detector should be able to detect the alloy steel of high manganese
content say 10% to 20% as sometimes shovel teeth and track pads are also
likely to pass over the conveyor along with R.O.M. coal. The metal detector will
be set at a predetermined range so that it works only when bigger size of
foreign material is passing over the conveyor.
The sensitivity of the equipment should detect sphere of dia 25mm, however, it
could be possible to set it to detect bigger size material only from 200mm or
above
4.1.12.0 CHAIN PULLEY BLOCK (MECH-012)
In addition to the provision of electric hoists, manual hoists, chain pulley blocks
of 10 t capacity shall also be provided at tail end and take-up arrangement of
all conveyors and wherever conditions required for effective maintenance of
the plant and equipment.
The hanging structures shall have an outside projection for easy handling of
material. The supply shall include complete chain pulley block with hanging
structure.
LOAD TEST
All hoists and hoisting systems shall be load tested as per the relevant Indian
Standards before supply and installation and necessary test certificates shall
have to be provided.
4.1.13.0 FIRE FIGHTING & PLANT CLEANING SYSTEM (MECH-013)
On the basis of scope, drawings enclosed, the tenderer will detail out the
workable and most economical scheme for fire fighting and plant cleaning and
assess the quantities of various equipments, pipes, fittings etc. required for
efficient working of system. The fire fighting system using water shall also be
used for plant cleaning purposes. The design and installation of the system
shall comply with the provisions of the recommendations of the Tariff Advisory
Committee (TAC) of India so that fire insurance policy can be readily arranged
by the successful bidder.
The complete conveyor system shall be provided with fire detection, smoke
detection, Linear Heat Detection (LHD) for detection of static fire, Black body
IR detector for detection of moving fire, CO Monitor for detection of fire in
earliest stage especially in enclosed areas, fire alarm system and various fire
extinguishing devices- both water reliant and solid aerosole reliant. They are
being elaborated as under:
Job No: 730176 IV - 59

4.1.13.1 AUTOMATIC FIRE DETECTION & SUPPRESSION SYSTEM (AFDSS) :
The proposed AFDSS shall consist of following
• Fire Detection & Alarm System (FDAS) - comprising of the following
detection systems:-
a) Heat detectors in Pent house/transfer houses and Fire Control
Room.
b) Smoke detectors
c) Linear Heat Detection (LHD) cable along with its interface
module.
d) Black body IR detector
e) CO Monitor
The Fire Detection & Alarm System shall monitor smoke, temperature rise
and absolute temperature. The sensing device should be able to detect
smoke signals after continuously monitoring and temperature rise of the
surrounding area.
•
Alarm & Control Unit (ACU) - For reading the signals from
sensors/detectors, giving audio/visual alarms & actuating the Fire
Extinguishing System
A Control room shall be established in the sub station II.
• Fire Extinguishing System (FES) – Self Aspirating high expansion
foam generators, Fire Hydrant and Water spray system. Water
Sprinkler system and Hose reel system which are activated either
electrically or manually.
The fire extinguishing system shall be based on
a) The condensed aerosol generator principle. The condensed aerosol
generator is a fire extinguishing system using solid material, which on
activation is transformed into a rapidly expanding fire extinguishing
aerosol. The extinguishing action shall not alter the quantity of oxygen
present in the environment significantly.
b) The water spraying/ sprinkling system. For this an underground
reservoir is proposed near the bunker as indicated in the plan as per
TAC norms.
• Other Items (OI) - like Change over Switch for switching
Extinguishing system between Automatic to Manual mode,
connecting cables, relays etc. necessary for commissioning &
reliable operation of the AFDSS.
4.1.13.2 GENERAL SPECIFICATION OF DETECTORS:
4.1.13.3 SMOKE & HEAT DETECTORS
• Heat & Smoke detector shall be robust, rugged, temper proof & suitable
for surface mounting.
• Heat & Smoke detector shall incorporate state of art optical chamber
providing efficient & accurate detection of fire with high level of
reliability & high immunity to spurious signal.
• Heat & Smoke detector shall incorporate integral LED indicator to show
the status of the detector.
Job No: 730176 IV - 60

• Each Heat & Smoke detector shall have suitable indications for
indicating Normal healthy mode & Alarm Indication mode.
• The detector’s alarm condition shall be visible from a distance of 6
Meters and shall be visually different from the indications of the other
conditions.
• The insulation resistance of the detector shall not be less than 10
Mohm.
• Failure of any indicators lamp shall not prevent the detector from
emitting fire signal indicating the existence of fire.
• Smoke detector shall be of Optical (Photoelectric) smoke detector and
shall confirm to IS: 11360-1985.
• The optical smoke detector operation shall be based on light
attenuation by smoke and/or light scattering by smoke particles.
• Smoke detector shall incorporate state of art optical chamber providing
efficient & accurate detection of fire with high level of reliability & high
immunity to spurious signal.
• Smoke detector shall be able to detect smoke and shall communicate
alarm signal to Control unit when optical density of smoke exceeds 0.1
dB/M (10 m visibility).
• The response threshold value (r. t. v.) of smoke detector shall not be
less than .05dB/m. and the ratio of highest r. t. v. and lowest r. t. v. shall
not exceed 1.6.
• The opening for smoke entry shall be at least 30 mm below the ceiling
level.
• The horizontal distance between any point in a protected area and the
detector nearest to that point shall not exceed 7.5 m in case of smoke
detector and 5.3 m in case of heat detector.
• The heat and smoke detector has been envisaged in tunnel area, pent
house and transfer houses only. Where the distance between the top of
apex and bottom of the roof exceeds 600 mm, spacing of detector at or
in the vicinity of apex may be spaced between 7.5 m and 8.5 m for
smoke detectors.
• Detectors shall not be mounted within 500 mm of any walls, partitions
or obstructions to flow of smoke or hot gases, such as structural beams
and ductwork, where the obstructions are greater than 250 mm in
depth.

4.1.13.4 LINEAR HEAT DETECTOR (LHD)
Temperature sensitive cable also known as Linear Heat Detector shall be
laid in all cable trays located in the tunnel. Signal about alarm temperature
shall be sent to Control Unit by LHD interface module attached with cable
system.
Linear Heat Detector cables shall be of temperature sensitive insulated wire
type. This linear heat sensing shall be in the form of continuous cables
consisting of copper conductors / cores and shall be of analogue type. Each
core of analogue Linear Heat Detecting cable shall be insulated with a
negative temperature coefficient material. An outer sheath of high
temperature, flame retardant PVC insulation, shall protect the cores. The
Job No: 730176 IV - 61

outer sheath, as well as the metallic braid shall not affect the performance of
the heat sensor.
The electronic interface module of the Linear Heat Detecting cable for each
zone / area shall sense the temperature variations by continuously
monitoring the resistance of the negative temperature.
The electronic interface module shall be located suitably (approx. at 15 m.)
The analogue linear heat sensing cable of every zone shall be continuously
monitored for open and short circuit. A breakage, disconnection or a short
between cores shall initiate a FAULT alarm on the fire alarm panel of Control
Unit.
LHD cable shall be automatically resettable type. The design of the
analogue, linear heat detecting cable and corresponding electronic sensing
circuits shall be such that the cable length and the number of required loops
should be set up to provide optimal coverage for the whole tunnel region with
cable length ranging within tunnel area and pent house. The system shall be
designed to have an optimum sensitivity. For a given length of sensing
cables it shall be possible to set the alarm temperature over a wide range
from 70 -130ºC with a interface Modulator and with a tolerance not to exceed
±5%.
The Linear heat Detecting cable should have strong capability to withstand
the mechanical damage, tensile, water and corrosion and electromagnetic
interference.
The LHD can be ceiling or pipe mounted or installed at either side of the belt
on or above the idler arms.

4.1.13.5 LINEAR HEAT DETECTING (LHD )INTERFACE MODULE
LHD Interface should be a microprocessor based start point device that
communicates between LHD Cable and Control Unit that will monitor LHD
cable for continuity and over temperature fire signatures. It shall be possible
to set any alarm temperature between70-130ºC through Interface module.
An increase in temperature at any location along the LHD cable's length shall
lower the resistance between conductors in the cable. The change in
resistance shall be detected by the interface module, which will trigger an
alarm at the control unit if the temperature rises above a preset threshold.
The LHD interface shall be able to distinguish between a Short Circuit
Condition & an Actual Fire Event in order to prevent unwanted activation of
fire alarm/ fire extinguishing system in case of an accidental short circuit fault
by damage to the sensor or field wiring.
The LHD interface should supervise the sensing cable for temperature rate
of rise condition, open & short circuit to generate a fault condition which shall
be displayed on the interface module faceplate by the 2 LED indicators:
FIRE LED & FAULT LED.
LED indicators shall also be provided for normal system operation, faults, pre
– alarm, fire – alarm status, battery low indication and alarm. LHD interface
should perform simulation test for fire alarm, pre – alarm and fault signals.
On belt conveyors, the LHD can be ceiling or pipe mounted or installed on

either side of the belt on or above the idler arms.
Messenger wires with cable standoffs shall support the Detector which is
Job No: 730176 IV - 62

used to activate a deluge sprinkler system..

4.1.13.6 IR BLACK BODY EMISSION DETECTOR
For “moving “ hazards, i.e., hot or burning coal imported on a traveling
conveyor can be detected with IR BLACK BODY EMISSION DETECTOR
which can detect 2000 F to 3800 F at speeds upto 20ft/sec.

4.1.13.7 CO MONITOR‐ It works best in enclosed areas. It requires no heat source and
can detect fire at the very earliest stage of pre- combustion. Fires in tunnels
have been detected by CO monitors when no other method sensed the
incomplete combustion stage
4.1.13.8 CONTROL UNIT
The control unit shall be located at sub station-II, near Semi ground bunker .
Detection, actuation and control system may be either automatic or manual.
Where they are automatic, provision should also be made for manual
operation.
The Control Unit shall be the central processing unit of the system, receiving
and analyzing signals from Heat detectors, Smoke Detectors releasing
devices, providing audible and visual information to the user. It shall have
suitable audio/visual alarms for drawing attention/indicating various events. It
shall also have the capability to electronically/electrically activate and release
Fire Extinguishing System. The Control Unit shall have sufficient input ports
for connecting various sensors/ detectors along with their interfaces & have
sufficient output ports for controlling fire extinguishing system,
operating/switching off electrical units and for interfacing with the existing
Data Logger system.
The Control Unit shall have means for the user to interact & shall have
suitable Detection & suppression to prevent unauthorized use.
The panel of the control unit shall have the facility of buzzer silence, alarm
silence and alarm activate, lamp test & reset. The panel shall indicate the
status like fire, fault, disable, test, supply, supply fault, battery fault, aux.
supply, fault, and earth fault by respective LEDs/other suitable means.
The Control Unit shall be able to communicate and display the exact number
of the Sensor or the Part of the Linear Heat Detecting Cable, which has
activated the Fire Detection System, to pinpoint location of the seat of fire.
The Control Unit shall be modular in structure, so that any fault in any of the
modules can be set right by simply replacing the Faulty Module, with a
spare.

4.1.13.9 AUDIOVISUAL ALARM :
Audiovisual alarm system shall get activated in Control Unit in case of
fire/smoke.
Audiovisual alarm shall be provided with provision of resetting the hooter
from Control Unit. However, visual alarm shall continue to be lit till such time
the alarm conditions exist.
The audio alarm for fire alarm shall be electronic hooter/horn/electric bell
Job No: 730176 IV - 63

having a frequency range of 500-1000 Hz. The sound of the fire alarm
should be continuous although the frequency & amplitude may vary.
When alarm signal is received from any of the heat or smoke detectors or
LHD module subsequently, after a time delay of at least 2 minutes (which
can be set by the user up to 10 minutes & shall be in multiples of 0.5
minutes) shall activate the fire suppression system.
The Alarm of Control Unit shall have means to indicate the location of sensor
in that part of tunnel which has reported the alarm situation. The Control unit
shall activate the fire extinguisher of that part only for extinguishing the fire.
4.1.13.10 FIRE SPEAKERS
An automatic fire alarm system is designed to detect the unwanted presence

of fire by monitoring environmental changes associated with combustion. In
general, a fire alarm system is classified as either automatically actuated,
manually actuated, or both. Automatic fire alarm systems can be used to
notify people to evacuate in the event of a fire or other emergency, to
summon emergency services, and to prepare the structure and associated
systems to control the spread of fire and smoke.
4.1.13.11 FIRE EXTINGUISHING MEDIUM
The fire extinction and extinguishing media dispensers shall be based on
self aspirating high expansion foam generators, water hydrant, water spray,
water sprinkler and Hose reel system.
Water shall flow through pipes into the tunnel as well as along the entire
conveyors length.
4.1.13.12 FIRE PUMPS
• FIRE FIGHTING PUMP – DIESEL OPERATED
The pump shall be diesel engine driven, complete with common base plate
and couplings etc. It shall be horizontal centrifugal pump with required
capacity. It shall be complete with all accessories.
• FIRE FIGHTING PUMP – ELECTRICALLY DRIVEN
Two numbers electrical fire pumps (One main pump and other jockey pump)
shall be motor driven, complete with common base plate and couplings etc.
The main pump shall be horizontal centrifugal pump with the capacity of
system requirement. It shall be connected to squirrel cage induction motor of
suitable rating.
Pump shall be complete with switch board with incoming circuit breakers and
starters and all associated control for the pump motor.
Power supply shall be 415 V , 3 phase, 4 wire, 50 Hz. Motor shall be suitable
for D.O.L. starting. It shall be TEFC squirrel cage induction motor, suitable for
continuous duty. Enclosure to provide protection shall conform to IP-55, and
class of insulation shall be 'B'.
Circuit breakers and starters shall be provided with overload, under voltage,
Job No: 730176 IV - 64

single phasing and short circuit protections. It is desirable to provide a reputed

make composite motor protection relay to provide the above mentioned
protections. The contactor of the starter shall be suitable for AC-4 duty.
Pumps shall be robust in construction & statically and dynamically balanced.
• ACCESSORIES
All the accessories required for successful and smooth operation of pumping
system shall be supplied along with the pumps.
Major accessories are mentioned below :

• Pressure gauges conforming to IS:3624.
• Cast steel sluice valves, conforming to IS:780.
• Cast steel non return valves conforming to IS:5858.
• Foot valves with strainers conforming to IS:4038.
• Primary tank with necessary accessories i.e. pipes and valves
etc.
4.1.13.13 PIPES AND PIPE FITTINGS
MS Pipes shall be conforming to IS:1239 (Current). Pipes shall be of suitable

diameter and threaded at both ends. These shall be painted red and meet the
requirement of fire fighting systems as per relevant Indian Standards.
Total requirement : as per system .
FITTINGS
The piping system shall have the requisite quantities of the following bends
and other fittings.
• 1200 bends
• 450 bends
• Other angular bends.
• Rubber gaskets for above all flanged tees
• Sluice valves
• Air valves etc.
• HYDRANT VALVES
The valves shall be manufactured from gunmetal as per relevant Indian

standard specifications. The hydrant valves are fitted with flanged inlet
connections for 150 mm dia. pipes and 65 mm female instantaneous outlet
connections with blank cap and chain. Only double hydrant valves shall be
provided. The pipe line shall be laid all along the conveyor. The distance
between two adjacent valves shall be kept as per relevant IS/Fire protection
manuals and shall not be more than 30 m. apart. The pipes and hydrant valves
along the conveyor gantries shall be installed on the ground separately with
their supports.
Total requirement: As per system requirement.
Job No: 730176 IV - 65

FIRE HOSE CABINET
Hose cabinet will be fabricated from structural steel with glass front door of
suitable size. It will be located close to each hydrant valve and will
accommodate two lengths canvass hose of 15 m long each with couplings,
branch pipes and nozzle of suitable size and conforming to relevant current IS.
Total requirement : As per system requirement.
• FIRE HOSE
These shall be Flax Canvass fire fighting delivery hose, 15 m length, 65 mm

(2.5 inch) dia. tested to a bursting pressure of 450 psi Hose shall be
impregnated with antirust chemical for high mildew resistance. These shall be
manufactured as per IS: 4927 and bearing ISI mark on each length. End shall
be fitted with 2.5 inch (65 mm) dia. male and female parts of gun metal
coupling of standard quality. For each hydrant there shall be two hose pipes of
15 m length each. Spare shall be provided as per relevant IS.
Total requirement : As per system specifications.(a double headed

hydrant counted as two)
BRANCH PIPE AND NOZZLES
Gun metal branch pipes with nozzles shall be conforming to relevant standards
of fire fighting system. Same shall be suitable for 63 mm dia fire hoses.
Total requirement: As per system requirement.
4.1.13.14 OTHER EQUIPMENT
To fight fires where water can not be used, other specific equipment are
required to be used such as sand buckets, chemical fire extinguishers
etc.These shall be provided as stipulated in latest version of the relevant IS.
The locations, number provided for each type shall be clearly indicated.
Chemicals, which are not permitted, shall not be used.
• FIRE BUCKETS
These shall be round bottom, fire bucket made out of 24 gauge M.S. sheet,
galvanized after manufacture, standard 9 liters capacity, painted fire red
outside with letter 'FIRE' in black and complete with brackets and shall be
installed at all the required locations as per requirement.
Job No: 730176 IV - 66

• PORTABLE/WHEEL MOUNTED HALON 1211 (BCF) FIRE

EXTINGUISHERS
Fire extinguisher shall be Halon 1211 (BCF) pressurised fire extinguisher filled
with Halon 1211 (Bromo: Chloro:Diflouro Methane), a vapourising liquid.
These shall be of 5 Kgs. capacity. These shall be hot dipped, lead lined to
give best protection against corrosion. These shall be complete with bracket,
initial charge and other accessories as required. These shall conform to
relevant Indian Standard specification with instructions for use on each
cylinder.
Total requirement: As per system specifications.
• PORTABLE / WHEEL MOUNTED MECHANICAL FOAM FIRE

EXTINGUISHERS
Mechanical foam fire extinguishers shall be of 9 litres capacity. These shall be

hot dipped lead lined to give best protection against corrosion, complete with
gun metal cap, with C9 gas cartridge and 540 ml of 6 % AFF concentrate.
These shall be fitted with nylon hose with plastic foam branch bracket and
initial charges. These shall be manufactured as per IS: 933 (bearing ISI mark
on each appliance).
Every extinguisher shall have instruction for using the same.

Total requirement : As per system specifications
Job No: 730176 IV - 67

4.1.14.0 DUST SUPPRESSION SYSTEM ( MECH-14)
4.1.14.1 OBJECTIVE
The objective is to suppress the dust particles at the place of generation by

spraying plain water in atomised condition to create mist / fog for accelerating
the process of dust settlement. The Tenderer may visit the site and get
acquainted with the site conditions and offer a system which can create an
environment as stipulated in the notification on "National Ambient quantity
standards" issued by "Central pollution Board" on 11-4-1994.
4.1.14.2 GENERAL
Coal from quarry size of (-) 100mm will be loaded to the truck receiving
hoppers and transported to SILO through series of conveyors. The successful
tenderer / contractor shall collect necessary data on the quantity and size of
particles of dust generated within the CHP. The dust suppression system will
be based scientifically on the above data collected. Dust suppression unit shall
operate only when the loaded conveyor is running. When belt stops or belt is
running empty the dust suppression unit will stop automatically. This will be
interlocked with water feeding system.
The dust suppression system will consist of number of nozzles, with flexible
pipe to spray mist of mixed water on coal at the designated points like truck
receiving hopper points, transfer chutes, tripper discharge zones over the
main bunker etc. The number of nozzles, their type size and configuration
shall be such as to achieve maximum efficiency of dust suppression.
4.1.14.3 DUST SUPPRESSION UNITS
4.1.14.3.1 PUMP MOTOR SET
i)PUMP
The main/booster pump will be of multistage, centrifugal type of required

discharge capacity and discharge head. The impeller shall be made from
close grained CI iron of Grade 20 conforming BIS 210 (current). The casing
shall be free from blow holes. The bearing housing shall be provided with
effective sealing arrangement against the entrance of water or dust. A drain
plug shall be provided below the housing. Grease cups shall be provided for
lubrication. Proper sealing arrangement comprising of stuffing boxes fitted with
suitable packing material shall be provided to prevent leakage within the
casing. The sealing arrangement shall be such that replacement of packing
material does not require dismantling of any other parts except glands.
Suitable antifriction bearings with proper lubrication arrangement shall be
provided for support of impeller shaft. Required flanges for connecting the
inlet/outlet pipe, priming funnel shall be provided. Suitable arrangement shall
be provided for balancing of hydraulic trust. The pump shall be of energy
efficient and suitable to operate at maximum efficiently at the head variation of
± 20% of rated head.
The motor shall be suitably rated to meet the requirements and shall conform
Job No: 730176 IV - 68

to IS 325 (current). The motor shall be horizontal, foot mounted, squirrel cage
induction type, TEFC, non-flange proof, IP54 protection, SI-continues
duty, class 'B' insulation, suitable for DOL starting , continuously rated, 1500
RPM (synchronous speed), suitable for operation on 415 V, 3 phase, 50 Hz
supply. The cable end boxes shall be suitable for 3 core PVCSWA
cables of Aluminum / Copper conductors of suitable size. The motor shall be
capable to deliver rated out put with -
a) The terminal voltage differing from its rated value by not more than
±5% or
b) The frequency differing from its rated value by not more than ±3% or
Provision for earthing of motor shall be as per IS 3043 (current) and relevant
IE rules. Minimum 2 points shall be provided. The limit of vibrations shall be
as per IS 4729 (current). The specifications on electric motors given else
where in this document shall also be applicable.
ii)COUPLING
The motor and pump shall be coupled by means of a flexible coupling having
transmitting capacity of 1.25 times the motor rating. The coupling shall absorb
the misalignments due to parallel, angular and axial loads. A coupling guard
made of expanded metal shall be provided. Coupling by 'V' belts is not
acceptable.
iii)STARTER
Push button type start / stop switch shall be provided at pump for starting and
stopping in case of emergency. Normally the pump will receive power from
MCC.
iv)BED FRAME
The base frame shall be fabricated form MS structural steel. The pump and
motor shall be properly aligned in the works and proper erection marks and
dowel pins shall be provided. Proper lifting lugs shall be provided.
The motor shall stop if the level of water in the sump falls below a
predetermined level for which floats may be used.
4.1.14.3.2 NOZZLES
The nozzles shall be light in weight, non clogging/self cleaning type. These
shall be provided with tips made of brass/stainless steel. The nozzles shall be
provided with protective CI housings, inbuilt strainers/filters. The nozzles shall
be capable of spraying the required quantity of water at required pressure in
the form of atomised condition to form mist/fog. The spray from the nozzles
shall be of full/solid cone type. The spray angle of the nozzle shall be as per
requirement. One end of the nozzles shall be threaded for screwing on to the
T joints fitted on the header pipe. The nozzles shall be easily approachable
Job No: 730176 IV - 69

and removed from the installation for cleaning of the same.
4.1.14.3.3 PIPES AND PIPE FITTINGS
The main pipes, branch pipes, header pipes shall be of Galvanised M.S.
conforming to IS 1239 (current). The dia. of the pipe shall be suitable for
carrying the required quantity of water with a velocity within the limits and the
pipe frictional losses shall be as low as possible. The header pipes shall be at
least 12.5 mm dia. and main pipes shall be of suitable size and in no case it
shall be less than 63 mm dia. The inside wall of the pipes shall be well
finished to reduce the frictional losses. The pipes shall have suitable threads
at the ends for joining the pipes with couplers. However, in case of necessary
flanges will be welded at site for joining. The flange dia. shall be as per IS and
shall have required holes for connection. Proper gaskets will be provided at
flange connection to avoid any leakage. Pressure filters may be provided in
the out let of the pump discharge. The pipes shall be ISI marked.
The bends/elbows, flanges, couplers, tees, diffusers, enlargers shall be
suitably galvanised. These shall be of medium duty and MS galvanised steel.
These shall conform to relevant Indian Standards. The pipes, bends/elbows
and other pipe fittings shall be IS marked.
All underground MS piping shall be protected against ground corrosion with
bitumen and Hessian cloth. All pipe lines shall be hydrostatically tested to 2
times the working pressure after erection. Location and types of pipe supports
are to be decided at site.
4.1.14.3.4 SLUICE VALVES, GLOBE VALVE, NON RETURN VALVES
The valves shall be manufactured conforming to latest Indian Standards.

These shall be suitable for use with the GI pipes of required diameter. The
dimensions, wall thickness, material of the other parts shall conform to IS 780
(current). The valves shall be operated by hand wheels. On the Upper side of
the rim the words open and shut with direction arrows shall be shown. The
castings shall be free of boreholes and manufactured to withstand 16 kg per
sq. cm water pressure. The valves shall be provided with flanges for
connecting to the pipe line. Required number of holes shall be provided in the
flanges. The valves shall be opened by operating in anti-clock wise direction
and closed by operating in clock wise direction.
4.1.14.3.5 SOLENOID VALVES
These valves shall be provided in the header pipe. The valves shall be opened
when the conveyor is in operation and closed when the conveyor stops. The
Solenoids may be interlocked with the respective motors of the belt conveyors.
Manually operated valves shall also be provided in addition
Job No: 730176 IV - 70

4.1.14.3.6 SUMP AND PUMP HOUSE
The sump/main ground water storage tank shall be of required capacity and
shall be of RCC construction. Provision for connecting the water mains from
the project's water supply system shall be kept in addition to the arrangement
for receiving water from deep boreholes to be made near the sump or from the
project’s water supply arrangement. Proper provision for cleaning of sump
shall be made. The provision shall be provided for laying the suction pipes of
pumps into the tank.
A pump house of suitable area to accommodate two numbers of pump motor
sets, required electrical installations and circulating space of min. 1 m. around
the pump motor set shall be made. The pump house shall be of brick
masonry construction with RCC roof. Required number of windows with glass
panels and wooden frame, door of required width shall be provided. The door
shall be made of seasoned teak wood and proper locking arrangement shall
be provided.
The pump house shall be properly illuminated with the help of tube lights.
The proposed sump of required capacity shall cater for the dust-suppression
only. Company will arrange for the supply of dirt free clean water to the sump.
The sump will be located near the over ground bunker as required in the
system.
4.1.15.0 CHUTE AND LINERS (MECH 015)
4.1.15.1 GENERAL
All the transfer chutes shall have a sloping angle of 60 degree. The chutes
shall be constructed in such a way that no off centre loading on the belt takes
place and material is fed in the direction of the motion of belt. The chutes shall
be fabricated from 10mm thick MS plates and 6mm thick MS plates for hood
portion of the chute by electric welding as per relevant IS Code of practices.
These shall be provided with necessary stiffeners and brackets for supporting
from the adjacent structures. The chutes shall be provided with polyurethane
wear resistant liner plate on their wearing and impact bearing surfaces. The
minimum thickness of the polyurethane liner shall be 40mm and shall have the
shore hardness of 640 A scale-D. The thickness of the hard layer and M.S
base plate of the liner and its hardness shall be designed and shall be offered
as per system requirement. For all impact areas, the liner plates shall be of
standard size and replaceable plate wise for ease of maintenance. The
minimum liner plate thickness shall be 10mm.
The liners shall be fastened with a flexible system to minimise instantaneous
impact and hence reduce the wear rate. The fastening system shall be either
through bolting or stud welded bolting for quick installation. For all impact
areas the bolt heads shall be protected by a rubber plug.
ROM crushed coal of the given characteristics are required to be conveyed
Job No: 730176 IV - 71

with speed, capacity and height of fall etc. as indicated in the enclosed
drawings. Taking into consideration the above facts and the possible coal
discharge profile, chutes and liners of suitable size, type and thickness are to
be designed and offered. The coal also may be considerably wet during rainy
season. The liner thickness etc. shall be designed to give a minimum
guaranteed life, which shall be important criteria for taking decision. However,
the thickness will not be less than what has been indicated elsewhere. The
working atmosphere may be dusty and surface temperature up to 50oC. The
relative humidity may be up to 95%.
4.1.15.3 CODES & STANDARDS
Design and manufacture of the chutes & liners shall conform to relevant Indian
Standards or in their absence with equivalent International standards
applicable.
4.1.15.4 HARDWARES
• All bolts, nuts, washers, CSK bolts will be of high quality, only
• Unlock nuts and adequate thick washers will only be used, for
jointing sub:assemblies.
• All hardware shall be procured from reputed suppliers and test
certificates shall be submitted. No testing will be done on these
items.
4.1.15.5 DESIGN CRITERIA FOR CHUTES
The main points to be considered while doing the design of chutes are as
follows:
• The transfer chutes shall be properly designed for efficient flow of
material keeping in view the elevations shown in the sectional
drawings, trajectory of the material, speed of the belt etc.
• The chutes shall be fully enclosed. These shall include covering
the full length of the skirt of the receiving conveyors and feeders
with M.S plates. The chutes shall be bolted to the skirt boards for
preventing any dust from escaping out from the transfer points. In
case it is not possible to bolt the chute with skirt plates necessary
dust seals shall be provided between the skirt plates and chute
plates.
• In case of mechanical equipment, the in feed and off take chutes
shall be bolted to the equipment body as per the equipment
manufacturer's recommendations.
• The chutes shall match the supporting structures and skirt boards
of the conveyors and other equipment in the coal handling plant
into which either they feed or from which they collect.
• Due care shall be given to trajectory of the material from the
discharge pulleys of the conveyors and also from other equipment.
• Chute angles must be sufficient to avoid any probable choking. For
calculating such angles, factors like presence of surface moisture
in coal because of climate, dust suppression arrangement,
Job No: 730176 IV - 72

coefficient of friction between coal and liners etc. shall be made. In

any case, chute angles shall not be less than 500.
• In every chute from a conveyor necessary stone boxes shall be
provided within the chutes to absorb heavy impact of the falling
material wherever possible.
• Discharge velocity and direction of flow of the material from the
chute shall match to the extent possible to the speed and direction
of the receiving conveyor to minimize drag and spillage of material
at the transfer points.
• Chutes shall be designed in such a way that the material by and
large is not discharged on the impact idlers of the conveyor. The
loading shall be at least 100 to 200 mm away from the preceding
impact idler of the belt conveyor to avoid any damage to the belt.
The material shall be discharged centrally on the conveyor or
equipment.
• Chute design shall be in coordination with the design of dust
suppression system which are also within the scope of this tender.
• The design of chutes shall not allow any dust to escape from the
transfer points while it is working in conjunction with dust
suppression system.
• The chutes shall have proper brackets for fastening the same
with structures.
• The skirt boards of the conveyor at transfer/loading point shall be
as per conveyor manufactures’ recommendations.
• Leather/belt flaps of bolted type shall be provided near the place
where the material enters the chute to avoid any dust nuisance.
• Chutes shall be designed in such a way that belt
cleaners/scrappers can be installed and replaced easily without
need for dismantling the chutes.
4.1.15.6 DESIGN CRITERIA FOR CHUTE LINERS
The main points to be considered while doing the design of chute liners are as
follows:
• The liner thickness shall be so selected that it will give maximum
working life. The contractor shall indicate the basis of liner
thickness selected.
• The liner plates shall be fixed with the mother plates with
adequately sized CSK bolts
• By and large the contractor shall use minimum varieties of liners as
far as sizes of liner plates are concerned to deal with either impact
or abrasion as the case may be, but stick to only one thickness
and size for each type to minimize inventory.
• All liners shall be of replaceable type. Welding or any type of
permanent fixing with the mother plate shall not be used.
4.1.15.7 FABRICATION AND ERECTION CRITERIA OF CHUTES
• The general arrangement drawings of all chutes shall have to be
Job No: 730176 IV - 73

got approved to MCL/ or their consultants before manufacture.

• The chutes shall be constructed / fabricated from M.S. plates of
minimum 10mm thick. These shall be adequately stiffened to meet
the duty conditions. The M.S. plate shall conform to IS: 226
(Current).
• Each chute shall be divided into subassemblies for ease of
transport, assembly, handling, erection, replacement of liners etc.
subassemblies shall be connected to each other through flanges
by bolts and nuts. The bolts shall not be less than M 12 size.
• Each subassembly shall be made up of basically two types of
chute plates,
• Tray type, and
• Plate type.
• The chute plates shall be joined by continuous welds and flanges
of the angles shall be joined together by intermittent welding of
min. 6mm fillet, 50mm long leaving gaps of max. 50mm ensuring
that welding starts from the ends. However, if the design requires,
the length of welds may be increased.
• To avoid any leakage of dust and to prevent noise, at the joints
between two subassemblies effective packing material shall be
provided.
• There shall be adequate clearances from all moving/rotating parts
of conveyors and other equipment into which the chutes will either
feed or collect the material. This clearance shall be min. 50mm.
Where it is not possible to have 50mm clearance, a clearance not
less than 20mm shall be maintained.
• Hinged type inspection doors shall be provided on all the chutes.
There shall not be any leakage of dust from the doors. The doors
shall be easily accessible and shall be provided with rubber
gaskets.
• Lifting hooks/lugs shall be attached at required places of heavy
subassemblies for lifting them as a unit as and when required.
4.1.16.0 SAMPLING SYSTEM (MECH 016)
Coal sample shall be collected automatically from coal streams for analysis of
quality of coal being dispatched. The sampling system shall consists of
i. Primary sampler fitted at discharge chute of Silo feeding conveyors.

ii. Primary sample feeder conveyor (if required)
iii. Crusher (single/double stage)
iv. econdary tertiary sampler
v. Sample collector
vi. Necessary power supply, control etc. to make the sampling system
complete.
The sampling system shall conform to IS/ISO/ASTM specifications. The

sampling system shall be complete in all respects for proper collection of
samples and shall be dust proof. It shall have inter-alia, the following features.
Job No: 730176 IV - 74

4.1.16.1 PRIMARY SAMPLE CUTTER:
Primary sample cutters shall be fitted suitably near the discharge end of belt
conveyors C7A & C7B at suitable location.
The sample cutter shall be fabricated with MS Plates and lined with abrasion
resistant stainless steel liner. The sample cutter shall be suitably designed to
extract representative samples as per Indian Standards from the stream of
coal of size up to 100 mm. The type and size of the cutter, cutter speed shall
be selected to suit the duty condition and these shall be clearly indicated in the
offer. The cutter opening shall be minimum 3 times the coal size and it shall be
of sufficient depth and designed to avoid any loss of sample. The sample
cutter shall pass through the stream to obtain the requisite samples.
The cutter lips shall be removable for wear replacement. There shall be no
protruding bolts or obstructions on coal contacting surfaces and corners of the
liners shall suitably radiused. The primary sampler drive shall be mechanical
or hydraulic. End travel of cutters to be verified and suitable logic shall be
provided to ensure that cutter has reached its end travel in a specified time.
Actual and radial travel type cutter paths through the stream are not allowed.
Adequate means such as dust doors or baffle plates shall be incorporated to
ensure sample cutter is in the park position. Frequency of sample increment
shall be in accordance with I.S. or equivalent international standard.
Inspection doors to observe sample cutter action shall be provided and dust
cover shall be of easily removable design.
4.1.16.2 PRIMARY SAMPLE BELT FEEDER:
There shall be belt feeder conveyors of suitable size to collect coal samples
from the sample discharge chute and then convey to sampling system. The
belt feeders shall be complete with head and tail sections, drive, skirting,
adjustable feed gate in feed and out feed sections, conveyor belting etc. The
complete system shall be designed to suit the duty requirement and to feed
the metered amount of coal to the sample crusher/secondary sampler without
loss of fines or moisture. The belt conveyor shall be completely sealed with
dust tight enclosures. A screw take up and pulley scraper are also to be
provided. The belt shall be fitted with variable speed drive for local manual
adjustment and an adequate means of adjusting the bed depth using a striker
gate at the feed hopper discharge. These adjustments shall be adequate to
ensure no contamination of one sample increment with the next following
increment otherwise also this has to be insured. The feed hopper shall be
designed to empty completely with no possibility of sample retention.
4.1.16.3 BIAS CONNECTIONS
There shall be bias connections in the chutes between the belt feeders and
crusher. This connection shall be utilized for collecting the primary sampled
coal into the Employer's container.
4.1.16.4 SAMPLE CRUSHER (PRIMARY):
The sample crusher module shall be designed to reduce the (-) 100 mm size
Job No: 730176 IV - 75

coal to minus 8 mesh without loss of fines as well as moisture. The crusher
may be of single stage or double stage type depending upon the type and size
of crusher.
4.1.16.5 SECONDARY SAMPLER
The crushed product shall be fed to the secondary sampling machine through
a belt feeder. The secondary sampler shall be self contained, dust tight to suit
the duty requirement and shall be installed between the inter-connecting chute
works. The internal surface coming in contact with the coal stream shall be
lined with abrasion resistant stainless steel liner plate. The sampler shall be
complete with cutter driver, flanged chute connections etc.
The secondary sampler drive shall be designed to take representative sample

of the crusher discharge. It shall operate through the coal stream in manner
similar to primary sampler. Sampler cutter speeds shall not exceed 0.6 m/sec.
The minimum number of increments shall be six times the number of primary
increments. Sample drive may be hydraulic or mechanical. The sample cutter
shall move through the whole stream at right angles to the flow. Accrual and
slot type feeders are not acceptable.
4.1.16.6 TERTIARY SAMPLER
This shall be self-contained, dust and moisture tight and be of modular

construction. The sampler shall be complete in all respects with M.S. housing,
inspection door, drive as required. The cutter shall be made of stainless steel
and shall be fixed position under a moving stainless steel hopper. The sample
cutter shall have adjustable cutter lips. The cutter opening shall be completely
sealed the prevent contamination when the hopper is parked.
The cutter opening for fine coal shall not be less than 30 mm. In the tertiary
sampler , the minimum size of sample shall not be less than 100 gm percent
and increment shall not be less than 60 (sixty).
4.1.16.7 SAMPLE COLLECTOR
The sample shall be collected in dust and moisture tight stainless steel
containers with proper fittings for engagements and removals. The rotating
table shall be driven by geared motor drive system. Capacity of each collector
shall not be less than 25 kgs.
4.1.16.8 REJECT BUCKET ELEVATOR
The rejected coal from the sampling system shall be fed back to the conveyor
system through bucket elevator. The bucket elevator shall be of centrifugal
discharge, continuous chain and bucket type. Bucket elevator shall be
complete with drive, motor, reduction gear-box, head and boot pulley etc. and
shall be totally enclosed.
Job No: 730176 IV - 76

4.1.16.9 SAMPLE SYSTEM CHUTES
All chutes within the sampling system including reject elevator discharge chute
shall be fabricated from 10 mm thick mild steel and lined with abrasion
resistant stainless steel liner of 3 mm thickness. All chutes shall have a
minimum valley angle of 60 degrees. All chutes shall be sealed against dust
loss.
4.1.16.10 SAMPLING SYSTEM CONTROL
The sampling system shall be provided with electrical control system with
timers etc. to provide for automatic start and close.
The sampling system shall be inter-locked to the in feed conveyor. The
electrical system shall be complete with motor control centre, relay panel
control, console with graphic display and other auxiliary equipment as per
latest international practice.
4.1.17.0 SPECIFICATIONS OF MISC. EQUIPMENT (MECH- 017)
4.1.17.1 SLOW SPEED BELT PULLING DEVICE
A slow speed belt pulling device is required to facilitate and to reduce the time
taken for belt replacement/jointing. This shall be suitable for pulling belt
envisaged in the system. This unit shall be suitable trolley mounted and shall
be capable of anchoring at a suitable location. It shall be complete with rope
diversion pulleys, sheaves etc.
4.1.17.2 FLAP GATE
MOTORISED FLAP GATE

Motorised flap gate with a two way chute shall be provided at the discharge
chute of belt conveyors C1, secondary crusher output, C7A & C7B. The flap
gate of the bifurcation chute shall be of robust construction and shall be
actuated by motor operated worm reduction gear actuator. The motor shall be
completely dustproof and its starting shall be able to provide sufficient thrust
for operation of the flap gate against the falling weight of coal. The flap gate
shall have locking arrangements for two extreme positions and a suitable
intermediate position. The flap gate assembly shall be mounted with bolted
connection for easy replacement. It shall consist of MS plate lined with rubber
liner or suitable thickness on either side. The flap gate shall be mounted on a
shaft which in turn shall be mounted on antifriction bearings. The bearing
housing should be dustproof.
Dust and explosion proof switches of an approved manufacture suitable for
use with 230 V, 50 Hz, AC supply shall be provided.
The equipment shall be capable of being operated for at least fifteen switching
per hour. Provision should be made for remote control (i.e. from the control
room) but it will have a local control also. Apart from this, provision for manual
operation of the flap gate should also be incorporated.
Job No: 730176 IV - 77

4.1.17.3 NOISE AND VIBRATION CONTROL
It is well accepted of that noise pollution causes fatigue to operation personnel.

Every effort will be made to keep down the noise level to the extent it is
feasible. All machine mountings will have suitable arrangement for reducing
the vibration and thereby noise. All transfer chutes shall be fitted with abrasion
resistant steel liner.
4.1.17.4 VULCANISING MACHINE:

SCOPE
This specification covers the design, manufacture, constructional features, and
performance requirements for supply, installations, painting, testing and
commissioning of belt vulcanising machine to be used in maintenance of coal
handling plant.
APPLICABLE STANDARDS & CODES
The equipment shall be designed and manufactured in accordance with the
latest revision of IS. Wherever IS are not available, British standard /
American standard/DIN/JIS or any other equivalent or superior standard shall
be followed. Any amendment / revision in above standard that may be in force
during the period of manufacture shall also be taken into consideration.
Besides the above, the equipment covered under this specification shall
comply with the requirement of all latest applicable statutory acts, regulations
which may be in force during they period of execution and which are related
with design, construction and operation of the equipment in the location where
it will be installed.
DUTY
The vulcaniser shall be light portable and suitable for belt vulcanising,
longitudinal rip repair and spot repair.
DESIGN AND CONSTRUCTIONAL FEATURES
a) The Machine should be light and portable.
b) The heating plates and crossbeam should be of high strength
extruded aluminium alloy plates & sections.
c) Size of plates should be adequate to cover the entire spliced area of
belt so as to vulcanise the belt in single setting.
d) The design layout and ratings of the heating elements in the platens
should ensure uniform temperature distribution. Vulcanising
temperature of 145 degree centigrade should be reached at the belt
with in 30 minutes.
e) Design should ensure accurate control of temperature 145o C (±5o C)
even with voltage fluctuation.
f) Hydraulic pressure system consisting of hydraulic hand pump,
distributor hoses and hydraulic cross beams should be provided.
g) High pressure hoses to be provided with quick release couplings for
quick and easy coupling and uncoupling.
Job No: 730176 IV - 78

h) Cross beams to be provided with closure nipples so that during

vulcanising even if there is a sudden pressure drop due to hose
burst or inadvertent quick release of release and vulcanising can
continue.
i) Adequate number of hydraulic cross beams to be provided for
uniform pressure over the entire spliced area of belt
j) Cross beams should be highly tempered extruded aluminium alloy
construction which shall resist any deformations even after repeated
use.
k) The same vulcaniser should be capable of vulcanising a range of
different belt widths and different ratings.
Job No: 730176 IV - 79

4.2 SPECIFICATION FOR ELECTRICAL EQUIPMENT
4.2.1.0 GENERAL
4.2.1.1 INTENT OF SPECIFICATIONS
The specification covered under this document relate to all electrical and
electronic equipment to be installed and will function at Lingaraj CHP and
Silo for power supply, illumination, emergency and safety lighting,
earthing, protection against direct stroke of lightning and traveling waves,
welding sockets and switches, signaling, centralized monitoring and auto
remote and auto sequence control of the plant, communication,
pressurization and air conditioning. However, items of work, not specially
mentioned but needed to meet the requirements of the specifications for
successful and trouble free operation, shall be deemed to be included in
the scope.
4.2.1.2 STANDARDS AND REGULATIONS
All equipment and installation covered under this document shall conform
to the latest relevant Indian standards. However, equipment conforming to
other international standards may also be accepted in the absence of
Indian standard, subject to approval from the customer.
All equipment and installation shall conform to the following rules /

regulations amended up to date.
a. The Indian Electricity Rules.

b. The Indian Electricity Act.
c. The Indian Electricity (Supply) Act.
d. Mining Acts and Rules.
e. CMR- 1957
Equipment complying with any other authoritative standard such as IEC,

British, USA, German etc. will also be considered if it ensures
performance equivalent or superior to Indian standard. In that case,
however the Bidder shall supply copies of specifications adopted by the
standard and shall clearly mention in what respect such standard
specifications differ from the corresponding Indian standard mentioned
elsewhere. The salient feature of comparison shall be brought out and
furnished along with the offer.
The specifications, codes and standard referred in this specification shall

govern in all cases where references are to be made. In case of conflict
between the referred specifications, code or standard and this technical
specification, the later shall govern.
JOB NO-730176 IV-80

Some of the relevant Indian standards for the equipment covered under
these specifications are given against equipment heads.
4.2.1.3 AMBIENT CONDITIONS
All equipment shall be designed to suit tropical climate coal dust prone
area and average ambient temperature of 450C, humidity 90% and altitude
up to 100 meters above mean sea level. Where equipment is installed
outside and exposed to direct sunrays, these shall be suitable for
operation at higher ambient temperature and rigorous weather conditions
under which they are required to operate.
All electrical equipment provided indoor, shall have IP: 52 enclosure

protection class whereas all equipment provided outdoor shall have IP: 55
enclosure protection class. Type of enclosure for any electrical control
panel mounted in bunker floors and transfer points shall be of IP: 62. All
enclosures shall be totally dust and vermin proof.
In order to check the compliance of degree of protection, all enclosure

shall be subject to standard routine checks. The customer reserves the
right to get any equipment tested as per relevant IS in case of a doubt.
4.2.1.4 SYSTEM PARAMETERS
The following system voltage shall be adopted while designing the

equipment and system.
a. Motor above 90 KW : 3300 V AC ±10%, 50 Hz

(Except Plough feeder)
b. Other motors : 415 V AC ±5%, 50 Hz
c. Motors below 0.2 KW : 240 V AC, 50 Hz
d. Control circuits : As required by the system
e. Lighting system : 230 V (L-L) through Independent
lighting transformer.
All equipment shall be designed for a voltage variation of + 10% for

3300V, + 5% for 415V and frequency variation of + 3%.
During starting, the voltage drop at the motor terminals shall not exceed
15 % with other loads under running conditions. All electrical equipment
shall operate satisfactorily during starting of any large or distantly located
electrical drive.
The voltage drop at any point in the lighting circuit shall not exceed 3%.
JOB NO-730176 IV-81

4.2.1.5 EARTHING SYSTEM
3300 V AC restricted earthed

415 V AC solidly earthed
240 V AC Neutral effectively earthed
The details of customers power supply are given elsewhere and therefore
the bidder shall furnish the equipment and the design accordingly.
4.2.1.6 PROTECTION
In general, for switchgear IP54 and for motors IP55 degree of protection
shall be provided.
4.2.1.7 TECHNICAL SPECIFICATIONS
Broad specifications of some of electrical and communication equipment

are given in this section. The bidder however shall give complete
specifications of all electric, electronic, communication equipment, cables
etc. as required for completion of installation of CHP, Substation/switch
stations, MCCs and SILO.
4.2.2.0 SPECIFICATION FOR 30 kV LIGHTNING ARRESTOR
4.2.2.1 STANDARDS TO BE FOLLOWED
The lightning arrestor shall conform to the latest issue of IS: 3070 & IS:
4004 unless otherwise specified. All accessories shall also conform to
the relevant Indian Standards.
The design and operational features of the equipment offered shall

comply with the provisions of the latest version of the following Acts and
Statutory Regulations:
a) Indian Electricity Act.

b) The Indian Electricity Rules.
c) Fire Insurance Regulations.
The supplier shall make suitable modification, addition/alteration in the

equipment wherever necessary to comply with the above mentioned
Acts/Rules/Regulations.
4.2.2.2 DESIGN FEATURES
The arrestor shall be self supporting heavy duty station class type with
metal top and metal base having arc transfer devices and pressure relief
with current limiting gaps.
JOB NO-730176 IV-82

The incoming and outgoing side terminal connections should be suitable
for ACSR and 50 mm. IPS Aluminum Tubular Bus respectively. Separate
attachment may be included with the supply to suit Tubular Bus and
ACSR conductor.
4.2.2.3 OPERATING REQUIREMENTS
The ambient conditions, system details, electrical features etc., have

been indicated in Annexure: I
4.2.2.4 FITTINGS AND SPARES
All fittings provided should be of standard make.
4.2.2.5 TEST
The successful bidder should submit all test certificates as required by

ISS and Indian Electricity Rules.
4.2.2.6. TECHNICAL PARTICULARS
The supplier shall furnish the technical particulars duly filled.
4.2.2.7 DEVIATIONS
Deviations, if any, from this specification shall be clearly indicated in the

offer by the tenderer.
4.2.2.8 LIST OF ANNEXURES
ANNEXURE: I
TECHNICAL PARAMETERS FOR 33 kV LIGHTNING ARRESTOR
i. Installation : Outdoor
ii. Class : Station
iii. Type of mounting : Pedestal
iv. Quantity : As per BOQ & supply of Equpt
v. No. of phases : 3(three)
vi. Frequency : 50 Hz.
vii. System voltage
(a) Nominal : 33 kV RMS
(b) Highest : 36 kV RMS
viii. Nominal discharge current : 10 kA
ix. System earthing : solidly earthed neutral.
x. Maximum ambient temp. : 50o C
JOB NO-730176 IV-83

4.2.3.0 SPECIFICATION FOR 33kV OFF LOAD ISOLATOR
4.2.3.1 This specification covers the technical details, operating requirement,

constructional details and some guidelines for the procurement of
isolators.
This specification applies to air break alternating current isolators for

outdoor installation, for 33 kV and service frequency of 50 Hz.
This specification shall be read in conjunction with enclosed sheets and

other relevant references as specified.
The isolator shall conform to the following Indian Standards:
i. Alternating current disconnector (Isolators) and Earthing Switches

for voltages above 1000V: IS: 9921.
ii. Code of practice for Earthing : IS : 3043

comply with the provisions of the latest version of the following Acts and
Statutory Regulations:
i. Indian Electricity Act

ii. Indian Electricity Rules
iii. The Factory Act.
iv. Fire Insurance Regulation
The supplier shall make suitable modification/ addition/ alteration in the

equipment wherever necessary to comply with the above mentioned
Acts/Rules/ Regulations.
Wherever service conditions etc. laid down in this specification differ

from those in Indian Standards Specifications, the conditions specified
herein shall prevail.
4.2.3.4 AMBIENT CONDITIONS
The ambient conditions are indicated in Annexure: I.
4.2.3.5 SYSTEM DETAILS
The rotating units shall be supported by thrust/taper roller bearings. All

moving parts shall be fitted with nonferrous bushes. The operating
mechanism shall comprise of suitable bar and GI pipe of adequate
JOB NO-730176 IV-84

length brought down from the pole to a handle provided with galvanized
guides. The same shall have arrangement for padlocking at OFF and
ON position of the switch.
The design of the isolators shall be in accordance with the latest

practice. However, the following points shall be taken into consideration.
4.2.3.7 ELECTRICAL FEATURES
4.2.3.7.1 INTER LOCK
Interlocking arrangement shall be provided with the control circuit

breaker to prevent On Load operation of the isolator. For this, necessary
number of auxiliary contacts shall be provided on the isolator.
4.2.3.8 MECHANICAL FEATURES
The isolator should be fitted with arcing horns to interrupt high load and
magnetizing current on transformer.
The isolator should be designed to withstand severe weather conditions

and should be capable to withstand electrodynamics stresses due to
short circuit. The incoming and outgoing side terminal connections shall
be suitable for 50mm. IPS aluminum tubular bus connection.
4.2.3.9 CONSTRUCTIONAL DETAILS
4.2.3.9.1 SWITCH BLADES
The blade shall be made of hard drawn electrolytic copper strips of

liberal section to give extra strength and thermal capacity. All copper
parts should be silver plated and ferrous parts metalised to give smooth
finish.
4.2.3.9.2 MAIN BEARING
The main bearing (ball, thrust or taper roller bearing) supporting the
main rotating insulator operating shaft shall be adjustable in the field, if
necessary. The insulator shall be bolted to the top of sheet steel base of
fabricated construction. All working parts shall be made of non rusting
steel or specially treated to resist corrosion and the hole shall be brass
bushed.
JOB NO-730176 IV-85

4.2.3.9.3 FITTING AND SPARES
All standard fittings should be provided.
4.2.3.9.10. TEST

4.2.3.11 TECHNICAL PARTICULARS
The supplier shall furnish the technical particulars duly filled in.
4.2.3.12 DEVIATION

offer.
4.2.3.13 LIST OF ANNEXURES
ANNEXURE: I
TECHNICAL PARAMETERS FOR 33kV OFFLOAD ISOLATOR
The isolator shall generally conform to IS: 9921 (latest). The basic
technical parameters are as follows:
i. Rated voltage : 33 kV (RMS)

ii. No. of phases : 3
iii. Frequency : 50 Hz
iv. Current rating : 630/1250 Amps.
v. Short time current : 13.12 kA corresponding to

rating for 3 second 750MVA.
vi. Type : Horizontal mounted, centre post

rotating, manually operated with/
without earthing switch.
vii. Rated Insulation level
a) One minute power frequency
withstand voltage : 70 kV (RMS)
b) Lightning impulse
withstand voltage : 170 kV (PEAK)
viii. Contact : Contacts shall be designed to

withstand 630/1250 Amps without
overheating. The switch shall have
self aligning Ù' type hard
copper/P.B. contacts and fitted with
hard copper/P.B. blade of liberal
JOB NO-730176 IV-86

cross section. The leakage
distance shall not be less than the
minimum specified in ISS. The
contacts shall be silver plated.
ix. Clearance between phases : As per relevant standard.

x. Application : Outdoor
xi. Quantity : As per BOQ
xii. Maximum ambient temp. : 50oC
xiii. Supporting insulator : The supporting insulator shall be 3
nos. of post type brown glazed
porcelain insulator per phase and
tested in accordance with relevant
IS.
4.2.4.0 SPECIFICATION FOR 33 kV VACUUM CIRCUIT BREAKER
4.2.4.1 SCOPE
i. This specification document covers the technical details, operating

requirement, constructional details, testing and some guidelines for
procurement and installation of 33kV, Vacuum Circuit Breaker.
ii. This specification applies to AC Vacuum circuit breakers, designed

for outdoor installation for operating at 50Hz and at a system
voltage of 33kV.
iii. This specification shall be read in conjunction with the enclosed

sheets and other relevant references as specified.
i) The Vacuum Circuit Breaker shall conform to IEC 56 /IS: 13118

(latest revision) unless otherwise specified.
ii) The design and operational features of the equipment offered shall
comply with provisions of the latest versions of the following Acts and
statutory regulations:
a) Indian Electricity Act.

b) Indian Electricity Rules.
c) Fire Insurance Regulations.
d) The Indian Electricity (Supply) Act.
e) The Indian Factory (Supply) Act.
f) TAC regulations.
g) National Fire Code.
h) DGMS regulations.
JOB NO-730176 IV-87

The tenderer shall make suitable modification/ addition/alteration in
the equipment wherever necessary to comply with the above
mentioned Act/Rules/ Regulations.
iii) Wherever service conditions etc. laid down in this specification differ
from those in Indian Standard Specification, the conditions specified
herein shall prevail.
i) The Circuit Breaker shall be designed for its full reliability in the most
hazardous conditions. Simplicity of design and less number of moving
parts will be preferred. Interchangeability of similar parts should be
ensured in the manufacturing process.
ii) The Circuit breaker shall be mounted on rigid, compact and weather-
proof frame work.
iii) Provision for remote control shall be made.
iv) The vacuum interrupter unit shall be so designed as to achieve a

desirable break- time.
v) The Vacuum circuit breaker shall have the following features:
a) High reliability.
b) High electrical and mechanical life.
c) Negligible maintenance.
d) Fitted with high quality vacuum interrupters.
e) capable of interrupting 100 full short circuit operations.
f) Rating and diagram plate.
4.2.4.4.1 SYSTEM DETAILS
The technical parameters have been indicated in Annexure-I.
4.2.4.4.2 OPERATING MECHANISM
The Circuit Breaker shall be provided with a motor operated spring

charged mechanism with electrical release. The mechanism shall be trip
free. Provision shall also exist for charging manually in the event of failure
of the mains.
The mechanism shall be provided with motor starter fitted with overload
release, auxiliary switches and socket for inspection lamp. The charging of
springs shall be done by a 240 volts AC single phase motor. The remote
control switch will be provided on the control panel, details of which have
been elaborated elsewhere in this document. Closing and tripping devices
JOB NO-730176 IV-88

shall operate at 110 volts DC available from the storage batteries. It is
envisaged that C.T. operated direct acting trip coil will also be fitted for
reliable protection. Some of the important precautions required are
mentioned below:
i. The spring, if charged cannot be released when the circuit breaker

is closed;
ii. Interlock shall be provided to prevent slow closing or opening of the
circuit breaker in its service position:
iii. If the spring fails, it should be possible to close the circuit breaker
manually
iv. It should be possible to recharge the spring automatically while the
circuit breaker is closed, thus preparing in advance for the next
closing operation.
v. Necessary limit switches should be incorporated in the automatic

spring charging circuit. The release of the spring shall be by
electrically operated coil for remote control. An emergency hand
release should be provided to work in case of power supply failure.
Visual ON/OFF indication should be provided for the circuit breaker. The
operating gear shall also have auxiliary contacts (6 NO + 6 NC) for wiring
at site, tripping and closing coils, mechanical operation counter,
mechanical position indicator showing "Spring charged" and "Spring free",
Local/Remote selector switch, space heater with control switches, cabinet
lamp etc. All the internal wirings shall be terminated in a connector box.
The vacuum interrupter should enable the metal vapour for arc discharge
through the plasma and is extinguished near current zero. The conductive
metal vapour should condense within a few micro second leading to the
rapid buildup of dielectric strength across the open contact gap.
4.2.4.4.3 SAFETY
Provision shall be made for interlocking with isolators or other circuit

breakers to avoid any mal-operation.
The live parts of the circuit breaker panel shall be properly shrouded as
per relevant safety rules.
4.2.4.4.4 CONSTRUCTION
The switchgear shall be mounted on structure.. The three poles of the

circuit breaker are mechanically connected through a linkage mechanism.
All the three poles of the circuit breaker are identical. Each pole is made of
vacuum interrupter chamber fitted on an insulated support column. They
are mechanically connected to the operating mechanism. Relays and
customer connection have been brought together in a centralizing cubicle,
JOB NO-730176 IV-89

located on the central pole. For the tri-polar design, the unit shall have only
one control block.
4.2.4.4.5 SAFETY INTERLOCKS
Mechanical and electrical interlocking shall be provided. Key type

mechanical interlocks shall be provided between circuit breaker and
isolator to facilitate maintenance works. Electrical interlock shall be
provided for switching operation and other necessary functions in order to
ensure correctness and safety. All types of interlocks required considering
the total system shall also be provided.
4.2.4.4.6 EARTHING SWITCH
Earthing switch shall be provided to ensure that
i. Circuit breaker is not cranked to service position if the switch is

closed.
ii. Earthing switch cannot be closed when the circuit breaker is in
service condition.
iii. Earthing of moving portion and current carrying parts shall be
provided.
4.2.4.4.7 SPARE PARTS, TOOLS & TACKLES
A detailed list of spare parts, tools and tackles shall be furnished.
4.2.4.4.8 TESTS

4.2.4.4.9 DEVIATIONS

offer.
4.2.4.5 LIST OF ANNEXURE
ANNEXURE-I
TECHNICAL PARAMETERS FOR 33kV VACUUM CIRCUIT BREAKER
The Vacuum Circuit Breaker shall generally conform to IS: 2516 of 1980
(latest revision). The basic technical parameters of the circuit breaker are
as follows:
1. Nominal system voltage : 33kV RMS

2. Highest system voltage : 36kV RMS
JOB NO-730176 IV-90

3. Voltage variation : + 10%
4. No. of phases : 3
5. Frequency : 50Hz
6. Frequency variation : + 3%
8. System Earthing : Restricted Earthing
9. Quantity required : As per BOQ
10. Application : Outdoor
11. Maximum ambient temp. : 50oC
12. Installation : Electrically exposed
13. Current rating : 630/1250 Amps.
14. Symmetrical breaking current & : 13.12kA, 750MVA.
corresponding breaking capacity :
15. Short time current rating for 1 sec. : 13.12kA
16. Rated insulation level
withstand voltage : 70kV RMS
b) Lightning impulse
withstand voltage : 170kV peak
17. Purpose : 33kV incomer
18. Degree of protection : IP-55
4.2.5.0 SPECIFICATION OF 33 kV BUSBAR
i. The Bus bar proposed for the substation shall be made of

Aluminium Tubes on post insulators. The Diameter of the tubular
bus shall be 50 mm.
ii. The deflection of the Bus bar supported on post insulators shall not
exceed half the Diameter of the Bus bar. Or 0.021 L (where L is the
span in meter), whichever is less.
iii. It shall be ensured that the insulators supporting the bus bars are
not subjected to high stresses.
iv. The maximum current density of the Bus bar and connections in
direct contact with air shall be such as not to exceed the following
operating temperature.
a) Maximum Permissible Temperature of 70 0C

b) Maximum Hot Spot Temperature of 75 0C
v. Current Density shall be maintained shall be maintained between

140 Amp/sq. cm. to 152 Amp/sq. cm.
vi. The maximum permissible current density shall not normally
exceed 18.6 kA/ sq.cm.
vii. The insulators, Busbars & connections shall not be stressed to not
more than 1/4 of the Breaking Load or 1/3 of their elastic limit,
whichever is lower.
viii. The Maximum Diameter of the Jumper on the substation structure,
wherever required shall be 0.635 cm.
JOB NO-730176 IV-91

4.2.6.0 SPECIFICATION FOR 33kV REMOTE CONTROL PANEL AND

RELAY MODULE
4.2.6.1 GENERAL
i. The 33kV remote control panel and relay module shall be indoor
type and used in the substation building. It shall be floor mounted,
free standing, dust and vermin proof, sheet steel clad cubicle. The
sheet steel cladding shall be minimum 2mm. thick and shall be
degreased, derusted, pickled, phosphatised, putty finished, pre
treated with two coats of anticorrosive primer and finally treated with
two coats of final metal paints. The panel shall be modular type. The
joints shall be smooth, close fitting and shall be non-obstructive.
ii. The panel shall control the operation of the primary 33kV circuit
breaker of 5MVA transformer. The panel shall house components
necessary for:
• Remote operation of the circuit breaker.

• Actuation of various protective devices as detailed afterwards in
this specification.
• Annunciation of the faults with Audio and Visual indications.
• Mimic Sections of painted mimic diagram and semaphore indicator
for circuit breaker.
4.2.6.2 COMPONENTS
The control panel for operation of the primary 33kV circuit breaker of
transformer shall have the following components mounted on the front
side of the panel:
i). 1Amps CT Secondary operated combined IDMT and High set

instantaneous Relay consisting of two overload units (Range
50% : 200%), one earth fault unit (Range 10%:40%) and three
igh set instantaneous units Range 400% : 1600 %).
ii). Auxiliary Relays for annunciation and actuation of the trip circuit
on :
a) Oil temperature Alarm.
b) Oil temperature Trip.
c) Winding temperature Alarm.
d) Winding temperature Trip.
e) Overload Trip.
f) Earth Fault Trip.
g) Short Circuit Trip.
iii). 110 Volts D.C. Operated high speed breaker trip auxiliary relay.
iv). 110 Volts D.C. power supply control switch and fuse.
JOB NO-730176 IV-92

v). 230 Volts A.C. power supply control switch and fuse.
vi). 110 Volts D.C. rated spring return breaker ON/OFF control switch.
vii). 230 Volts A.C. rated spring return motor operating switch.
viii). Push button for `TRIP CIRCUIT HEALTHY' Test.
ix). Push button for ÈMERGENCY TRIP'.
x). Indicating lamps with current limiting resistor:
a) GREEN for Breaker ÒFF'
b) RED for Breaker ÒN'
c) AMBER for Breaker ÀUTO TRIP' on Fault.
d) WHITE for `TRIP CIRCUIT HEALTHY'.
xi. Charged indicator for Circuit Breaker Operating spring.
xii. Indicating lamp (with current limiting resistor) for :
a) 110Volts D.C. POWER SUPPLY ON.
b) 230Volts A.C. POWER SUPPLY ON.
xiii. 1Amp C.T secondary operated ammeter with selector switch
xiv. 110Volts AC PT Secondary operated voltmeter with selector
switch (Range 0:40kV, P.T. Ratio:33kV/110V).
xv. Power factor meter.
xvi. kWh meter.
xvii. kVA meter.
xviii. kW meter.
xix. kVAr meter.
The control panel shall have audio and visual annunciation facilities with
ACCEPT/TEST/RESET facilities for the following:
a) Oil temperature Alarm and Trip.

b) Winding temperature Alarm and Trip.
c) IDMT relay Trip for over current, Earth fault and short circuit.
The annunciation of fault will be indicated by an Audio alarm and Visual

indicator. Pressing on "ACKNOWLEDGEMENT" button shall stop the
Audio alarm but visual indicator shall render the circuit breaker
inoperative till the fault is rectified and the respective protective relay is
reset
Relevant name plates will be fixed wherever required.
4.2.6.3 INTERNAL WIRING
The control panel shall be neatly wired using 650 volts grade PVC
insulated single Core Copper conductor of cross section 2.5mm2. All
wiring shall be bunched in groups by nonmetallic clips and each wire
shall be identified at both ends by ferules indicating the designation of
the wire in accordance with the wiring diagram. All the wiring shall be
terminated in terminal blocks for external connection.
JOB NO-730176 IV-93

4.2.6.4 CABLE ENTRY
The control panel shall have cable entry preferably from the bottom of
the cable entry shall be dust and vermin proof and shall be through
compression type glands. The plate supporting the cable glands shall
be sufficiently strong to take the load of the cables.
4.2.6.5 INDICATING LAMPS
The indicating lamps shall preferably be miniature filament type with

lamps of colored translucent lenses. The lamps shall conform to IS:
1901.The lamps shall be so fitted that they can be removed from the
front of the panel without disturbing the holders and internal wirings.
The control voltage for the operations of the relays shall be made
available from a separate 110Volts battery source. The 110Volts A.C.
supply for meters shall be taken from the potential transformer installed
in the bay.
4.2.7.0 SPECIFICATION FOR 33kV CURRENT TRANSFORMER
4.2.7.1 SCOPE
The Current Transformer shall be single phase, filled with 33kV grade
mineral oil and shall operate in conjunction with the 33kV vacuum Circuit
Breaker to control, protect and measure the electrical power supply of
the system. The current transformer shall conform to IS: 2705 of 1981
(latest revision) and also to the following technical parameters:
4.2.7.2 TECHNICAL PARAMETERS
i. Nominal system voltage : 33 kV RMS.

ii. Highest system voltage : 36 kV RMS.
iii. Frequency : 50 Hz
iv. No. of phases : 3
v. Application : Outdoor
vi. Mounting : Shall be suitable for
Mounting on structures.
vii. System Earthing : Neutral effectively
earthed
viii. Installation : Electrically exposed
Installation.
ix. Transformation Ratio
a) Core: I : 100/1
b) Core: II : 100/1
c) Core: III : 100/1
x. Purpose
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a) Core:I : Metering
b) Core:II : Protection
c) Core:III : Protection
xi. Rated Burden
a) Core:I : As per requirement
b) Core:II : As per requirement
c) Core:III : As per requirement
xii. Rated Insulation Level
withstand voltage : 70 kV (RMS)
b) Impulse withstand test voltage
with standard full wave : 170kV (Peak)
xiii. Accuracy Limit : 10 for protective cores

(Core Nos. II and III)
and less than 5 for
metering Core (Core No.I)
xiv. Short time current rating for 1 sec. : 13.12 kA
4.2.7.3 LIST OF FITTINGS AND ACCESSORIES
The supply of the current transformers shall be complete with the

following accessories:
i. Primary terminals.
ii. Nitrogen filling valve with cap.
iii. Oil level indicator.
iv. Secondary terminals.
v. Secondary terminals box.
vi. Lifting lugs.
vii. Cable gland.
viii. Primary Reconnection links.
ix. Oil filling plug.
x. Arcing horn.
xi. Oil drain plug.
xii. Earthing Terminals.
xiii. Abnormal pressure release device.
xiv. Rating and Diagram Plate.
4.2.7.4 TEST

.
4.2.7.5 DEVIATIONS
Deviations, if any, from this specification shall be clearly indicated in this

offer.
JOB NO-730176 IV-95

4.2.8.0 SPECIFICATION FOR 33kV POTENTIAL TRANSFORMER
4.2.8.1 SCOPE
The (33kV/1.732)/(110V/1.732)/(110V/1.732) single phase, mineral oil

filled outdoor type Potential Transformers are required for supply of
power to the measuring and protective devices in the 33kV control
panels and relay modules of the substation. The Potential Transformer
shall conform to IS: 3156 parts 1 & 2:1978 (latest revision) and also to
the following technical parameters.
4.2.8.2 TECHNICAL PARAMETERS
i. Nominal system voltage : 33kV RMS

ii. Highest system voltage : 36kV RMS
iii. Frequency : 50Hz
iv. No. of phases : 3
v. Application : Outdoor
vi. Mounting : Shall be suitable for mounting
on structures.
vii. System Earthing : Neutral effectively earthed
viii. Installation : Electrically exposed
installation.
ix. Transformation Ratio : (33KV/1.732)/(110V/1.732)
/(110V/1.732)
x. Class of Accuracy
a) Metering : 1
b) Protection : 5P SF10
xv. Purpose : Metering and protection.

xvi. Rated Burden : As per requirement
xvii. Rated Insulation Level
withstand voltage : 70kV (RMS)
b) Impulse withstand test voltage

With standard full wave : 170kV (Peak)
xv. Short time current

rating for 1 second : 13.12 kA.
4.2.8.3 LIST OF FITTINGS AND ACCESSORIES
The supply of the potential transformers shall be complete with the

following accessories:
JOB NO-730176 IV-96

i. HT terminals.
ii. Abnormal pressure release device.
iii. Oil level indicator.
iv. Lifting lugs.
v. Secondary terminal box with HV neutral terminal.
vi. Tertiary terminal box with neutral terminal.
vii. Earthing terminal.
viii. Earthing terminal box.
ix. Oil filling plug.
x. Oil drain plug.
xi. Nitrogen filling valve with cap.
xii. Rating and Diagram plate.
4.2.8.4 TESTS

4.2.8.5 DEVIATIONS
Deviations, if any, from this specification shall be clearly indicated in this

offer.
4.2.9.0 SPECIFICATION FOR 5000 kVA, 33/3.3 kV, POWER TRANSFORMER
4.2.9.1 SCOPE
This specification covers the requirements for two winding power

transformer protected by primary circuit breaker, alarm, temperature
indicator, tap change, marshalling box and neutral grounding resistor.
The exact voltage ratio and kVA rating of the transformer has been
specified in Annexure: I.
The transformers shall comply with the latest revisions of IS: 2026 and
IEV: 76 except where modified or extended by the provisions of this
specification and relevant parts of standards.
Material and component not specifically stated in this specification but

necessary for trouble free operation of the equipment and accessories
specified herein shall be deemed to be included.
4.2.9.2 OTHER RELEVANT STANDARDS
The other relevant standards applicable are as under:
• IS: 10561 : Application guide for power transformers.

• IS: 10028 : Code of practice for selection, installation and
maintenance of transformers.
• IS: 1866 : Code of practice for maintenance and supervision of
JOB NO-730176 IV-97

mineral insulating oil.
• IS: 2099 : Bushing for alternating voltage above 1000V.
• IS: 3639 : Fittings and accessories for power transformers.
• IS: 8603 : Dimensions for porcelain transformer bushings for
use in heavily polluted atmosphere (12 KV:36KV
class).
• IS: 335 : New insulating oil for transformers.
• IS: 6600 : Guide for loading of oil immersed transformers.
• IS: 2165 : Insulation coordination.
• IS: 2071 : Method of impulse voltage testing.
• IS: 2705 : Current transformers.
• IS: 1248 : Direct acting indicating analogue electrical measuring
instruments.
• IS: 3043 : Code of practice for earthing.
• IS: 2147 : Degree of protection provided by enclosures for low
voltage switchgear and control gear.
• IS: 7404 : Paper covered copper conductors.
• IS: 1271 : Thermal evaluation and classification of electrical
insulation.
• IS: 1554 : PVC insulated heavy duty) electric cables – 1100V
(Part: I).
• IS: 6772 : Industrial cooling fans.
• IS: 104 : Primary paints for steel surfaces.
• IS: 2932 : Final paints for steel surfaces.
• IS: 5 : color for ready mix paints.
Equipment complying with other internationally accepted standards like

BS, VDE, JIS etc. shall also be considered if they ensure performance
and constructional features equivalent or superior to standards listed
before. In such a case the bidder shall clearly indicate the standards
adopted, furnish a copy in English of the latest revision along with copies
of all amendments and revisions in force as on date of opening of bid
and shall clearly bring out the salient features for comparison.
4.2.9.3 SERVICE CONDITION
• Ambient Air temperature : Minimum 5oC to Maximum 50oC

with daily average ambient air
temperature of 40oC.
• Altitude : Maximum up to 1000 meters above
MSL.
• Humidity : Relative humidity maximum up to
100% during rainy season.
• Location : Outdoor
4.2.9.4 RULES AND CODES
JOB NO-730176 IV-98

comply with the provisions of the latest version of the following rules and
codes.
a) The Indian Electricity Rules.

b) National Electricity Code
The manufacturer shall make suitable modifications, addition/alteration

in the equipment whenever necessary to comply with the above
mentioned rules/codes.
The design of the transformers and accessories shall be in accordance

with the latest standard practice and shall be such as to facilitate
inspection, cleaning, repairs, maintenance and operation and shall
ensure safe operation under situation of sudden variations of loads and
voltages as may be required under local operating conditions.
(A) ELECTRICAL FEATURES
The electrical features shall ensure the following:
a) Continuous operation at rated kVA provided service conditions

does not exceed the values given in this specification.
b) Continuous operation at rated kVA with ±10 percent variation of
voltage and ±3 percent frequency.
c) Continuous operation at rated kVA at each of the tap voltages.
d) Over loading of units as indicated in IS: 6600 (latest).
e) Temperature rise limited to the following values :
Cooling Oil Winding
ONAN 50oC 55oC
f) The insulation level shall conform to the following values :
Nominal Highest Rated lightning Power frequency

system system impulse withstand voltage 1 minute
voltage
kV kV kV kV
rms rms peak rms
33 36 170 70
B) MECHANICAL FEATURES
a) The transformer shall withstand the electro-dynamic stress due to

terminal short circuit of the LV side assuming the HV side fed
from an infinite bus. All leads and windings in cores shall be
JOB NO-730176 IV-99

properly supported, clamped and tightened after vacuum drying to
ensure the short circuit withstand ratings. The short withstand
duration shall be minimum 2 sec.
b) The transformer shall be so designed as to minimize any undue
noise and vibration.
4.2.9.6.1 CORE
a) The transformer core shall be made of high grade non-ageing

grain oriented cold rolled silicon steel sheets of low hysteresis
loss and high permeability. The core structure shall be securely
grounded to prevent electrostatic potential. Lifting eyes and lugs
shall be provided on the limbs and coils assembly. Preferably no
bolt shall be used in the cores. Clamping shall be done externally
to the limb.
b) The design of the magnetic circuit shall be such as to avoid static
discharges, development of short circuit paths within itself or to
the earthed clamping structure and the production of flux
component at right angles to the plane of lamination which may
cause local heating.
c) Cores and windings shall be capable of withstanding shocks
during transport, installation & service and adequate provision
shall be made to prevent movement of core and winding relative
to tank during these conditions.
d) All steel sections used for supporting the core shall be thoroughly
sand blasted after cutting, drilling and welding.
e) The manufacture shall furnish the details such as type of core
material, source of procurement and BH curve & design flux
density at normal tap.
4.2.9.6.2 TANKS
a) Tanks shall be welded construction and fabricated from boiler

steel plates of adequate thickness. The weld procedure and
performance shall be in line with ASME BPV: IX.
b) All seams and joints those are not required to be opened at site
shall be factory welded and wherever possible they shall be
double welded.
c) Tanks stiffeners shall be provided for general rigidity and these
shall be designed to prevent retention of water.
d) The tanks shall be designed to withstand :
i). Mechanical shocks during transportation.
ii). Vacuum filling of oil
iii). Short circuit force
e) The transformer tank and its accessories shall be designed
without pockets wherein gas may collect.
f) Adequate space shall be provided at the bottom of the tank for
settlements of sediments.
JOB NO-730176 IV-100

g) Suitable guides shall be provided in the tank for positioning the
core and coil assembly.
h) The tank shall be suitable for movement in both directions during
shipment. Each tank shall be provided with
i) Lifting lugs suitable for lifting the complete transformer
j) A minimum of four jacking pads.
4.2.9.6.3 TANK COVER
a) The tank cover shall be sloped to prevent retention of rain water

and shall not distort when lifted.
b) At least two adequately sized inspection covers one at each end
of the tank shall be provided for easy access to bushings and
earth connection. The inspection covers shall have suitable lifting
arrangement.
c) The tank covers shall be fitted with thermometer pockets (in the
position of maximum oil temperature) for bulbs of oil and winding
temperature indicators. The thermometer pocket shall be fitted
with a captive screwed top to prevent ingress of water. It shall be
possible to remove these bulbs without lowering the oil in the
tank.
d) Bushings, turrets, inspection covers, thermometer pockets etc.
shall be designed to prevent ingress of water into or leakage of oil
from the tank.
e) All bolted connections shall be fitted with weather proof hot oil
resistant neoprene gasket in between for complete oil tightness. If
gasket is compressible metallic stop shall be provided to prevent
over compression.
4.2.9.6.4 MOUNTING ARRANGEMENT
a) The transformers shall be provided with two nos bi-directional

skids and pulling eyes integral with the tank body for fixing the
transformer tank on foundation.
b) These skids shall be such that the bottom of the tank is at a
sufficient height above foundation for cleaning purposes. Each
transformer shall be provided with unit/bi-directional, flat/flanged
rollers of suitable length.
4.2.9.6.5 CONSERVATOR TANK
a) The conservator tank shall have adequate capacity to

accommodate oil preservation system and volumetric expansion
of the total cold oil volume in the transformer and radiators for a
change in temperature from minimum ambient air temperature of
5oC to 110oc.
b) The conservator shall be bolted into position so that it can be
removed for cleaning purposes.
c) The conservator tank, shall be fitted with a silica gel filter
JOB NO-730176 IV-101

breather.
d) The conservator shall be fitted with magnetic oil level gauge with
two independent low level electrically insulated alarm and trip
contracts. The oil level at 30oc shall be marked on the gauge.
4.2.9.6.6 PRESSURE RELIEF DEVICE
a) The transformers shall be provided with the single diaphragm type

of explosion vent and a spring loaded pressure relief device.
b) An equalizer pipe shall be connected to explosion vent from the
conservator.
c) The pressure relief device shall be sufficient size for rapid release
of any pressure that may be generated in the tank. The device
shall operate at a static pressure less than the hydraulic test
pressure of transformer tank. Means shall be provided to prevent
ingress of rain water. An extension pipe fitted above the device
shall direct the major flow of ejected oil downwards and permit its
removal without disturbing the device.
4.2.9.6.7 BUCHHOLZ RELAY
A double float type Buchholz Relay conforming to IS : 3637 (amended

up to date) shall be provided. All gas evolved in the transformer shall be
collected in this relay. The relay shall be provided with a test cock
suitable for a flexible pipe connection for checking its operation. A
copper tube shall be connected from the gas collector to a valve located
about 1200 mm above ground level to facilitate sampling with the
transformer in service. The device shall be provided with two potential
free contacts, one for alarms on gas accumulation and the other for
tripping on rise of pressure.
4.2.9.6.8 TEMPERATURE INDICATOR
A) OIL TEMPERATURE INDICATOR (OTI)
The transformers shall be provided with a dial type thermometer for

top oil temperature indication. The thermometer shall have
adjustable, potential free alarm and trip contacts, maximum reading
pointer and resetting device and shall be mounted in the marshalling
box. A temperature sensing element suitably located in a pocket in
the top oil shall be furnished. This shall be connected to the OTI by
means of capacity tubing. Accuracy class of OTI shall be 2oC or
better. The OTI shall have full scale deflection of at least 2400C and
shall have linear graduation to read every 2oC.
B) WINDING TEMPERATURE INDICATOR (WTI)
A device for measuring the hot spot temperature of the winding shall be
provided. The accuracy class of winding temperature indicator shall be
±2oC or better. It shall comprise the following:
JOB NO-730176 IV-102

i) Temperature sensing element.

ii) Image coil and bushing current transformer.
iii) Auxiliary CTs if required to match the image coil, shall be
furnished and mounted in the marshalling box.
iv) 150 mm local indicating instrument with max. reading pointer
mounted in marshalling box. It shall have two adjustable potential
free contacts, one for winding temp. high alarm and one for trip, in
addition to the contracts required for control of cooling equipment.
v) Automatic ambient temp. compensation.
vi) All contracts shall be adjustable on a scale and suitable for
connection in 240V circuit. These shall be accessible on removal
of the cover.
vii) The WTI shall have a full scale deflection of at least 240oC and
shall have linear graduations to read every 2oC.
4.2.9.6.9 WINDINGS
a) The conductors shall be electrolytic grade copper free from scales

and burns.
b) All windings shall be fully insulated. No graded insulation shall be
accepted. Use of enamel as a sole conductor insulation is
prohibited.
c) The insulation of transformer windings and connections shall be
free from insulating compounds which are liable to soften, ooze
out, shrink or collapse and be non catalytic and chemically inert in
transformer oil during service.
d) Coil assembly and insulating spacers shall be so arranged as to
ensure free circulation of oil and to reduce the hot spot of the
winding.
e) Tapings shall be so arranged as to preserve the magnetic
balance of transformers at all voltage ratios.
f) The maximum fault level to which the transformers may be
subjected is 750 MVA. Transformers manufacturer may take this
aspect into account while designing the transformer for the
through fault withstand capability.
g) All bus bars and leads shall be adequately supported in insulated
cleats or frames from the clamping locked.
h) The studs, set screws or bolts provided for securing cleats or
frames shall be effectively locked.
i) Bus bars and leads shall be supported throughout their length to
ensure that they do not move under normal service or during
transport or are not forced out from the prescribed position during
any short circuit.
j) The impedance values shall be as per relevant IS.
k) The winding shall be connected to achieve a Vector group of
Dy11.
l) The transformer shall have two windings as specified in the
Annexure: I.
JOB NO-730176 IV-103

4.2.9.6.10 INSULATION MATERIALS
a) Class ‘A’ insulating materials specified in IS:1271 shall be used

Wood insulation, where used, shall be well seasoned and treated.
b) Insulating Oil
i. The new insulating oil supplied with the transformer shall

conform to the requirements of IS:335. No inhibitors shall be
used in the oil.
ii. Prior to filling the oil in the main tank suitable number of
samples shall be tested for BDV, moisture content, resistivity
at 90 deg c, tan delta at 90 deg C and interfacial tension. The
oil samples taken from the transformer at site shall conform to
the requirements of IS:1866.
iii. The manufacturer shall dispatch the transformer filled with oil.
Ten percent (10%) extra oil shall be supplied for topping up, in non
returnable sealed containers suitable for outdoor storage.
4.2.9.6.11 EARTHING TERMINALS
Two earthing terminals suitable for connecting 50 x 8 mm mild steel flat

shall be provided at positions close to the two diagonally opposite
bottom corners of tank. These grounding terminals shall be suitable for
bolted connection. Two earthing terminals shall also be provided on
marshalling box and any other equipment mounted separately.
14.2.9.6.12 OIL PRESERVATION SYSTEM
The transformer shall be provided with conservator preservation system.

The top of the conservator shall be fitted with a silica get filter breather. It
shall be so designed that:
i) Passage of air is through dust filter and silica gel.

i) Silica gel is isolated from atmosphere an oil seal.
ii) Moisture absorption indicated by a change in colour of the tinted
crystal can easily observe from a distance.
iii) Breather shall be mounted not less than 1400 mm above rail top
level.
4.2.9.6.13 TERMINAL ARRANGEMENT
A) PORCELAIN BUSHING
i). The minimum clearances in air between the phases and

between the phase and earth potential of the porcelain bushing
shall be in accordance with IS: 2026 – Part V.
ii). Bushing terminals shall be provided with suitable terminal
connectors of approved type and size for ACSR / aluminum
tubular conductors on HV side and suitable size cable on LV
JOB NO-730176 IV-104

side.
iii). All transformers bushing shall be of solid porcelain with rain
sheds conforming to IS: 8603.
iv). The removal of bushing shall be possible without disturbing the
current transformers, secondary terminals and connectors or
pipe work.
B) CABLE BOXES AND DISCONNECTING CHAMBERS
i). Wherever cable connections are specified suitable air insulated

type cable boxes of sufficient sizes shall be provided to
accommodate cable termination. Cable boxes shall be designed
and installed such that it shall be possible to move away the
transformer without disturbing the cable termination leaving the
cable box on external supports. The support for the cable box
shall be of galvanised iron.
ii). Cable boxes shall have terminal connectors of adequate size
and bolt hoes to receive cable lugs.
iii). The bidder shall provide earthing terminals on the cable box to
suit 50 x 8 mm GI flat.
iv). All necessary cable terminating accessories such as supporting
brackets, power cable lugs, hard ware etc. shall be provided by
the bidder.
v). Cable boxes shall have removable top cover and ample
clearance shall be provided to enable either transformer or each
cable to be subjected separately to high voltage test.
vi). Cable boxes shall have degree of protection IP: 55 as per IS:
2147.
4.2.9.6.14 CURRENT TRANSFORMERS
a) Bushing CTs shall be provided. It shall be possible to remove the

turret mounted CTs from the transformer tank without removing
the tank cover.
b) The current transformers shall comply with IS: 2705.
c) All secondary leads of bushings mounted CTs shall be brought to
a terminal box gear each bushing and then wired up to
transformer marshalling box. The CTs terminals shall have
shorting facility.
4.2.9.6.15 TERMINAL MARKING
The terminal marking and their physical position shall be in accordance

with IS: 2026.
A. TERMINATION ARRANGEMENT FOR NEUTRALS
a) The transformer shall be restricted earthed at the secondary

neutral.
b) The neutral terminal brought on to a separate neutral bushing
JOB NO-730176 IV-105

shall be connected to associated neutral grounding pit by a
neutral grounding resistor.
B. OFF CIRCUIT TAP CHANGE SWITCH
a) The tap change switch shall be three phase, hand operated, for
simultaneous switching of similar taps on the three phases by
operating an external handle.
b) Arrangement shall be made for securing and pad locking the tap
changer in each of the working positions, and it shall not be
possible for setting or padlocking in any intermediate position. An
indicating device shall be provided to show tap in use.
c) The cranking device for manual operation shall be removable and
suitable for operation by a man standing on ground level. The
mechanism shall be complete with following :
i. Mechanical operation indicator.

ii. Mechanical tap position indicator which shall be clearly
visible from the transformer.
iii. Mechanical stops to prevent over cranking of the mechanism
beyond extreme tap position.
iv. The manual operating mechanism shall be labeled to show
the direction of operation for raising the secondary voltage
and vice versa.
v. A warning plate indicating “the switch shall be operated only
when the transformer has been de-energized” shall be fitted.
4.2.9.6.16 RADIATORS
The radiator shall be detachable type, mounted on the tank. Each

radiator shall be provided with the following.
a) A drain valve at the bottom.

b) An air release plug at the top.
c) Shut off valve at each point of connection to the tank. The location
and configuration of radiators shall be subject to purchaser
approval.
4.2.9.6.17 MARSHALLING BOX
a) A sheet weather, vermin and dust proof marshalling box shall be

provided with each transformer to accommodate.
i) Temperature indicators.
ii) Terminal blocks for incoming and outgoing cables.
b) The sheet steel used shall be at least 2.0 mm thick. The box shall
be free standing floor mounted type with a sloping proof. The
degree of protection shall be in accordance with IS: 2147.
c) The temperature indicators shall be so mounted that the dials are
JOB NO-730176 IV-106

not more than 1600 mm from ground level.
d) The marshalling box shall have a glazed door of suitable size for
convenience of temperature indicators readings.
e) All cables shall enter the kiosk from the bottom and the gland
plate shall be not less than 450 mm from the base of the box. The
gland plate and the associated compartment shall be sealed in
suitable manner to prevent the ingress of moisture, rodents,
insects etc. from the cable trench. Gland plates, cable lugs, cable
glands, etc. shall be provided.
f) The marshalling box shall be supplied with space heater and
cubicle lighting with ON:OFF switches and associated fuses.
g) It shall be located in such a way that, the front shall not face the
transformer. It shall be mounted at least 500 mm above the
ground level.
h) The gland plate shall be made into two detachable halves, for
facilitating termination of incoming and outgoing cables
separately.
4.2.9.6.18 PAINTING
The internal and external surfaces including oil filled chambers and
structural work to be painted shall be sand blasted to remove all rust and
scale or foreign adhering matter. All steel surfaces in contact with
insulating oil shall be painted with two coats of heat resistant, oil
insoluble, insulating varnish. All steel surface exposed to weather shall
be given a primary coat of zinc chromate, second coat of oil and weather
resistant varnish of a color distinct from primary. At least two coats of
flossy oil and weather resisting non facing paint of light grey color
corresponding to shade no.631 of IS:5. Primary paint shall be as per IS:
104 and intermediate and final coat of paint shall be as per IS: 2932.
4.2.9.6.19 BOLTS AND NUTS
All bolts and nuts exposed to weather shall be of hot dip galvanised or
cadmium plate or zinc passivated steel. All bolts, nuts and washers in
contact with non ferrous part which carry current shall be of phosphor
bronze.
4.2.9.6.20 CONTROL WIRING
a) All controls, alarms, indicating and relaying devices provided with

the transformer shall be wired by the bidder up to the terminal
blocks inside the marshalling box. The bidder shall supply and
install the required 1100 V grade heavy duty PVC insulated, steel
wire armoured, PVC sheathed, multi core cables with copper
conductors of the least 2.5 mm2 conforming to IS: 1554. The
cables shall be properly supported.
b) All devices and terminal blocks within the marshalling box shall be
clearly identified by symbols corresponding to those used on
applicable schematic or wiring diagrams.
JOB NO-730176 IV-107

c) Not more than two (2) wires shall be connected to one terminal.
At least 20% spare terminals shall be provided. Each terminal
shall be suitable for connecting two numbers 2.5 mm2 stranded
copper conductor from each side.
d) Terminal blocks for CT secondary shall have shorting facility.
4.2.9.6.21 FITTINGS
The following fittings shall be provided with all the transformers:

a) Rating and diagram plate.
b) Terminal marking plate.
c) Two earthing terminals.
d) Lifting lugs
e) Jacking lugs
f) Drain valve with plug
g) Dehydrating breather
h) Buchholtz Relay
i) Plain oil level indicator with minimum marking.
j) Magnetic oil level indicator with two electrical contacts, one for
alarm and other for tripping.
k) Thermometer pocket
l) Marshalling box
m) Off load tap changing switch
n) Neutral grounding resistor
o) Oil filling hole with cover
p) Conservator
q) Air release device and explosion vent
r) Oil temperature indicator with one electrical contact for alarm
s) Winding temperature indicator Skids and pulling eyes on both
sides
t) Rollers: Flat unidirectional
u) Bushing with metal parts and gasket
v) Filter valves at the top of the transformer tank
w) Inspection cover
4.2.9.6.22 PERFORMANCE
A) OPERATING CONDITIONS
i). The transformers shall be capable of being loaded in accordance

with IS: 6600 up to load of 15%. There shall be no limitation
imposed by bushing, tap changer etc.
ii). The transformers shall be capable of being continuously without
danger on any taping at the rated KVA with voltage variation of
±10% corresponding to the voltage of the taping.
iii). For consideration of specific loading, the transformer shall be
JOB NO-730176 IV-108

suitable for continuous operation for flux densities of 1.2 to 1.9
weber/m 2.
B) FAULT CONDITIONS
i) The transformer and all accessories including CTs shall be

capable for withstanding any external short circuit at bushing
terminal without damage for two (2) seconds.
ii) The maximum flux density in any part of the cores and yoke at
normal voltage and frequency shall not exceed 1.9 wb/m2.
C) IMPEDANCE
The impedance on principal taping shall be guaranteed to be as

specified in Annexure: I.
4.2.9.6.23 INSPECTION
The manufacturer shall carry out a comprehensive inspection and testing

programme during manufacture for all bought out items like the core
material and also workmanship during this stage. The manufacturer shall
submit the inspection programme at least four weeks prior to the
purchaser. The inspection shall cover but not be limited to the following.
A) TANK AND ACCESSORIES
i) Physical and dimensional check of the tank and its accessories.

ii) Weld procedure
iii) Crack detection of welds dye penetration test
B) CORE
i) Sample core material for specific loss, bend properties,

magnetisation characteristic and thickness
ii) Quality of varnish used on the stampings.
iii) Inter:laminar insulation between core sections before and after

pressing.
iv) Assembled core material for measurement of iro loss and for
any hot spot by exciting the core at the pre:designed value of
flux density.
C) INSULATING MATERIAL
i) Physical and electrical properties of material as per relevant IS.

ii) Dielectric strength
iii) Reaction of hot oil on insulating material
D) WINDING
JOB NO-730176 IV-109

Paper insulated winding conductor for mechanical properties and
electrical properties as per relevant IS.
E) ASSEMBLED TRANSFORMER
Provision of all fittings and accessories on the assembled unit as per

approved general arrangement drawing.
F) PRE SHIPMENT CHECKS AT MANUFACTURER’S WORKS
i) Proper packing and preservation of accessories like radiators,

bushings, explosion vent, dehydrating, breather, connecting
pipes, conservator etc.
ii) Proper bracing to arrest the movement of the core winding
assembly inside the tank.
iii) Leakage test.
4.2.9.6.24 TEST
The manufacturer shall carry out al standard routine tests in accordance

with IS: 2026 on each transformer. The manufacturer shall also carry out
type test in accordance with IS: 2026 on one piece of one rating.
While the routine test shall be carried out at manufacturer’s works under
prior information to purchaser, the type test certificates from reputed test
houses shall be submitted for purchaser’s approval giving details of each
test and evaluation of test data.
Test which are common to both type and routine test may be covered
under routine test in the presence of purchaser’s representative, if
required. At least four (4) weeks advance notice shall be given for
witnessing the tests.
The sequence of testing shall be as under:
Sl.No. Description of test Nature of test

1 Oil samples Routine
2 Winding resistance at each/principal Routine

tap
3 Routine
Voltage ratio at each/principal tap
4 Routine
Vector group and polarity
5 Routine
No load losses and magnetising
current at rated freauquency at 90%,
100% and 110% of rated voltage
6 Routine
Impedance voltage and short circuit
impedance at each/principal tap
JOB NO-730176 IV-110

7 Routine
Insulation resistance
8 Type
Temperature rise
9 Type
Oil samples (repeat test)
10 Type
Insulation resistance (repeat test)
11
Dilectric Routine
i) Power frequency withstand Routine
ii) Lightning impulse withstand Type
iii) Switching impulse withstand
12 Routine
13 Routine
14
Tank Routine
i) Pressure Routine
ii) Vacuum Type
iii) Leakage
ANNEXURE: 1
4.2.9.6.25 TECHNICAL PARAMETERS FOR POWER TRANSFORMERS
i. Rated Capacity : 5000 kVA

ii. Quantity : two nos.
iii. Type of transformer : Core type oil immersed
iv. Number of phases : 3
v. Frequency : 50Hz + 3%
vi. Location : Outdoor
vii. Type of cooling : ONAN
viii. Type of oil : Mineral oil
ix. Rated capacity at the main tapping : Rated kVA as at sl.no.1
x. Rated Voltage
HV Winding : 33000V+10%
LV Winding : 3300 V± 10%
xi. Highest system voltage
HV Winding 36000 Volts
LV Winding : 3600 Volts
xii. Impedance voltage at rated current : 7.15%± 10%
xiii. Method of system earthing
HV Winding : Nil
LV Winding : Star – Restricted
xiv. Rated Insulation level
JOB NO-730176 IV-111

withstand voltage : 70 k V rms
b) Switching impulse withstand test
voltage with Standard full wave for
windings for 1/50 Microsecond : 170 k V peak
c) Lightning withstand voltage for
winding for 1.2/50 microsecond : 170 kV peak
xi. Connection symbol : DY11

xii. Earthing of neutral terminals : Required for L.V. windings
xiii. Tap changer type : Off circuit
xiv. Taping voltage percentages : ±2.5, ±5, ±7.5, ±10
xv. Terminal Arrangement
a) HV side : Weather proof
porcelain Bushing
b) LV side : cable box
xvi. Temperature rise

a) Temperature rise (Over Ambient) in oil : 500C
b) Temperature rise (Over Ambient) in Winding: 550C
xvii. Type of winding : Double wound copper
xviii. Details of Auxiliary supply voltage for

a) Alarms/Relays : 240V AC
xix. Standard applicable for transformer : IS : 2026
xx. Standard applicable for oil used : IS: 335
4.2.10.0 SPECIFICATION FOR 200kVA, 33/0.415KV STATION TRANSFORMER
4.2.10.1 SCOPE

transformer. The exact voltage ratio and kVA rating of the transformer
has been specified in Annexure: I.
The transformers shall comply with the latest revisions of IS 2026 and
IEC: 76.
THE RELEVANT STANDARDS
The other relevant standards that are applicable are as under:
IS: 10561 : Application guide for power transformers

IS: 10028 : Code of practice for selection, installation and
maintenance of transformers
JOB NO-730176 IV-112

IS: 1866 : Code of practice for maintenance and supervision
of mineral insulating oil.
IS: 2099 : Bushing for alternating voltages above 1000V
IS: 3639 : Fittings and accessories for power transformers.
IS: 335 : New insulating oil for transformers
IS: 6600 : Guide for loading of oil immersed transformers
IS: 2165 : Insulation coordination.
IS: 2071 : Method of Impulse voltage testing
IS: 3043 : Code of practice for earthing
IS: 1271 : Thermal evaluation and classification of electrical
insulation
IS: 1554 : PVC insulated (heavy duty) electric cables –
1100V (Part: I)
IS: 7404 : Paper covered copper conductors
IS: 104 : Primary paints for steel surfaces
IS: 2932: final paints for steel surfaces
IS: 5 : colour for ready mix paints.

BS, VDE and JIS etc. shall also be considered if they ensure
performance and constructional features equivalent or superior to
standards listed before. In such a case the bidder shall clearly indicate
the standards adopted, furnish a copy in English of the latest revision
along with copies of all amendments and revisions in force as on date of
opening of bid and shall clearly bring out the salient features for
comparison.
A) Ambient Air Temperature: Minimum 5oC to Maximum 50oC with daily

average ambient air temperature of 40oC.
B) Altitude : Maximum up to 1000 meters above MSL
C) Humidity : Relative humidity maximum up to 100%
during rainy season.
D)Location : Outdoor
The design and operational features of the equipment offered shall comply
with the provisions of the latest version of the following rules and codes.
a) The Indian electricity Rules

The manufacturer shall make suitable modifications, addition/alteration in

the equipment whenever necessary to comply with the above mentioned
rules/Codes.
JOB NO-730176 IV-113

1. The design of the transformers and accessories shall be in

accordance with the latest standard practice and shall be such as to
facilitate cleaning, repairs, maintenance and operation and ensure
safe operations under situation of sudden variations of loads and
voltages as may be required under local operating conditions.
2. Electrical Features

a. Continuous operation at rated kVA within ±10 percent variation
(combined) of voltage and frequency.
b. Over loading of units as indicated in IS: 6600
c. Temperature rise limited to the following values :
Cooling Oil Winding
O
ONAN 50 c 55Oc
d. The insulation levels shall conform to the following values :
Nominal Highest Rated lighting 1 Minute Power

System System impulse Frequency
Voltage Voltage withstand Withstand
Voltage Voltage
(kV rms) (kV rms) ( kV Peak) (kV rms)
33 36 170 70
3. MECHANICAL FEATURES
a) The transformer shall withstand the electro: dynamic stress due to

terminal short circuit of the LV side assuming the HV side fed
properly supported, clamped and tightened after vacuum dying to
ensure the short circuit with stand ratings. The short circuit
withstand duration shall be minimum 2 sec.
b) It shall be so designed as to minimize any undue noise and

vibration.
4.2.10.5.1 CORE
i). The transformer core shall be made of high grade non grain
oriented cold rolled silicon steel sheets of low hysteresis loss and
high permeability. The core structure shall be securely grounded to
prevent electronic potential. Lifting eyes and lugs shall be provided
on the limbs and coils assembly. Preferably no bolt shall be used in
the cores. Clamping shall be done externally to the limb.
ii). The design of the magnetic circuit shall be such as to avoid static
JOB NO-730176 IV-114

discharge, development of short circuit paths within itself or to the
earthed clamping structure and the production of flux component at
right angles to the plane of lamination which may cause local
heating.
iii). Cores and windings shall be capable of withstanding shocks during
transport, installation & service and adequate provision shall be
made to prevent movement of core and winding relative to tank
during these conditions.
iv). All steel sections used for supporting the core shall be thoroughly
sand blasted after cutting, drilling and welding.’
v). The manufacturer shall furnish the details such as type of core
material, source of procurement, its BH curve & design flux density
at normal tap.
4.2.10.5.2 TANKS
i). Tanks shall be of welded construction and fabricated from

boiler steel plates of adequate thickness. The weld procedure and
performance shall be in line with ASME BPV:IX.
ii). All seams and joints those are not required to be opened at site
shall be factory welded and wherever possible they shall be double
welded.
iii). Tanks stiffeners shall be provided for general rigidity and these
iv). The tanks shall be designed to withstand :
(a) Mechanical shocks during transportation
(b) Vacuum filling of oil
(c) Short circuit force
v). The transformer tank and its accessories shall be designed without
pockets wherein gas may collect.
vi). Adequate space shall be provided at the bottom of the tank for
vii). Suitable guides shall be provided in the tank for positioning the core
and coil assembly.
viii). The tank shall be suitable for movement in both direction during
(a) Lifting lugs suitable for lifting the complete transformer
(b) A minimum of four jacking pads
4.2.10.6 TANK COVER
i). The tank cover shall be sloped to prevent retention of rain water
ii). At least two adequately sized inspection covers one at each end of
the tank shall be provided for easy access to bushing and earth
connection. The inspection covers shall have suitable lifting
arrangement.
iii). Bushings, inspection covers etc shall be designed to prevent
ingress of water into or leakage of oil from the tank.
iv). All bolted connections shall be fitted with weather proof hot oil
JOB NO-730176 IV-115

over compression.
4.2.10.7 MOUNTING ARRANGEMENT
i). The transformers shall be provided with two nos. bi-directional

ii). These skids shall be such that the bottom of the tank is at a
transformer shall be provided with unidirectional, flat rollers of 1000
mm length.
4.2.10.8 CONSERVATOR TANK
i). The conservator tank shall have adequate capacity to

accommodate oil preservation system and volumetric expansion of
the total cold oil volume in the transformer and radiators for a
change in temperature from minimum ambient air temperature of 5
0
C to 110 0C.
ii). The conservator shall be bolted into position so that it can be
iii). The conservator tank, shall be fitted with a silica gel filter breather.
iv). The conservator shall be fitted with plain oil level gauge. The oil
level at 300C shall be marked on the gauge.
4.2.10.9 EXPLOSION VENT
i). The transformers shall be provided with the single type of explosion
vent with air release device.
ii). An equalizer pipe shall be connected to explosion vent from the
conservator.
4.2.10.10 TEMPERATURE INDICATOR
The transformers shall be provided with a 150 mm dial type thermometer

for top oil temperature indication. The thermometer shall have
box. A temperature sensing element suitably located in a pocket in the
top oil shall be furnished. This shall be connected to the OTI by means of
capacity tubing. Accuracy class of OTI shall be 2oC or better. The OTI
shall have full scale deflection of at least 240oC and shall have linear
graduation to read every 2oC.
JOB NO-730176 IV-116


of the cover.
4.2.10.11. WINDINGS
i). The conductors shall be of electrolytic grade copper from scales

and burns.
ii). All windings shall be fully insulated. No grade insulation shall be
prohibited.
iii). The insulation winding and connections shall be free from insulating
compounds which are liable to soften, ooze out, shrink or collapse
and be non catalytic and chemically inert in transformer oil during
service.
iv). Coil assembly and insulating spacers shall be so arranged as to
ensure free circulation of oil and to reduce the hot sport of the
windings.
v). Tapings shall be so arranged as to preserve the magnetic balance
of transformers at all voltage ratios.
vi). The fault level to which the transformers may be subjected are as
under :
Nominal System Voltage Maximum Fault Level

(kV rms) (MVA)
33 750
Transformer manufacturer may take this aspect into account while

designing the transformer for the through fault with stand capability.
i). All bus bars and leads shall be adequately supported in insulated
cleats or frames from the clamping structure.
ii). The studs, set screws or bolts provided for securing cleats or
JOB NO-730176 IV-117

iii). Bus bars and leads shall be supported throughout their length to
transport or are not forced from the prescribed position during any
short circuit.
iv). The impedance values shall be as per relevant IS.
v). The windings shall be connected to achieve a vector group of
DY11. In case of dual H.V. voltages, the rated capacity shall be
delivered at each H.V. voltage through series parallel combination
of the H.V. windings.
vi). The transformer shall have two windings as specified in the
Annexure.
4.2.10.12. INSULATION MATERIALS
i). Class ‘A’ insulating materials specified in IS: 1271 or latest version
shall be used. Wood insulation, where used, shall be well seasoned
and treated.
ii). Insulating Oil
(a) The new insulating oil supplied with the transformer shall
conform to IS: 335. No inhibitors shall be used in the oil.
(b) Prior to filling the oil in the main tank suitable number of
at 90 deg. C, tan delta at 90 deg. C and interfacial tension.
The oil samples taken from the transformer at site shall
conform to the requirements of IS: 1866.
(c) The manufacturer shall dispatch the transformer filled with
oil.
4.2.10.13 EARTHING TERMINALS
Two earthing terminals suitable for connecting 50 x 8mm mild steel flat shall
be provided at positions close to the two diagonally opposite bottom corners
of tank. These grounding terminals shall be suitable for bolted connections.
4.2.10.14 OIL PRESERVATION SYSTEM
The transformers shall be provided with the conventional conservator

preservation system with a single compartment with dry air filling of
space above the oil.
The top of the conservator shall be connected to the atmosphere
through a silica gel filter breather. It shall be so designed that:
i) In the passage of air through dust filter and silica gel, moisture
absorption is indicated by a change in colour of the tinted crystal
JOB NO-730176 IV-118

can easily observed from a distance.
ii) Breather shall be mounted not less than 1400 mm above rail top
level.
4.2.10.15 BUCHHOLZ RELAY (wherever applicable)
A double float type Buchholz Relay conforming to IS: 3637 (amended up

to date) shall be provided. All gas evolved in the transformer shall be
collected in this relay. The relay shall be provided with a test cock suitable
for a flexible pipe connection for checking its operation. A copper tube
shall be connected from the gas collector to a valve located about 1200
mm above ground level to facilitate sampling with the transformer in
service. The device shall be provided with two potential free contacts, one
for alarms on gas accumulation and the other for tripping on rise of
pressure.
4.2.10.16 TERMINAL ARRANGEMENT
i) The minimum clearances in air between the phases and between

the phase and earth potential of the porcelain bushings shall be in
accordance with IS: 2026 – part v, 1994.
ii) Bushing terminal shall be provided with suitable terminal
connectors of a proven type and size for ACSR/aluminium tubular
conductor on high voltage side and suitable size cables on low
voltage side.
iii) All transformer bushing shall be of solid porcelain with plain sheds
conforming to IS: 8603.
iv) The removal of bushing shall be possible without disturbing the
current transformers, secondary terminals and connectors or pipe
work.
B) CABLES BOXES AND DISCONNECTING CHAMBERS
i. Wherever cable connections are specified, suitable air insulated

shall be galvanized iron.
ii. Cable boxes shall have terminal connectors of adequate size and
bolt holes to receive cable lugs.
iii. The bidder shall provide earthing terminals on the cable box to
iv. All necessary terminating accessories such as supporting
the bidder.
JOB NO-730176 IV-119

v. Cable boxes shall have removable top cover and ample clearance
shall be provided to enable either transformer or each cable to be
subjected separately to high voltage test.
vi. Cable boxes shall have degree of protection of IP:55 as per IS:
2147.
4.2.10.17 RADIATORS
The radiator shall be detachable type, mounted on the tank. Each

radiator shall be provided with the following.
approval.
4.2.10.18 MARSHALLING BOX

degree of protection shall be IP 53 in accordance with IS: 2147.
cubicle lighting with ON-OFF switches and associated fuses.
ground level.
separately.
4.2.10.19 TERMINAL MARKING

with IS: 2026
A) TERMINATION ARRANGEMENT FOR NEUTRALS
JOB NO-730176 IV-120

a) The transformer shall be restricted earthed at the secondary

neutral.
b) The neutral terminal brought on to a separate neutral bushing shall
be connected to associated neutral grounding pit by a copper flat.
mechanism shall be complete with the following :
i). Mechanical operation indicator
ii). Mechanical tap position indicator which shall be clearly visible
from the transformer.
iii). Mechanical stops to prevent over cranking of the mechanism
iv). The manual operating mechanism shall be labeled to show the
direction of operation for raising the secondary voltage and vice
versa.
v). A warning plate indicating “The switch shall be operated only
when the transformer has been de-energized’ shall be fitted.
B) OFF CIRCUIT TAP CHANGING EQUIPMENT
The tap change switch shall be three-phase hand operated, for

simultaneous switching off the similar taps on the three phases by
operating an external hand wheel. Tap changing shall be possible
without disturbing the transformer in any way except de-energising.
Arrangement shall be made for securing and padlocking the tap changer
in any of the working positions and then setting and pad locking in any
intermediate position shall not be possible. The cranking device for
manual operation of the off circuit tap changing gear shall be removable
and suitable for operation by a man standing on ground level. The
mechanism shall be complete with the following:
i) Mechanical position indicator, which shall be clearly viewed from

near the transformer.
ii) Mechanical stops to prevent over cranking of the mechanism.
iii) A warning plate indicating "The switch shall be operated with
transformer de energised"
4.2.10.20 COOLING TUBES
The tubes shall be mounted on the tank.
4.2.10.21 PAINTING
The internal and external surfaces including oil filed chambers and
scale or foreign adhering matter. All steel surface in contact with insulating
oil shall be painted with two coats of heat resistant, oil insoluble, insulating
JOB NO-730176 IV-121

varnish. All steel surface exposed to weather shall be given a primary coat
of zinc chromate, second coat of oil and weather resistant varnish of a
colour distinct from primary and last two coats of flossy oil and weather
resisting non fading paint of light grey color corresponding to shade
no.631 of IS:5. Primary paint shall be as per IS: 104 and intermediate and
final coats of paint shall be as per IS: 2932.
4.2.10.22 BOLTS AND NUTS
All bolts and nuts exposed to weather shall be of hot dip galvanized or
contact with non ferrous parts which carry current shall be of phosphor
bronze.
4.2.10.23 FITTINGS
a. Rating and diagram plate

b. Terminal marking plate
c. Two earthing terminals
d. Lifting lugs
e. Jacking lugs
f. Drain valve with plug, 50 mm size
g. Dehydrating breather
h. Buchholz relay
i. Plain oil level indicator with minimum marking
j. Off load tap changing switch
k. Oil filling hole with cover
l. Conservator
m. Explosion vent with air release device
n. Skids and puling eyes on both sides
o. Rollers
p. Flat unidirectional limited to 1000mm
q. H.V. porcelain bushing with metal parts or H.V. cable box
r. Filter valve
s. Inspection cover
t. L.V. cable box
4.2.10.24 PERFORMANCE
i) The transformers shall be capable of being loaded in accordance

ii) The transformer shall be capable of being operated continuously
without danger on any taping at the rated KVA with voltage
variation of ± 10% corresponding to the voltage of the taping.
JOB NO-730176 IV-122

iii) For consideration of specific loading the transformer shall be
wber/m2.
B) FAULT CONDITION
i) The transformer and all accessories shall be capable for

withstanding any external short circuit at bushing terminal
without damage for two (2) seconds.
C) IMPEDANCE

indicated in Annexure: I.
D) WINDING



iii) Leakage test.
4.2.10.25 TEST

with IS: 2026 on each transformer. The manufacturer shall submit type
test certificate in accordance with IS: 2026.
required.

JOB NO-730176 IV-123

2 Winding resistance at Routine

each/principal tap
3 Routine
4 Routine
5 Routine
current at rated frequency at 90%,
100% and 110% of rated voltage
6 Routine
Impedance voltage and short
circuit impedance at
7 each/principal tap Routine
8 Insulation resistance Type
9 Temperature rise Type
10 Oil samples (repeat test) Type
11 Insulation resistance (repeat test)

Routine
Dielectric Routine
i) Power frequency withstand Type
ii) Lightning impulse
12 withstand Routine
iii) Switching impulse
14 Oil samples (repeat test)

Routine
Insulation resistance (repeat test) Routine
Type
Tank
iv) Pressure
v) Vacuum
vi) Leakage
JOB NO-730176 IV-124

ANNEXURE: 1
4.2.10.26 TECHNICAL PARAMETERS FOR STATION TRANSFORMER
1. Rated Capacity : 200 kVA

2. Quantity : One
3. Type of transformer : Core type, oil immersed
4. Number of phases : 3
5. Frequency : 50Hz + 3%
6. Location : Outdoor
7. Type of cooling : ONAN
8. Type of oil : Mineral oil
9. Rated capacity at the main tapping : Rated kVA as at sl.no.1
10. Rated Voltage
HV Winding : 33000 Volts ±10%
LV Winding : 415 Volts ± 10%
11. Highest system voltage
HV Winding : 36000 Volts
12. Impedance voltage at rated current: 4%
13. Method of system earthing
HV Winding : Nil
LV Winding : Star
14. Rated Insulation level
• One minute power frequency

withstand voltage : 70kV rms
• Switching impulse withstand test
voltage with standard full wave
for windings for 1/50 Microsecond : 170 kV peak
15. Connection symbol : DY11
16. Earthing of neutral terminals : Required for L.V. windings
17. Tap changer type : Off circuit
18. Taping voltage percentages : ±2.5, ±5, ±7.5, ±10
19.Terminal Arrangement
a) HV side : Weather proof porcelain
bushing
b) LV side : cable box
20. a) Temperature rose

(Over Ambient) in oil : 500C
b) Temperature rise
(Over Ambient) in Winding : 550C
21. Type of winding : Double wound copper
22. Details of Auxiliary supply voltage for

23. Standard applicable for transformer : IS: 2026 (current)
24. Standard applicable for oil used : IS: 335
JOB NO-730176 IV-125

4.2.11.0 SPECIFICATION FOR NEUTRAL GROUNDING RESISTOR
The neutral grounding resistance shall be used to ground the neutral of

secondary winding of 5 MVA, 33/3.3 kV, Dy11 transformers.
For the main secondary circuit breakers, the back up ground fault relay
may be operated through the CT by sensing the magnitude of the
current flowing through the resistor.
Adequate time delay shall be provided for attaining series discrimination

of earth fault relays.
The protective system grounding of the neutral of secondary side of the

transformer shall be isolated from the main substation grounding with
adequate separation of the main substation ground and LT protective
ground.
The neutral grounding resistor shall conform to the following

specifications.
1. System Voltage : 3.3 kV at 3 phase 50 hz
2. Location : Outdoor
3. Resistance Element : Stainless steel wire wound,
supported on Cast resin mica
insulators.
4. Time Rating : 10 Seconds
5. Rated Resistance : Suitable to limit the fault current to
50 Amps.
6. Enclosure : The resistance element shall be
covered with sheet steel enclosure
and shall be protected against entry
of dust and moisture. The enclosure
shall be provided with lifting hooks
louvers, dust catchers etc.
7. Degree of protection: The degree of protection of
enclosure shall be IP:33 (minimum)
8. Connections : The external connections shall be
made through bushings.
9. Mountings : The neutral grounding resistance
shall be mounted on structures.
Provision shall be kept for providing
Earth fault Protection CT at the
ground end of the resistance.
10. Testing : The neutral grounding resistance
shall be tested as per relevant Indian
standard specifications.
JOB NO-730176 IV-126

4.2.12.0 SPECIFICATION FOR 3.3 kV CAPACITOR BANK
4.2.12.1 SCOPE
This specification covers requirements for shunt capacitor banks suitable
for indoor installation.
The capacitor banks shall comply with the latest version of IS: 2834 and
IEC: 831:1 & 831:2 except where modified or extended by the provision of
this specification and with the relevant parts of standards mentioned in
clause 4.2.12.2
Any material and component not specifically stated in this specification but
specified here in shall be deemed to be included. Nothing in this
specification shall be construed as to relieve the supplier of the
responsibility for correctness of the design and construction of the
equipment.
4.2.12.2 OTHER RELEVANT STANDARDS:
The other relevant Indian standards are as under.
• IS: 12672 Internal fuses and internal over pressure

disconnectors for shunt capacitors.
• IS: 9046 A.C.contactors of voltages above 1000V up to and
including 11000V.
• IS; 13118 General requirements for circuit breakers for
voltages above 1000V
• IS: 9920 Switches and switch isolators for voltages above
1000V
• IS: 13947 LV switch gear and control gear (Part 4 section 1:
contactors)
• IS: 13947 LV switch gear and control gear (Part 3: switches)
• IS: 13947 LV switch gear and control gear (Part 2: circuit

breakers)
• IS: 9402 High voltage fuses for the external protection of
shunt capacitors
• IS: 13703 LV fuses for voltages not exceeding 1000 V AC
• IS: 7098 Cross linked polyethylene insulated PVC sheathed
cables up to and including 33 KV
• IS: 3043 Code of practice for earthing
In case of conflict between this specification and those (IS codes,

standards etc.) referred to herein, the former shall prevail.
The equipment covered under this specification shall comply with all the
latest applicable statutory rules, regulations, acts and safety codes which
may be in force during the period of supply/ execution and which are
JOB NO-730176 IV-127

related with design, construction and operation of equipment in the locality
where the equipment is to be installed.
Equipment complying with other internationally accepted standards such

as BS, VDE and ANSI are also acceptable if they ensure performance and
constructional feature equivalent or superior to standards listed before. In
such a case, the bidder shall clearly indicate the standard adopted, furnish
a copy in English of the latest version along with copies of all official
amendments.
4.2.12.3 SERVICE CONDITIONS
Operating conditions
a. Nominal system voltage 3300 V (± 10% )

b. Supply frequency 50 Hz (±3% )
c. Earthing Effectively earthed
d. Highest fault level 75 MVA
e. Location
i). Maximum ambient temperature – Mean over One year 350
Celsius
ii). Maximum ambient temperature – Mean over 24 hours 450
Celsius
iii). Maximum ambient temperature – Mean over 1hour 400
Celsius
iv). Maximum relative humidity: Mean over 1hour 100%
v). Pollution – Heavily polluted with coal dust
4.2.12.4 DESIGN
The capacitor units shall be designed for the following
a. Watt losses between 0.2 to 0.5 kW per kVAR

b. Temperature withstand category of 550 Celsius
c. Output ( kVAR ) tolerance not exceeding 10%
d. Capacitor – fuse co-ordination to reduce risk of tank rupture
e. Use of bio degradable eco friendly dielectric compound
f. Switching life not less than 60,000 operations
4.2.12.5 CONSTRUCTION
1 The basic units shall be made of dielectric compound polypropylene

film impregnated with non PCB bio-degradable liquid. Foil shall be
proffered over paper for better heat dissipation and low operating
temperature.
2 The electrodes shall be of metal alloy special vacuum deposited with
reinforced edges to sustain the faults.
3 The basic units shall be insulated for power frequency withstand
voltages as indicated in the annexure.
JOB NO-730176 IV-128

4 The basic units shall be provided with protection against sustained
overload, earth fault and voltage/current unbalance as indicated in
the annexure.
5 Each unit shall be provided with self healing type pressure sensitive
detector for sensing excessive internal pressure.
6 Each unit shall be provided with pressure activated tripper switch for
tripping.
7 Each bank shall be provided with discharge resistors.
8 Each unit shall be supplied in a M.S. container with enamel paint
finish.
9 The bank shall be supplied with peripherals indicated in the
annexure
10 Each unit shall be designed for withstanding inrush current as
indicated in the annexure
1 The unit shall deliver rated output within the limits of watt losses
indicated in clause 4.2.12.4 without over heating within the limits of
ambient temperature indicated in clause 4.2.12.3.
4.2.12.7 TESTS AND TEST REPORTS
1 The successful tenderer shall submit report of type tests in

accordance with the relevant code conducted on a piece of
equipment having specification identical to the one included in this
document.
2 The successful bidder shall submit report of routine tests in
accordance with the relevant code conducted on each piece of
equipment for which this specification is drawn.
4.2.12.8 QUALITY ASSURANCE PROGRAMME
1. All materials, components and equipments covered under this

specification shall be procured, manufactured, erected,
commissioned and tested as per a comprehensive quality assurance
programme to be approved by the purchaser. The quality assurance
plan furnished by the successful bidder shall include copies of the
reference documents, plant standards, acceptance norms and test &
inspection procedure to be adopted. In the quality assurance plan
the purchaser shall identify Customer Hold Points (CHP) which shall
be carried out in presence of purchaser’s representative and beyond
which the work shall not precede without the written consent of the
purchaser.
2. The purchaser reserves the right to witness any or all of the tests
identified in the CHP and verify the documents also mentioned in the
CHP.
3. The sub venders proposed by the successful bidders, if any, for
procurement of major bought out items including finished, semi
JOB NO-730176 IV-129

finished, assembled and raw materials shall be subject to
purchaser’s approval.
4. The successful bidder shall carry out tests and inspections as per
QAP aforesaid at his works to check the accuracy of components,
compliance with drawings, conformance to functional and
performance requirements, identify and accept all materials and
components. The tests shall establish that the equipment offered
confirms to the requirements of this specification and relevant
codes/standards also included in this specification.
5. Approval of the test results conducted as per QAP will not however
prejudice the right of the purchaser to reject the equipment if it does
not comply with the requirements of this specification and does not
give complete satisfaction and will not limit the liabilities and
responsibilities of the successful bidder in ensuring the complete
conformance of the equipment supplied to this specification and
relevant codes/ standards also included in this specification.
ANNEXURE 1
4.2.12.9 TECHNICAL PARAMETERS FOR 3.3 KV CAPACITOR BANK
1. Applicable standard :IS: 2834

2. Rated Voltage :3300V
3. No. of Phases :Three
4. Connection :Delta
5. Output kVAR :As per BOQ
6. Peripherals to be supplied :discharge resistors, HRC
Fuses, Racks, and Isolators
7. Optional accessories :Manual control panel
4.2.13.0 SPECIFICATION FOR 3.3/0.415KV DISTRIBUTION TRANSFORMERS
4.2.13.1 SCOPE

transformer. The exact voltage ratio and kVA rating of the transformer has
been specified in Annexure: I.
The transformers shall comply with the latest revisions of IS 2026 and
IEC: 76.
4.2.13.2 THE RELEVANT STANDARDS
The other relevant standards that are applicable are as under:
IS: 10561 : Application guide for power transformers
JOB NO-730176 IV-130

maintenance of transformers
IS: 1866 : Code of practice for maintenance and supervision
of mineral insulating oil.
IS: 2099 : Bushing for alternating voltages above 1000V
IS: 335 : New insulating oil for transformers
IS: 6600 : Guide for loading of oil immersed transformers
IS: 2165 : Insulation coordination.
IS: 2071 : Method of Impulse voltage testing
IS: 3043 : Code of practice for earthing
insulation
IS: 1554 : PVC insulated (heavy duty) electric cables –
1100V (Part: I)
IS: 7404 : Paper covered copper conductors
IS: 104 : Primary paints for steel surfaces
IS: 2932: final paints for steel surfaces

BS, VDE and JIS etc. shall also be considered if they ensure performance
of all amendments and revisions in force as on date of opening of bid and
shall clearly bring out the salient features for comparison.
A) Ambient Air Temperature: Minimum 5oC to Maximum 50oC with daily

B) Altitude : Maximum up to 1000 meters above MSL

C) Humidity : Relative humidity maximum up to 100%
D) Location : Indoor
a. The Indian electricity Rules

b. National Electricity Code

rules/Codes.
JOB NO-730176 IV-131

1. The design of the transformers and accessories shall be in

accordance with the latest standard practice and shall be such as
to facilitate cleaning, repairs, maintenance and operation and
ensure safe operations under situation of sudden variations of
loads and voltages as may be required under local operating
conditions.
2. Electrical Features

a. Continuous operation at rated kVA within ±10 percent
variation of voltage and ±3 percent frequency.
b. Over loading of units as indicated in IS: 6600
c. Temperature rise limited to the following values :
Cooling Oil Winding
ONAN 50Oc 55Oc
d. The insulation levels shall conform to the following values :
Nominal Highest Rated lighting 1 Minute Power

System System impulse withstand Frequency
Voltage Voltage Voltage Withstand
Voltage
(kV rms) (kV rms) ( kV Peak) (kV rms)
3.3 3.6 20 10
3. MECHANICAL FEATURES
a) The transformer shall withstand the electro: dynamic stress due

to terminal short circuit of the LV side assuming the HV side fed
properly supported, clamped and tightened after vacuum dying to
ensure the short circuit with stand ratings. The short circuit
b) It shall be so designed as to minimize any undue noise and

vibration.
1. CORE
i). The transformer core shall be made of high grade non grain
oriented cold rolled silicon steel sheets of low hysteresis loss and
high permeability. The core structure shall be securely grounded to
prevent electronic potential. Lifting eyes and lugs shall be provided
on the limbs and coils assembly. Preferably no bolt shall be used in
the cores. Clamping shall be done externally to the limb.
JOB NO-730176 IV-132

ii). The design of the magnetic circuit shall be such as to avoid static
discharge, development of short circuit paths within itself or to the
earthed clamping structure and the production of flux component at
right angels to the plane of lamination which may cause local
heating.
iii). Cores and windings shall be capable of withstanding shocks during
transport, installation & service and adequate provision shall be
made to prevent movement of core and winding relative to tank
during these conditions.
iv). All steel sections used for supporting the core shall be thoroughly
sand blasted after cutting, drilling and welding.’
v). The manufacturer shall furnish the details such as type of core
material, source of procurement, its BH curve & design flux density
at normal tap.
2. TANKS
i). Tanks shall be of welded construction and fabricated from

boiler steel plates of adequate thickness. The weld procedure and
performance shall be in line with ASME BPV: IX.
ii). All seams and joints those are not required to be opened at site
shall be factory welded and wherever possible they shall be double
welded.
iii). Tanks stiffeners shall be provided for general rigidity and these
iv). The tanks shall be designed to withstand :
• Mechanical shocks during transportation
• Vacuum filling of oil
• Short circuit force
v). The transformer tank and its accessories shall be designed without
vi). Adequate space shall be provided at the bottom of the tank for
vii). Suitable guides shall be provided in the tank for positioning the core
and coil assembly.
viii). The tank shall be suitable for movement in both directions during
• Lifting lugs suitable for lifting the complete transformer
• A minimum of four jacking pads
4.2.13.7 TANK COVER
i). The tank cover shall be sloped to prevent retention of rain water
ii). At least two adequately sized inspection covers one at each end of
the tank shall be provided for easy access to bushing and earth
connection. The inspection covers shall have suitable lifting
arrangement.
iii). Bushings, inspection covers etc shall be designed to prevent
JOB NO-730176 IV-133

iv). All bolted connections shall be fitted with weather proof hot oil
over compression.
4.2.13.8 MOUNTING ARRANGEMENT
i) The transformers shall be provided with two nos. bi-directional

ii) These skids shall be such that the bottom of the tank is at a
transformer shall be provided with unidirectional, flat rollers of 1000
mm length.
4.2.13.9 CONSERVATOR TANK
i) The conservator tank shall have adequate capacity to

5 0C to 110 0C.
ii) The conservator shall be bolted into position so that it can be
iii) The conservator tank, shall be fitted with a silica gel filter breather.
iv) The conservator shall be fitted with plain oil level gauge. The oil
level at 300C shall be marked on the gauge.
4.2.13.10 EXPLOSION VENT
1. The transformers shall be provided with the single type of

explosion vent with air release device.
2. An equalizer pipe shall be connected to explosion vent from the
conservator.
4.2.13.11 TEMPERATURE INDICATOR
a. OIL TEMPERATURE INDICATOR (OTI)

b. WINDING TEMPERATURE INDICATOR (WTI)
JOB NO-730176 IV-134


of the cover.
4.2.13.12 WINDINGS
i) The conductors shall be of electrolytic grade copper from scales

and burns.
ii) All windings shall be fully insulated. No grade insulation shall be
prohibited.
iii) The insulation winding and connections shall be free from insulating
compounds which are liable to soften, ooze out, shrink or collapse
and be non catalytic and chemically inert in transformer oil during
service.
iv) Coil assembly and insulating spacers shall be so arranged as to
ensure free circulation of oil and to reduce the hot sport of the
windings.
v) Tapings shall be so arranged as to preserve e the magnetic
balance of transformers at all voltage ratios.
vi) The fault level to which the transformers may be subjected are as
under :
Nominal System Voltage Maximum Fault Level

(kV rms) (MVA)
3.3 75
Transformer manufacturer may take this aspect into account while

designing the transformer for the through fault with stand capability.
i) All bus bars and leads shall be adequately supported in insulated

cleats or frames from the clamping structure.
ii) The studs, set screws or bolts provided for securing cleats or
JOB NO-730176 IV-135

iii) Bus bars and leads shall be supported throughout their length to
transport or are not forced from the prescribed position during any
short circuit.
iv) The impedance values shall be as per relevant IS.
v) The windings shall be connected to achieve a vector group of
DY11. In case of dual H.V. voltages, the rated capacity shall be
delivered at each H.V. voltage through series parallel combination
of the H.V. windings.
vi) The transformer shall have two windings as specified in the
Annexure.
4.2.13.13 INSULATION MATERIALS
i) Class ‘A’ insulating materials specified in IS: 1271 or latest version

shall be used. Wood insulation, where used, shall be well seasoned
and treated.
ii) Insulating Oil
a. The new insulating oil supplied with the transformer shall
conform to IS: 335. No inhibitors shall be used in the oil.
b. Prior to filling the oil in the main tank suitable number of
at 90 deg. C, tan delta at 90 deg. C and interfacial tension.
The oil samples taken from the transformer at site shall
conform to the requirements of IS: 1866.
c. The manufacturer shall dispatch the transformer filled with
oil.
4.2.13.14 EARTHING TERMINALS
Two earthing terminals suitable for connecting 50 x 8mm mild steel flat shall
be provided at positions close to the two diagonally opposite bottom corners
of tank. These grounding terminals shall be suitable for bolted connections.
4.2.13.15 OIL PRESERVATION SYSTEM
The transformers shall be provided with the conventional conservator

preservation system with a single compartment with dry air filling of
space above the oil.
The top of the conservator shall be connected to the atmosphere
through a silica gel filter breather. It shall be so designed that:
i) In the passage of air through dust filter and silica gel, moisture
absorption is indicated by a change in colour of the tinted crystal
can easily observed from a distance.
JOB NO-730176 IV-136

ii) Breather shall be mounted not less than 1400 mm above rail top
level.
4.2.13.16 BUCHHOLZ RELAY (wherever applicable)

collected in this relay. The relay shall be provided with a test cock suitable
for a flexible pipe connection for checking its operation. A copper tube
shall be connected from the gas collector to a valve located about 1200
mm above ground level to facilitate sampling with the transformer in
service. The device shall be provided with two potential free contacts, one
for alarms on gas accumulation and the other for tripping on rise of
pressure.
4.2.13.17 TERMINAL ARRANGEMENT

the phase and earth potential of the porcelain bushings shall be in
accordance with IS: 2026 – part v, 1994.
ii) Bushing terminal shall be provided with suitable terminal
connectors of a proven type and size for cable termination on high
voltage side and bus duct connector /cables on low voltage side.
iii) All transformer bushing shall be of solid porcelain with plain sheds
work.
B) CABLES BOXES AND DISCONNECTING CHAMBERS
i) Wherever cable connections are specified, suitable air insulated

cable box on external supports. The support for the cable box shall
be galvanized iron.
ii) Cable boxes shall have terminal connectors of adequate size and
bolt holes to receive cable lugs.
iii) The bidder shall provide earthing terminals on the cable box to suit
50 x 8 mm GI flat.
iv) All necessary terminating accessories such as supporting brackets,
power cable lugs, hard ware etc. shall be provided by the bidder.
v) Cable boxes shall have removable top cover and ample clearance
JOB NO-730176 IV-137

vi) Cable boxes shall have degree of protection of IP:52 as per IS:
2147.
4.2.13.18 RADIATORS
The radiator shall be detachable type, mounted on the tank. Each radiator
shall be provided with the following.
approval.
4.2.13.19 MARSHALLING BOX

e) All cables shall enter the kiosk from the bottom and the gland plate
shall be not less than 450 mm from the base of the box. The gland
plate and the associated compartment shall be sealed in suitable
manner to prevent the ingress of moisture, rodents, insects etc.
from the cable trench. Gland plates, cable lugs, cable glands, etc.
shall be provided.
transformer. It shall be mounted at least 500 mm above the ground
level.
facilitating termination of incoming and outgoing cables separately.
4.2.13.20 TERMINAL MARKING

with IS: 2026
A. TERMINATION ARRANGEMENT FOR NEUTRALS
JOB NO-730176 IV-138

a) The transformer shall be restricted earthed at the secondary neutral.

b) The neutral terminal brought on to a separate neutral bushing shall
be connected to associated neutral grounding pit by a copper flat.
mechanism shall be complete with the following :
i) Mechanical operation indicator
ii) Mechanical tap position indicator which shall be clearly visible
from the transformer.
iii) Mechanical stops to prevent over cranking of the mechanism
iv) The manual operating mechanism shall be labeled to show the
direction of operation for raising the secondary voltage and vice
versa.
v) A warning plate indicating “The switch shall be operated only
when the transformer has been de-energized’ shall be fitted.
B) OFF CIRCUIT TAP CHANGING EQUIPMENT


4.2.13.21 COOLING TUBES
The tubes shall be mounted on the tank.
4.2.13.22 PAINTING
The internal and external surfaces including oil filed chambers and
scale or foreign adhering matter. All steel surface in contact with insulating
oil shall be painted with two coats of heat resistant, oil insoluble, insulating
varnish. All steel surface exposed to weather shall be given a primary coat
JOB NO-730176 IV-139

of zinc chromate, second coat of oil and weather resistant varnish of a
colour distinct from primary and last two coats of flossy oil and weather
resisting non fading paint of light grey color corresponding to shade
no.631 of IS:5. Primary paint shall be as per IS: 104 and intermediate and
final coats of paint shall be as per IS: 2932.
4.2.13.23 BOLTS AND NUTS
contact with non ferrous parts which carry current shall be of phosphor
bronze.
4.2.13.24 FITTINGS
a. Rating and diagram plate

b. Terminal marking plate
c. Two earthing terminals
d. Lifting lugs
e. Jacking lugs
f. Drain valve with plug, 50 mm size
g. Dehydrating breather
h. Buchholz relay
i. Plain oil level indicator with minimum marking
j. Off load tap changing switch
k. Oil filling hole with cover
l. Conservator
m. Explosion vent with air release device
n. Skids and puling eyes on both sides
o. Rollers
p. Flat unidirectional limited to 1000mm
q. H.V. porcelain bushing with metal parts or H.V. cable box
r. Filter valve
s. Inspection cover
t. L.V. cable box

ii) The transformer shall be capable of being operated continuously
without danger on any taping at the rated KVA with voltage
variation of ± 10% corresponding to the voltage of the taping.
iii) For consideration of specific loading the transformer shall be
wber/m2.
JOB NO-730176 IV-140

B) FAULT CONDITION

withstanding any external short circuit at bushing terminal
without damage for two (2) seconds.
C) IMPEDANCE

indicated in Annexure: I.
D) WINDING



iii) Leakage test.
4.2.13.26 TEST

with IS: 2026 on each transformer. The manufacturer shall submit type
test certificate in accordance with IS: 2026.
required.

2 Winding resistance at Routine

each/principal tap
3 Routine
JOB NO-730176 IV-141

4 Routine
5 Routine
current at rated frequency at
90%, 100% and 110% of rated
6 voltage Routine
Impedance voltage and short

7 circuit impedance at Routine
each/principal tap
8 Type
Insulation resistance
9 Type
Temperature rise
10 Type
11
Insulation resistance (repeat test) Routine
Routine
Dielectric Type
iv) Power frequency
v) Lightning impulse
vi) Switching impulse
14 withstand
Routine
Oil samples (repeat test) Routine
Type
Tank
vii) Pressure
viii) Vacuum
ix) Leakage
ANNEXURE: 1
4.2.13.27 TECHNICAL PARAMETERS FOR DISTRIBUTION TRANSFORMERS
1. Rated Capacity : As Per Design

2. Quantity : AS per BOQ
3. Type of transformer : Core type, oil immersed
6. Location : Indoor
JOB NO-730176 IV-142

10. Rated Voltage
LV Winding : 415 Volts ± 10%
12. Impedance voltage at rated current : As per IS
HV Winding : Nil
LV Winding : Star
14. Rated Insulation level
•One minute power frequency

withstand voltage : 10kV rms (for 3.3 kV)
• Switching impulse withstand test
voltage with standard full wave for
windings for 1/50 Microsecond : 20 kV peak (for 3.3 kV)
15. Connection symbol : DY11
16. Earthing of neutral terminals : Required for L.V. windings
18. Taping voltage percentages : ±2.5, ±5, ±7.5, ±10
19.Terminal Arrangement
a) HV side : Cable end box to
accommodate PVCSWA
cable of suitable size
b) LV side : Cable end box to
accommodate PVCSWA
cable of suitable size or
suitable size Bus duct
20. a) Temperature rose (Over Ambient)

in oil : 500C
b) Temperature rise (Over Ambient)
in Winding : 550C
22. Details of Auxiliary supply voltage for

23. Standard applicable for transformer : IS: 2026 (current)
24. Standard applicable for oil used : IS: 335
JOB NO-730176 IV-143

4.2.14.0 100 kVA, 3.3/0.230 kV (L-L) LIGHTING TRANSFORMER
4.2.14.1 SCOPE
This specification covers the requirements for two winding transformer.

The exact voltage ratio and kVA rating of the transformer has been
specified in Annexure-I.
The transformers shall comply with the latest revisions of IS: 2026 and
IEV: 76 except where modified or extended by the provisions of this
specification and relevant parts of standards.
specified herein shall be deemed to be included.
The other relevant standards applicable are as under:
IS: 10561 : Application guide for power transformers.

maintenance of transformers.
IS: 1866 : Code of practice for maintenance and supervision of
mineral insulating oil.
IS: 2099 : Bushing for alternating voltage above 1000V.
IS: 8603 : Dimensions for porcelain transformer bushings for
use in heavily polluted atmosphere
IS: 335 : New insulating oil for transformers.
IS: 3637 : Gas operated relays.
IS: 3638 : Application guide for gas operated relays.
IS: 6600 : Guide for loading of oil immersed transformers.
IS: 2165 : Insulation co-ordination.
IS: 2071 : Method of impulse voltage testing.
IS: 1248 : Direct acting indicating analogue electrical
measuring instruments.
IS: 3043 : Code of practice for earthing.
IS: 7404 : Paper covered copper conductors.
insulation.
IS: 1554 : PVC insulated (heavy duty) electric cables – 1100V
(Part-I).
IS: 104 : Primary paints for steel surfaces.
IS: 2932 : Final paints for steel surfaces.

BS, VDE and JIS etc. shall also be considered if they ensure performance
JOB NO-730176 IV-144

of all amendments and revisions in force as on date of opening of bid and
shall clearly bring out the salient features for comparison.
a) Ambient Air temperature -Minimum 5oC to Maximum 50oC with daily

b) Altitude - Maximum up to 1000 metres above MSL.
c) Humidity - Relative humidity maximum up to 100%
d) Location - Indoor
a) The Indian Electricity Rules.
rules/codes.
The design of the transformers and accessories shall be in accordance

with the latest standard practice and shall be such as to facilitate
inspection, cleaning, repairs, maintenance and operation and shall ensure
safe operation under situation of sudden variations of loads and voltages
as may be required under local operating conditions.
4.2.14.5.1 ELECTRICAL FEATURES
a) Continuous operation at rated kVA provided service conditions

does not exceed the values given in this specification.
b) Continuous operation at rated kVA within ±10% variation of
voltage & ±3% frequency..
c) Continuous operation at rated kVA at each of the tap voltages
d) Overloading of units as indicated in IS: 6600
e) Cooling shall be ONAN with temperature rise of 500C (Oil) & 550C
(Winding)
f) The insulation level shall be uniform & conform to the following
values:
Nominal System Voltage (kV rms): 3.3
Highest System Voltage (kV rms) : 3.6
Rated lightning withstand
JOB NO-730176 IV-145

Impulse voltage (kV peak) : 20
Power frequency 1 minute
Withstand voltage (kV rms) : 10
4.2.14.5.2 Mechanical Features
a) The Transformer shall be able to withstand the electro-dynamic

stress due to terminal short circuit of the LV side assuming the HV
side fed from an infinite bus. All leads, windings in cores shall be
properly supported, clamped and tightened after vacuum drying to
ensure the short circuit withstand ratings. The short circuit
b) The transformer shall be so designed as to minimize any undue
noise and vibration.
4.2.14.6.1 CORE
The Transformer core shall be made of high grade non-ageing grain

oriented cold rolled silicon steel sheets of low hysterisis loss & high
permeability. The core structure shall be securely grounded to prevent
electrostatic potential. Lifting eyes & lugs shall be provided on the limbs &
coil assembly. Preferably no bolt shall be used in the cores. Clamping
shall be done externally to the limb.
The design of the magnetic circuit shall be such as to avoid static

discharges, development of short circuit paths within itself or to the
earthed clamping structure and the production of flux component at right
angles to the plane of lamination which may cause local heating.
Cores & winding shall be capable of withstanding shocks during transport,

installation & service and adequate provision shall be made to prevent
movement of core & winding relative to tank during this condition.
All steel section used for supporting the core shall be thoroughly sand
blasted after cutting, drilling and welding.
The manufacturer shall furnish the exact type of core material, its BH
curve, design flux density at normal tap and the source of procurement.
4.2.14.6.2 TANKS
a. Tanks shall be of welded construction and fabricated from boiler

steel plates of adequate thickness. The weld procedure and
performance shall be in line with ASME BPV- IX.
b. All seams & joints those are not required to be opened at site shall
be factory welded and wherever possible they will be double
welded.
JOB NO-730176 IV-146

c. Tank stiffeners shall be provided for general rigidity and these shall
be designed to prevent retention of water
d. The tank shall be designed to withstand
i) Mechanical shocks during transformation
ii) Vacuum filling of oil
iii) Short circuit force
e. The transformer tank and its accessories shall be designed without
f. Adequate space shall be provided at the bottom of the tank for
g. Suitable guides shall be provided in the tank for positioning the core
and coil assembly.
h. The tank shall be suitable for movement in both directions during
shipment. Each tank shall be provided with:
i) Lifting lugs suitable for lifting the complete transformer
ii) A minimum of four jacking pads to be raised or lowered using
hydraulic or screw jacks.
4.2.14.6.3 TANK COVER
a) The tank cover shall be sloped to prevent retention of rain water

b) At least two adequately sized inspection covers one at each end of
the tank shall be provided for easy access to bushings and
earth connection. The inspection covers shall have suitable lifting
arrangement.
c) Bushings, inspection covers etc. shall be designed to prevent
d) All bolted connections shall be fitted with weather proof hot oil
over compression.
4.2.14.6.4 MOUNTING ARRANGEMENT
a) The transformers shall be provided with two nos bi-directional skids

and pulling eyes integral with the tank body for fixing the
b) These skids shall be such that the bottom of the tank is at a
transformer shall be provided with unit/bidirectional, flat/flanged
rollers.
4.2.14.6.5 CONSERVATOR TANK
a) The conservator tank shall have adequate capacity to

5oC to 110oc.
JOB NO-730176 IV-147

b) The conservator shall be bolted into position so that it can be
c) The conservator tank shall be fitted with a silica gel filter breather.
d) The conservator shall be fitted with magnetic oil level gauge with
two independent low level electrically insulated alarm and trip
contracts. The oil level at 30oc shall be marked on the gauge.
4.2.14.6.6 PRESSURE RELIEF DEVICE
a) The transformers shall be provided with the single diaphragm type

of explosion vent and a spring loaded pressure relief device.
b) An equalizer pipe shall be connected to explosion vent from the
conservator.
c) The pressure relief device shall be sufficient size for rapid release
of any pressure that may be generated in the tank. The device shall
operate at a static pressure less than the hydraulic test pressure of
transformer tank. Means shall be provided to prevent ingress of rain
water. An extension pipe fitted above the device shall direct the
major flow of ejected oil downwards and permit its removal without
disturbing the device.
4.2.14.6.7 TEMPERATURE INDICATOR


mounted in marshalling box. It shall have two adjustable
potential free contacts, one for winding temp. high alarm and
one for trip, in addition to the contracts required for control of
cooling equipment.
JOB NO-730176 IV-148

v) Automatic ambient temp. Compensation.
connection in 240V circuit. These shall be accessible on
removal of the cover.
4.2.14.6.8 WINDINGS
a) The conductors shall be electrolytic grade copper free from scales

and burns.
b) All windings shall be fully insulated. No graded insulation shall be
prohibited.
c) The insulation of transformer windings and connections shall be
free from insulating compounds which are liable to soften, ooze out,
shrink or collapse and be non-catalytic and chemically inert in
transformer oil during service.
d) Coil assembly and insulating spacers shall be so arranged as to
ensure free circulation of oil and to reduce the hot spot of the
winding.
e) Tapings shall be so arranged as to preserve the magnetic balance
of transformers at all voltage ratios.
f) All bus bars and leads shall be adequately supported in insulated
cleats or frames from the clamping locked.
g) The studs, set screws or bolts provided for securing cleats or
h) Bus bars and leads shall be supported throughout their length to
transport or are not forced out from the prescribed position during
any short circuit.
i) The impedance values shall be as per relevant IS.
j) The winding shall be connected to achieve a vector group of DY11.
k) The transformer shall have two windings as specified in the
Annexure-I.
4.2.14.6.9 INSULATION MATERIALS
a) Class ‘A’ insulating materials specified in IS:1271 shall be used

Wood insulation, where used, shall be well seasoned and treated.
b) Insulating Oil
i) The new insulating oil supplied with the transformer shall
conform to the requirements of IS:335. No inhibitors shall be
used in the oil
ii) Prior to filling the oil in the main tank suitable number of
at 90 deg c, tan delta at 90 deg C and interfacial tension. The
oil samples taken from the transformer at site shall conform to
the requirements of IS: 1866.
III) The manufacturer shall dispatch the transformer filled with oil.
JOB NO-730176 IV-149

Ten percent (10%) extra oil shall be supplied for topping up, in
non returnable sealed containers suitable for outdoor storage.
4.2.14.6.10 EARTHING TERMINALS
Two earthing terminals suitable for connecting 50 x 8 mm GI flat shall be

provided at positions close to the two diagonally opposite bottom corners
of tank. These grounding terminals shall be suitable for bolted
connection. Two earthing terminals shall also be provided on marshalling
box and any other equipment mounted separately.
4.2.14.6.11 BUCHHOLZ RELAY (wherever applicable)

collected in this relay. The relay shall be provided with a test cock
suitable for a flexible pipe connection for checking its operation. A
copper tube shall be connected from the gas collector to a valve located
about 1200 mm above ground level to facilitate sampling with the
transformer in service. The device shall be provided with two potential
free contacts, one for alarms on gas accumulation and the other for
tripping on rise of pressure.
4.2.14.6.12 TERMINAL ARRANGEMENT

the phase and earth potential of the porcelain bushing shall be in
accordance with IS: 2026 – Part V.
ii) Bushing terminals shall be provided with suitable terminal
connectors of a proven type and size for cable termination on
high voltage side and low voltage side.
iii) All transformers bushing shall be of solid porcelain with rain sheds
work.
B) CABLE BOXES AND DISCONNECTING CHAMBERS
i) Wherever cable connections are specified suitable air insulated

JOB NO-730176 IV-150

shall be of galvanised iron.
ii) Cable boxes shall have terminal connectors of adequate size and
bolt hoes to receive cable lugs.
iii) The bidder shall provide earthing terminals on the cable box to
iv) All necessary cable terminating accessories such as supporting
the bidder.
v) Cable boxes shall have removable top cover and ample clearance
vi) Cable boxes shall have degree of protection of IP-52 as per IS:
2147.
4.2.14.6.13 RADIATORS
The radiator shall be detachable type, mounted on the tank. Each radiator
shall be provided with the following.
approval.
4.2.14.6.14 MARSHALLING BOX

JOB NO-730176 IV-151

ground level.
separately.
4.2.14.6.15 OFF CIRCUIT TAP CHANGING EQUIPMENT


4.2.14.6.16 PAINTING
The internal and external surfaces including oil filled chambers and
scale or foreign adhering matter. All steel surfaces in contact with
insulating oil shall be painted with two coats of heat resistant, oil
insoluble, insulating varnish. All steel surface exposed to weather shall
be given a primary coat of zinc chromate, second coat of oil and weather
resistant varnish of a colour distinct from primary. At least two coats of
flossy oil and weather resisting non facing paint of light grey colour
corresponding to shade no.631 of IS:5. Primary paint shall be as per IS:
104 and intermediate and final coat of paint shall be as per IS: 2932.
4.2.14.6.17 BOLTS AND NUTS
contact with non ferrous part which carry current shall be of phosphor
bronze.
JOB NO-730176 IV-152

4.2.14.6.18 CONTROL WIRING
a) All controls, alarms, indicating and relaying devices provided with

the transformer shall be wired by the bidder up to the terminal
blocks inside the marshalling box. The bidder shall supply and
install the required 1100 V grade heavy duty PVC insulated, steel
wire armoured, PVC sheathed, multi core cables with copper
conductors of the least 2.5 mm2 conforming to IS: 1554. The
cables shall be properly supported.
b) All devices and terminal blocks within the marshalling box shall be
clearly identified by symbols corresponding to those used on
applicable schematic or wiring diagrams.
c) Not more than two (2) wires shall be connected to one terminal. At
least 20% spare terminals shall be provided. Each terminal shall be
suitable for connecting two numbers 2.5 mm2 stranded copper
conductor from each side.
d) Terminal blocks for CT secondary shall have shorting facility.
4.2.14.6.19 FITTINGS

a) Rating and diagram plate.
b) Terminal marking plate.
c) Two earthing terminals.
d) Lifting lugs
e) Jacking lugs
f) Drain valve with plug 50 mm up to 10 MVA and 80 mm above 10
MVA.
g) Dehydrating breather
h) Plain oil level indicator with minimum marking.
i) Magnetic oil level indicator with two electrical contacts, one for
alarm and other for tripping.
j) Thermometer pocket
k) Marshalling box
l) Off load tap changing switch
m) Oil filling hole with cover
n) Conservator
o) Air release device and explosion vent
p) Oil temperature indicator with one electrical contact for alarm
q) Winding temperature indicator
r) Skids and pulling eyes on both sides
s) Rollers
t) Bushing with metal parts and gasket
u) Filter valves at the top of the transformer tank
v) Inspection cover
JOB NO-730176 IV-153


with IS: 6600 (amended up to date) up to load of 15%. There shall
be no limitation imposed by bushing, tap changer etc.
ii) The transformers shall be capable of being continuously without
danger on any taping at the rated KVA with voltage variation of
±10% corresponding to the voltage of the taping.
B) FAULT CONDITION

withstanding any external short circuit at bushing terminal without
damage for two (2) seconds.
C) IMPEDANCE

indicated in Annexure:I.
D) WINDING



iii) Leakage test.
4.2.14.8 TEST

with IS: 2026 on each transformer. The manufacturer shall also carry out
type test in accordance with IS: 2026 on one piece of one rating.
JOB NO-730176 IV-154

required.
Sl.No Description of test Nature of test

2 Winding resistance at each/principal tap Routine
3 Voltage ratio at each/principal tap Routine
4 Vector group and polarity Routine
5 No load losses and magnetising current at rated Routine
frequency at 90%, 100% and 110% of rated
voltage
6 Impedance voltage and short circuit impedance Routine
at each/principal tap
7 Insulation resistance Routine
8 Temperature rise Type
9 Oil samples (repeat test) Type
10 Insulation resistance (repeat test) Type
11 Dielectric
vii) Power frequency withstand Routine
viii) Lightning impulse withstand Routine
ix) Switching impulse withstand Type
12 Oil samples (repeat test) Routine
13 Insulation resistance (repeat test) Routine
14 Tank
x) Pressure Routine
xi) Vacuum Routine
xii) Leakage Type
JOB NO-730176 IV-155

ANNEXURE-1
4.2.14.9 TECHNICAL PARAMETERS 100 kVA LIGHTING TRANSFORMER
1. Rated Capacity : 100 kVA

2. Quantity : Three nos
3. Type of transformer : Core type oil immersed
6. Location : Indoor
10. Rated Voltage
LV Winding : 230 Volts (L-L) ± 5%
12. Impedance voltage at rated current : 4%
HV Winding : Nil
LV Winding : Star Solid
14. Connection Symbol : DY11
15. Earthing of neutral terminals : Required for L.V.
windings
16. Rated Insulation Level :
17. One minute power frequency
Withstand Voltage. : 10 kV rms for 3.3 kV
18. Switching impulse withstand test : 20 kV peak for 3.3 kV
with voltage standard full wave for
windings for 1/50 microseconds.
19. Lightning withstand test voltage : 20 kV peak for 3.3 kV
with standard full wave for winding
for 1.2/50 microseconds.
21. Tap percentage : ±2.5, ± 5 and + 7.5%
22. Terminal Arrangement
a) HV side : Cable end box to
accommodate PVCSWA
b) LV side : Cable end box to
accommodate PVCSWA
23. a) Temperature rise (Over Ambient)
in oil : 500C
JOB NO-730176 IV-156

b) Temperature rise (Over Ambient)
in Winding : 550C
25. Standard applicable for transformer : IS: 2026 (Current)
26. Standard applicable for oil used : IS: 335 (Current)
4.2.15.0 SPECIFICATION FOR 3.3 kV SWITCH BOARD PANEL
This specification covers the technical details, operating requirement,

constructional details and provides some guidelines for testing at works for
procurement of a Switchboard as per this document and enclosed sheets.
This specification shall be applicable for indoor installed Switchboard

connected to primary side of transformer for distribution of power to
various load points.
The following broad requirements shall be applicable to 3300-volt

switchboard to be supplied and erected under these specifications. The
switchboard shall consist of vacuum circuit breakers or a combination of
required number of vacuum circuit breaker and vacuum contractor panels
as described in scope of work.
4.2.15.1 DESIGN REQUIREMENT
The equipment shall be used for system having the following

parameters:
a) System voltage – 3300 volt, 3 phase, restricted earthed, 50 Hz

AC
b) Basic Impulse level- As per IS
c) There shall be no radio interference when the equipment operates
at maximum service voltage.
d) The equipment shall be installed indoors in hot, humid and
tropical climate. All equipment accessories and wiring shall be
provided with tropical finish to prevent fungus growth.
e) The de-rating of the equipment shall be made taking into
consideration at 50 deg. C as an ambient temperature.
f) Circuit breaker shall be capable of interrupting rated power with
recovery voltage not exceeding the line service voltage at rated
frequency and at power factor not exceeding 0.15.
g) The circuit breaker shall be suitable for interruption of low current
with very high inductance as well as high capacitance without
undue over voltage.
JOB NO-730176 IV-157

h) The Bidder shall clearly indicate the following:
i). The method adopted for limiting over voltage and equipment
distribution of voltage across each breaker.
ii). The method adopted to limit low reactive current interruption.
iii). The method adopted and protections provided to selectively

trip the circuit breaker on earth leakage along with circuit
diagram, relays, etc.
4.2.15.2 TECHNICAL REQUIREMENT
The 3300-volt switchboard shall be sectionalised and suitable for

operation on 3300 volt, 3 phases, 50Hz, restricted earthed neutral system
with a fault level of 75 MVA.
The switchboard shall comprise of 3300-volt vacuum circuit breakers and

vacuum contactor panels. The switchboard shall be of free floor standing,
floor mounting, compartmentalised type and suitable for indoor installation
and extensible on either side.
The vacuum circuit breakers (VCB) shall be fully drawn out type mounted
on wheeled tracks which can be easily transported to repair bay. This will
ensure quick replacement of effective breakers and easy transportation for
repair and maintenance. The VCB shall have vertical isolation.
The vacuum contactor panels (VCP) shall be of fixed type.
The entire control circuit diagram of the switchboard with technical

particulars of each element and index of symbol shall be submitted for
approval from customer/consultant before manufacturer is taken up. Brief
write up shall accompany the diagram for better appreciation and quick
disposal.
Any special tools and tackles required for quick dismantling and fitting the
parts of vacuum circuit breaker shall be supplied with the equipment.
4.2.15.3.1 WIRING
JOB NO-730176 IV-158

The wiring shall be done with 2.5 sq. mm stranded copper conductor,
PVC insulated cable. All wires shall be identified at both ends with
ferrules in accordance with wiring diagram. All cables shall be neatly
bunched and care should be taken to ensure that the layout of the wiring
is neat and orderly.
4.2.15.3.2 CONFORMITY TO STANDARDS
The switchboard and all the components including accessories shall

conform to relevant Indian standard mentioned elsewhere.
4.2.15.3.3 TESTING
The switchboard with all its components shall be tested as per the
applicable Indian Standard.
4.2.15.3.4 LABELS
Labels shall be provided on each unit showing the duty of each

incoming/outgoing feeder.
4.2.15.3.5 CABLING
Outgoing cable connections for both power and control circuits shall be
bottom entry type. Bottom gland plates shall be removable type.
4.2.15.3.6 EARTHING
All equipment shall be earthed as laid down in Indian Electricity Rules

and Coal Mining Regulations. A horizontal earth bus at the bottom of the
complete switchboard shall connect adjacent sections and also to the
isolator integral earthing switch. This earth bus will be connected to the
main earthing system of the respective building.
4.2.15.3.7 MAIN CONTACTS FOR ARC QUENCHING
Complete details of the contacts and arc quenching devices should be

furnished. A Type test report on the rated breaking capacity assigned to
each type of circuit breaker or contactor shall be submitted.
JOB NO-730176 IV-159

4.2.15.3.8 INSULATORS
The porcelain insulators used shall be free from flaws which may impair
their mechanical and dielectric strength.
4.2.15.3.9 BUSBARS
Air insulated main busbar of electrolyte copper running horizontally along

the top rear of the enclosure shall be provided. This will be fitted with
each vertical section, which will in turn be connected to subsequent
sections. The jointing will by fishplates. The busbars shall be supported
on strong epoxy insulators and shall be generously spaced to ensure
adequate clearance and through fault capacity. The busbar
compartments shall be provided with removable bolted covers. Busbar
sleeving shall also be provided with proper colour coats. The busbars
shall be of suitable size to meet the requirement.
4.2.15.3.10 CURRENT TRANSFORMERS
The current Transformers provided for operation of meters and

protection shall comply with IS 2705 and shall have the following class of
accuracy.
For protection 5 p 10
For metering Class I
4.2.15.3.11 VOLTAGE TRANSFORMER
The voltage transformer shall be of suitable output VA rating per phase

to meet the requirement of metering, protecting, operating and tripping
circuits as per IS 3156.
4.2.15.3.12 VACUUM CIRCUIT BREAKERS
The vacuum circuit breaker forming part of the switchboard shall consist
of the following:
Operating mechanism spring charged, motor would have operating

mechanism suitable for both local and remote operation from control
desk. Manual charging facility of the spring for manual tripping
JOB NO-730176 IV-160

arrangement shall also be provided. The mechanism shall be provided
with feature of anti-pumping and trip free feature.
A. PROTECTION
a) For incoming circuit breakers the following protections
shall be provided
-Overload IDMT 50-200%

-Short circuit 400-1600%
-Earth Fault protection IDMT 10-40%
-CBCT operated earth leakage protection
b) The outgoing circuit breakers shall have
-Overload IDMT 50-200%,

-Short circuit 400-1600%,
-Earth Fault protection IDMT 10-40%
-Neutral displacement relay ( for capacitor bank
panel only)
.
B. INSTRUMENTS
a) For incoming circuit breakers:
i) Ammeter with selector- switch and transducer

ii) Voltmeter with selector switch and transducer
iii) Energy meter
iv) Power factor Meter
b) For outgoing breakers:
i) Ammeters with selector- switch and transducer

ii) Energy meter
c) No instrument shall be provided for bus sectionalising

circuit breaker.
C. INDICATION
Electrical and Mechanical ON, OFF & TRIP indication shall be

provided and the indication of these shall be carried to the
control desk in central control room.
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D. INTERLOCK
The two incoming circuit breakers and the bus sectionalising circuit
breakers shall be interlocked electrically and mechanically.
E. TRIPPING
Shunt trip shall be from inherent DC source. The tripping circuit of

the circuit breaker shall have provision to be connected to the
auxiliary contacts of winding temperature relay of the transformer.
Besides alarm and annunciation for indication of temperature
alarm/signal/trip and alarm cancellation shall be provided. The
emergency tripping of the circuit breaker shall be provided on the
control desk.
F. OPERATIONAL COUNTER
Operational counter to record tripping of circuit breakers shall be

provided.
4.2.15.4 VACUUM CONTACTOR PANELS
The panels shall be built in single tire construction in rigid free standing,
sheet steel enclosed section. Each vertical section shall contain main
busbars, isolator, contactor, CTs, PTs meters, HRC fuses etc.
The Contactor Panel shall form part of complete 3300 volts switch board.
The outgoing vacuum contactor panels will control 3300 volts motors
(suitable for direct on line starting). Each vertical section shall be divided
into four compartments namely bus bar chamber, isolator, contactors,
protection and metering compartments. Provision shall be made to ON-
OFF the VCP from a remote control desk.
The vacuum contactor panel forming part of the switchboard shall consist
of the following:
A. ISOLATOR:
The isolator shall be provided with integral earthing switch. The door
interlock shall be such as to prevent the front cover opening till the
isolator is off and earthed. A safety shutter shall be provided to prevent
accidental contact with the live contacts when the door will open. The
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isolator handle shall be lockable in ON and OFF position. A glass
covered window shall be provided to give a clear view of isolator in OFF
and earthed position.
B. H.T CONTROL COMPARTMENT
A separate enclosure below the isolator compartment housing the HRC

power fuses, vacuum contactors, CTs and power connections shall be
provided. The fuses and contactor shall be accessible from the front
after opening a separate door, positively interlocked with the isolator
compartment door.
C. L.V. COMPARTMENT
Control and indicating equipment, meters, relays etc. shall be housed in

separate and completely segregated compartment. Space for additional
relays, meters etc. shall also be provided at the top.
D. MOTOR PROTECTION RELAYS

Reliable relays shall be provided for comprehensive protection against
overload, short circuit, single phasing, stall, earth leakage, under voltage
etc.
E. AUXILIARY CONTACTS
The breakers and contactor panels shall be provided with suitable nos.
of NO and NC auxiliary contacts for remote operation and indication in
addition to the required for their own operational requirement.
F. TIMER DEVICE
Suitable timer device shall be provided in the VCP panel controlling the
drive motors of a multi drive unit to start the motors at a definite time lag.
JOB NO-730176 IV-163

4.2.16.0 SPECIFICATION OF MOTOR CONTROL CENTRES
4.2.16.1 INTENT OF SPECIFICATION
The following requirements shall be applicable to all motor control

centers, furnished under these specifications. Any item which is not
specifically mentioned but required for successful and trouble free
operation of the system shall be furnished under these specifications.
4.2.16.2 CODES AND STANDARDS
All equipment shall in general comply with updated issues of
i) Applicable Indian Standards

ii) Indian Electricity Act
iii) Indian Electricity Rule
Equipment complying with any other authoritative standards such as

IEC, BRITISH, USA and GERMAN etc. will also be considered if it
ensure performance equivalent or superior to Indian Standards. In the
event of supply of equipment conforming to any
international/internationally recognized standard, the salient features of
comparison shall be brought out and furnished.
The specification codes and standards referred to in this specification

shall govern in all cases where reference thereto is made. In case of
conflict between the referred specifications, the codes or standards and
this technical specification, the latter shall govern to the extent of such
differences.
Some relevant Indian standards for the equipment covered under this
specification, are given elsewhere.
4.2.16.3 GENERAL REQUIREMENT
i.) The motor control centre (MCC) shall be located indoor and be
suitable for operation in 415 volt, 3 phases, 50 Hz, restricted
earthed neutral system with a fault level of 35 MVA. The MCCs
shall be with two incoming Air Circuit Breaker to receive incoming
cable and one sectionaliser Air Circuit Breaker..
ii. Each motor feeder shall have DOL/ Reversible DOL starters,
contactor, bimetallic overload relays with built in single phasing
preventer, Earth leakage protection (for motor 5kW and above),
and motor protection relay (for motor rated 45kW and above in
sequence control), backed by a Isolator with Switch fuse unit with
inherent short circuit protection. Each motor feeder shall be
provided with ammeter.
JOB NO-730176 IV-164

iii.) All other feeder shall be provided by a Isolator with Switch fuse unit
with inherent short circuit protection, contractors, bimetallic
overload relays with built in single phasing preventer and other
required protection.
iv.) 10% spare outlets shall be provided in the MCC for each size type
of feeder feeding power to motor / other loads with a minimum of
one.
v.) Provision shall be made to facilitate for sequence control of the

equipment which will receive power through MCC.
vi.) The control desk shall be located in the central control room.
4.2.16.4 CONSTRUCTION REQUIREMENTS
The MCC shall be with steel enclosure, cubicle type, dust and vermin
proof, floor mounting, single front construction. It shall have fully drawn out
type units over chassis arranged in suitable multi tier formation.
All 415V Air Circuit Breakers shall be of fully draw out type, which can be
drawn out without having to unscrew any connections. The circuit
breakers shall be mounted on rollers and guides for smooth movement
between SERVICE, TEST and ISOLATED positions, and testing of the
breaker shall be possible in the TEST position.
The MCC shall consist of vertical sections fabricated from cold rolled
sheet steel of thickness not less than 2mm shaped and reinforced to form
rigid free standing structure and having a degree of protection not less
than IP: 52.
All panel edges and cover/door edges shall be reinforced against

distortion by rolling, bending or by the addition or welded reinforcement
members. The complete structures shall be rigid, self supporting, free from
flows, twists and bends. All cut outs shall be true in shape and devoid of
sharp edges.
MCCs shall be divided into vertical sections. Each vertical section shall be
provided with a cable alley, which shall cover the entire height.
For draw out type equipment pertaining to a circuit shall be mounted in a

withdraw able chassis, which can be drawn out without having to unscrew
any wire or to the equipment mounted on the chassis.
All equipment and components shall be neatly arranged and shall be

easily accessible for operation and maintenance. The internal layout of all
modules shall be subject to customer's/consultant's approval. Bidder shall
submit dimensional drawings showing complete internal details of bursars
and module components, for each type and rating for approval.
JOB NO-730176 IV-165

All single front MCCs shall be provided with removable bolted covers at
the rear. The covers shall be provided with danger labels.
All sheet work shall be pre treated in tanks, in accordance with IS 6005.
Degreasing shall be done by alkaline cleaning. Rust and Scale shall be
removed by pickling with acid. After pickling, the parts shall be washed in
running water. Then these shall be rinsed in slightly alkaline hot water and
dried. The phosphate coating shall be ‘Class: C’ as specified in IS 6005.
The phosphated surface shall be rinsed and passivated prior to application
of stoved lead oxide primer coating after primer application, two coats of
finishing synthetic enamel paint on panels shall be applied.
Electrostatic painting shall also be acceptable. Finishing paint on panels

shall have shade 692 (Smoke grey) of IS: 5 unless required otherwise by
the Customer/consultant. The inside, of the panels shall be glossy white.
Each coat of finishing shall/not be less than 50 microns. Finished parts
shall be coated by healable compound by spraying method to protect the
finished surfaces from scratches, grease, dirt and oily spots during testing,
transportation, handling and erection.
The temperature of the bus bar and all other equipment, when carrying the
rated current continuously shall be limited as per the stipulation of the
relevant Indian standards, duly considering the specified ambient
temperature 50 deg C. The Continuous temperature rise shall be no case
exceeds 55 deg C. with silver plated joints and 40 deg C with all other type
of joints over on outside ambient temperature of 50 deg C.
All disconnecting contacts for power circuits shall be robust design and
fully self aligning. Fixed and moving contacts of the power draw out
contact system shall be silver plated. Both fixed and moving contacts shall
be replaceable.
The Bidders shall indicate clearly the derating factors employed for each
component and finish the basis for arriving at these derating factors duly
considering the specified ambient temperature of 40 deg C.
4.2.16.5 BUSBARS
All bus bar and jumper connections shall be of high conductivity

electrolytic copper of adequate size. The busbars shall be rated in
accordance with the specified continuous and short time current rating.
The Cross section of the busbars shall be uniform throughout the length of
switchgear and shall be adequately supported and braced to withstand the
structure due to the specified short circuit currents.
All busbars shall be adequately supported by non hydroscopic, non

combustible, track resistant and high strength type polyester fiber glass
molded insulators. Separate supports shall be provided for each phase
and neutral bus bar. If a common support is provided, anti tracking barrier
JOB NO-730176 IV-166

shall be provided between the supports, All bus bar joints shall be
provided with high tensile steel bolts, Belleville/Spring washers and nuts,
so as to ensure good contacts at the joints. Non silver plated Bus bars
joint shall be thoroughly cleaned at the joint locations and suitable contact
grease shall be applied just before making a joint.
All busbars shall be color coded as per IS 375.
Auxiliary buses shall be provided for AC and DC control power supplies.

The material for all buses for control shall be electrolytic copper. The
supply for AC auxiliary Buses shall be tapped from the main power buses
before the incomer, for each switchboard. Individual fuse and neutral links
shall be provided at each circuit of AC or DC auxiliary busbar and the
circuit for space heater should include an insulating air break switch. The
auxiliary busbar compartment shall be completely segregated from main
busbar compartment and shall also run horizontally.
4.2.16.7 EARTH BUS:
A galvanized steel earthing bus shall be provided at the bottom of each

panel and shall extend throughout the length of each switchboard. It shall
be welded/ bolted to the framework of each panel and breaker earthing
contact bar. Vertical earth bus shall be provided in each vertical section,
which shall in turn be bolted/ welded to main horizontal ground bus.
The earth bus shall have sufficient cross sections to carry momentary the
system short circuit and short time fault currents to earth.
4.2.16.8 TECHNICAL REQUIREMENT:
The technical requirement of various components of Motor Control Centre

is given below:
A) SWITCH FUSE UNIT
i. Switch Fuse unit shall be used to protect the outgoing feeders from
short circuit fault and shall be of quick make, quick break and
current limiting type having trip free mechanism.
ii. The operating handle shall give a clear trip indication and shall be
suitable for interlocking with the cubicle door.
B) L.T. CIRCUIT BREAKER
The incoming Air Circuit Breakers shall be of 3 pole air break draw out
type suitable for an operating duty B: 3 min. MB – 3 mm – MB with a
fault level of 35 MVA and shall conform to the following:
i. Operating mechanism – Motor operated spring charged, suitable

for remote operation from control Desk.
JOB NO-730176 IV-167

ii. Protection – Overload, short circuit, Earth Fault & Earth Leakage.
iii. Instrument – Ammeter with selector switch, voltmeter with selector
switch – with provisions of the Ammeter and voltmeter signals
carried on to the control desk in the Central Control Room.
iv. Indication: ON OFF TRIP
These indications shall be carried on to the control desk in the Central

Control Room.
I) TRIPPING – SHUNT TRIP FROM DC SOURCE.
The spring charging motor shall be such that it requires not more than 30
seconds for fully charging the closing spring. Once the closing springs
are discharged, after one closing operation of circuit breaker, it shall
automatically initiate recharging of the spring.
The mechanism shall be such that as long as power available to the

motor, a continuous sequence of closing and opening operations shall
be possible. After failure of power supply, at least one open close open
operation shall be possible. Provision shall be made for emergency
manual charging and as soon as this manual charging handle is
coupled, the motor shall automatically get mechanically de coupled.
All circuit Breakers shall be provided with closing and trip coils. The
closing coil shall operate correctly at all values of voltage between 85%
to 110% of rated control voltage. The trip coil shall operate satisfactorily
under all values of supply voltage between 70% to 110% of rated control
voltage. For safety, the trip circuit supervision relay should be provided.
Provision for mechanical closing of the breaker only in ‘TEST’ and

‘WITHDRAWN’ positions shall be made.
C) CONTACTOR
i) Motor starter contactors shall be of air break, electro magnetic

type rated for uninterrupted duty as per IS 2959.
ii) Contactors shall be double break, non: gravity type and their
main contacts shall be silver faced.
iii) Direct on line starter contactors shall be of utilization category of
AC3 and reversing starter shall comprise of forward and reverse
contactors mechanically and electrically interlocked with each
other. These contactors shall be of utilization category AC4 as per
IS 1822.
iv) Each contactor shall be provided with required number of
normally open (NO) and normally closed (NC) auxiliary
contacts.
v) Operating coils of contactors shall be of 220 V AC. The
contactors shall operate satisfactorily 85% to 110%of the rated
voltage. The contactor shall not drop out at 70% of the rated
voltage.
JOB NO-730176 IV-168

D) INSTRUMENT TRANSFORMER
i) The current transformer shall be of suitable VA rating and have

accuracy class for protection 5P 10 and for metering Class:1.
ii) The voltage transformer shall be of suitable VA rated.
E) INDICATING INSTRUMENT
Indicating instrument shall be of flush mounting type, and shall have an

accuracy class of not less than 1.5.
F) CONTROL AND SELECTOR SWITCH
All control and selector switches shall be of rotary type, having

escutcheon plates clearly marked to show the function and positions.
G) PUSH BUTTON
Push button shall be of spring return push to actuate type having

escutcheon plate to mark the function.
H) INDICATING LAMP
Indicating lamp shall be of cluster LED type with escutcheon plates to

indicate the function.
I) NAME PLATE AND LABEL
All cubicles shall have name plate for feeder designation. The nameplate
shall be of non: rusting metal with white engraved letter on black
background.
J) CONTROL AND SECONDARY WIRING
i) All switchboards shall be supplied completely wired internally, up to

the terminal blocks.
ii) All inter cubicle and inter panel wiring and connections between
panels of same switchboard including all bus wiring for AC and DC
supplies shall be provided by the Contractor.
iii) All internal wiring shall be carried out with 650 V grade, single core
and 1.5 mm2 or larger stranded copper wires having colour codes,
PVC insulation and CT circuits shall be wired with 2.5 mm2 copper
wires, other wire similar to the above.
iv) Extra flexible wires shall be used for wiring to devices mounted on
moving parts such as hinged door.
v) All wiring shall be properly supported, neatly arranged, readily
JOB NO-730176 IV-169

accessible and securely connected to equipment terminals and
terminal blocks.
vi) Internal terminations of stranded conductors shall be made with
soldieries crimping type tinned copper lugs, which shall finally grip
the conductor, or by an equally secure method. Insulating sleeves
shall be provided over the exposed parts or lugs.
vii) Engrave core identification ferrules marked to correspond with
panel wiring diagram shall be fitted at both ends o each wire. The
wire numbers shall be in accordance with IS 375.
4.2.16.9 TESTS
Type test reports for circuit Breaker, Bus bars and Panels, Contactors
shall be furnished. Type test certificates for all important components like
instrument transformers, meters, fuses, etc. shall be furnished before the
fabrication of switch gear is started. The reports shall cover all applicable
type tests listed in relevant Indian Standards for all components of type
and ratings being supplied.
Routine tests shall be carried out on all switchboards and associated

equipment, as per relevant standards at Bidders’ cost.
The Customer reserves the right to witness any or all the tests, for which
at least 20 days advance notice shall be given by the Contractor.
Testing of switchboard enclosures and busbar chambers to observe

compliance to degree of protection first and second numerals, shall be as
under:
a) It shall not be possible to insert a One :( 1) mm dia steel wire into

the enclosure from any direction, without using force.
b) It shall not be possible to insert a thin sheet of paper under
gaskets and through enclosure joints.
4.2.17.0 SPECIFICATIONS OF POWER DISTRIBUTION BOARDS
4.2.17.1 INTENT OF SPECIFICATIONS

The following requirements shall be applicable to all Power distribution
boards for controlling power distribution to various equipment operating at
415 V, 3-phase, 50 Hz supply system. Any item not specified but are
required for successful and trouble free operation of the system shall be
furnished under these specifications. These specifications shall be read in
conjunction with the plant description and scope of supply / scope of work
as described elsewhere in this document.
JOB NO-730176 IV-170

The general requirements of the sub distribution boards shall be as

given below.
These shall be indoor type and suitable for 415 V, 3 phases, 50 HZ,
restricted earthed neutral system with a fault level of 35 MVA.
The incoming feeder control will be modules Isolator with Switch fuse
unit with inherent short circuit protection, contactors and bimetallic
overload relays with built in single phasing preventer and other
required protection.
The motor control feeders (vibratory feeders) shall have modules of

DOL/ Reversible DOL starters, Isolator with Switch fuse unit with
inherent short circuit protection, contactor, bimetallic overload relays with
built in single phasing preventer, Earth leakage protection (for motor
5kW and above) and other protections. Each motor control feeder shall
be provided with ammeter.
All other feeder shall be provided with Isolator with Switch fuse unit with
inherent short circuit protection, contactors and bimetallic overload
relays with built in single phasing preventer and other required
protection.
Provision shall be made to facilitate for sequence control of the
equipment.
10% of spare out lets for each type shall be provided with a minimum of
one.

The power distribution boards shall be designed and manufactured as per
relevant Indian standards, practices and requirements.
The Power distribution boards shall be free standing, floor mounting, multi
tire (4 compartments), cubicle type, single front, non draw out. The
enclosure shall be dust, vermin and weather proof type. The enclosure
shall have a degree of protection not less than IP 52. The board shall have
provision of cable entry from the bottom.
The distribution board shall be fabricated from not less than 2 mm thick
steel sheet and properly stiffened. All panel edges and cover/ door edges
shall be properly stiffened against distortion by rolling, bending. The
supporting structure shall be free from flaws, twists and bends. Rear side
of the distribution boards will be covered by removable bolted covers. The
hinged doors provided in the front shall be provided with proper locking
facility and rubber gaskets all around. Proper inter locking arrangement
shall be provided so that incoming fuse switch unit is brought to OFF
position before the door is opened. The minimum clearance between the
JOB NO-730176 IV-171

floor and bottom of the panel shall be 500mm and is covered from the
front and end sides by detachable MS sheet. The structural steel shall be
properly surface treated. Two coats of lead primer shall be applied first
over which two coats of synthetic enamel paint shall be applied for a
smooth and elegant surface. The operating handles, meters, required
labels, danger plates shall be provided on front door of the board.
The board shall consist of number of panels for feeding power to different
equipment. Each panel shall be of maximum 4 tire formation. The bottom
compartment shall house terminal blocks for terminating cables. An earth
bus shall be provided in this compartment and extended throughout the
length of the board. The earth bus shall have sufficient cross section to
carry the momentary short circuit and short time fault currents occurred in
the system to the earth. The panel shall have two earth terminals. The
earth bus shall be made of galvanised steel. Vertical earth bus shall be
provided in each panel.
In the top compartment 4 numbers of bus bars (3 phases and 1 neutral)
and required Isolator will be provided. The bus bars shall run throughout
the length of the board. The bus bars shall be accessible and properly
spaced. These bus bars shall be properly supported on non-hydroscopic,
non-combustible, track resistant and high strength type polyester fibre
glass moulded insulators. Separate supports shall be provided for each
bus bar. If a common support is provided, anti tracking barrier shall be
provided between the supports. The bus bars shall be made of hard drawn
high conductivity copper and provided with proper colour sleeves of PVC
(Red, Yellow, Blue, Black) to identify the phases and neutral. The bus bars
will be sufficient cross section and uniform throughout the length. The
cross section of bus bar shall be able to withstand stresses due to
specified short circuit currents, however the bus bar rating shall not be
less than the rating of incoming Switch fuse unit. The bus bar temperature
shall not be more than 70 degrees celcius at full load considering the
ambient temperature as 50 degree celcius. All bus bar joints shall be
provided with high tensile steel bolts, belleville /spring washers and nuts to
ensure good contacts at joints. Non-silver plated bus bar joints will be
thoroughly cleaned at the locations and suitable contact grease shall be
applied just before making a joint. Dropper bus bars shall run entire height
of the panel behind for feeding power to each cubicle.
The incoming feeder shall be controlled by an `modules of isolator, switch
fuse, contactors and other protections of non draw out type. Ammeter and
voltmeter with selector switch shall be provided on the front panel.
Indications such as ON, OFF, TRIP shall be provided and these shall be
carried to the central control desk provided in the central control room.
Motor starter contactors shall be air break, double break, electromagnetic
type, non-gravity type, silver faced and rated for uninterrupted duty as per
IS 2959. The contactors shall normally be suitable for DOL operation of
squirrel cage induction motors and of utilization category of AC-3 duty and
that for reversing motors it shall be of AC 4 duty. Each contactor shall be
provided with required number of normally opened (NO) and normally
closed (NC) auxiliary contacts for various functional requirements. The
JOB NO-730176 IV-172

operating coils of the contactors shall be of 110 V AC and receive power
from a control transformer of sufficient capacity provided in the switching
room. Single phasing protections shall also be provided. All out going
feeders (5kW and above) shall be provided with earth leakage protection.
Motor protection relay shall be provided for comprehensive protection to
the motors rated 45kW and above.
Properly rated switch fuse unit shall be provided before the contactors.
The switch fuse unit, contactor starter shall be provided in the middle two
cubicles. Required instruments such as ammeter with selector switch of
required accuracy shall be provided. One set of indicating lamps of LED
type shall be provided in the front panel of cubicle for indicting the status.
All the internal wiring shall be carried out in the factory with 650 V grade,
single core, 2.5 sq. mm or larger cross section as per requirement. The
cables shall be PVC insulation type with copper conductors. Extra flexible
wires shall be used for wiring various devices mounted on hinged doors.
All wiring shall be properly supported, neatly arranged, readily accessible
and securely connected to the equipment terminals and terminal blocks.
Internal terminations of standard conductors shall be made with solder
less crimping type tinned copper lugs which shall finally grip the
conductors. Insulating sleeves shall be provided on exposed lugs or joints.
Proper ferrules shall be provided for identification of wiring.
Necessary indicating name boards shall be provided on the front door of
the panel.
4.2.17.4 MAIN COMPONENTS OF SWITCH BOARD

Modules with switch fuse unit.
The incoming/outgoing modules shall have switch fuse unit, contactors
and other protection of followings:
Quantity : As per requirement
Service : Incoming/Outgoing
Normal supply voltage : 415 volts
Frequency : 50 Hz
Application : Indoor
No. of phases : Three
SFU rating : Triple pole of suitable rating.
Protection : i) Bimetallic overload
ii) Short circuit
iii) Earth leakage
iv) Single phasing
Cable entry : From bottom of the panel
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Metering : CT operated ammeter and
Voltmeter with selector switch
for incomer and ammeter for
motor feeder of suitable range.
4.2.18.0 SPECIFICATION OF EQUIPMENT FOR ILLUMINATION SYSTEM
The following broad requirement shall be applicable for the equipment for
illumination system furnished and erected under these specifications. The
Bidder shall however give the detailed specification of the items.
The minimum illumination level of different areas shall not be less than the
values specified elsewhere in this specification.
Inverter type emergency lights shall be located in the sub station/switch

stations and Control rooms. The emergency lights shall be complete with
fitting. The unit shall be complete with battery of suitable AH capacity to
run for three hours continuously and fitted with automatic battery
charging/inverter device. It shall be complete with all accessories and shall
be supplied with one hydrometer each to test the specific gravity of the
electrolyte. The electrolyte level in the battery should have device for
continuous monitoring.
The following minimum illumination level shall be achieved and

guaranteed by the Bidder after considering maintenance factor 0.6 and
coefficient of utilization depending on the area to be illuminated. The
details of calculation as well as the mounting scheme shall be submitted
by the Bidder for approval of the customer/consultant and the final
approved scheme shall be applicable in furnishing and installation of the
illumination system.
Sl. Location Level of Type of lighting fixture

no illumination
(LUX)
1 Substations/switching 200 Single /Double, Fluorescent
stations , Maintenance tube lights (36/40W) with
cum testing room, stores/ industrial type lighting
tools room, engineer’s fixtures with energy efficient
room compressor room, choke
Pump house etc.
2 Control Room 300 Single/Double, fluorescent
tube lights (36/40 W) or four
fluorescent tube lights
(18/20 W) with Decorative
lighting fixture with energy
JOB NO-730176 IV-174

efficient choke
3 Conveyor Gantries, 70 Metal Halide/ HPSV lamps
tunnel, Ground Bunker, (70 watts) with well glass
Loop take-up house, floor lighting fixtures
of tripper and reclaim
conveyor in O/H bunkers,
4 Transfer houses, drive 150 Metal Halide/ HPSV lamps
houses, Hopper complex, (70/150/ 250W) with flood
Floor of hoppers, various light fitting
platforms in silo and
Sampler house, Silo
loading area.
5 Substation outdoor yard, 10 Metal Halide/ HPSV lamp
roads inside area and (150 /250 /400W) with street
along the conveyers Light/Flood light fitting
6 Lighting near truck 20 Lighting through 15 m/30m
receiving stations, outside high lighting mast Metal
bunker and SILO complex Halide/ HPSV (400 W) flood
light fittings.
The actual requirement shall be as per calculation to be worked out by the

bidder during detailed design engineering stage. The lighting fixtures and
accessories shall be of reputed make. All lighting fixtures shall be
complete with lamp and accessories and shall be designed for use in 240
+ 10% volts, 50Hz system under ambient temperature condition of 50 deg.
C. The details shall be finalized during detail engineering stage.
In the areas like control room etc. local switch boards shall be concealed
and flushed with the walls. The front cover of the switch board shall be
brown Bakelite sheet (minimum 3.5 mm thick) and the switches and
receptacles shall be flush mounted switches shall be of piano type.
Junction boxes shall be of cast iron and 3 mm sheet screwed over junction
boxes used outdoors shall be weather proof type with neoprene gaskets.
JOB NO-730176 IV-175

4.2.19.0 PECIFICATION FOR MAIN/SUB LIGHTING DISTRIBUTION BOARDS
4.2.19.1 General
The lighting distribution boards shall be of indoor type and suitable for
operation at 230 V (L-L), 3 phase, 50 Hz. supply system. These
specifications shall be read in conjunction with scope of work/supply.
4.2.19.2 Constructional features
The lighting distribution board shall be designed and manufactured as per

relevant Indian Standards, practice and requirements.
The distribution board shall be fabricated from sheet steel not less than
2mm thick and properly stiffened. The enclosure of distribution boards
shall be weather, dust and vermin proof. The door of the board shall be
provided with pad locking arrangement. The board shall be adequately
surface treated and painted with double coat synthetic enamel paint after
application with two coats of red oxide primer. The distribution boards will
be suitable for mounting on wall as well as on pedestals. The distribution
boards will be of front opening type.
The size of the enclosure shall be suitable to accommodate the required

number of MCCB/ MCB s, HRC fuses, busbar, timer contractor etc. as the
case may be with proper clearance for safety and easy maintenance. The
arrangement of bus-bar, MCCB/MCB, HRC fuses shall be so designed
that they can be easily replaced and approachable.
The copper busbar of adequate size shall be provided. The busbars shall
be properly spaced to facilitate taking vertical connections to individual
circuits through MCCB/MCBs having back up HRC fuses. The busbar
sizes shall be so selected that the temperature shall not be more than
70oC at full load taking ambient temperature as 50o C. However the
busbar rating shall not be less than the rating of incoming MCCB rating.
The busbar shall be provided with proper colour sleeves for phases and
neutral as per standard practice.
The distribution boards assembly shall be fully factory wired as per

requirement. The busbar, bare conductors, terminals of cables shall be
shrouded with proper insulated tape. Suitable cable termination
arrangement shall be provided to accommodate the incoming and
outgoing PVCSWA aluminum conductor cables from bottom in each panel
of the distribution boards. Proper cable glands shall be provided.
All distribution boards shall have minimum two earthing terminals.
i. The MCCB s / MCB s shall have built in overload and short circuit
protections. The MCCB will have short circuit breaking capacity of
35kA and MCB will have short circuit breaking capacity of 9kA. The
JOB NO-730176 IV-176

MCCB will be of 3-pole type, where as MCB will be of two poles. The
MCB shall be less than 16A rating. Suitable HRC cartridge fuses
shall be provided for back up protection for each panel.
ii. The MCCB/MCB s shall be of quick make, quick break and current
limiting type having trip free mechanism. These shall be provided
with magnetic release which will protect the circuit against short
circuit. The operating lever shall give a clear trip indication and shall
be suitable for interlocking with cubical door. The MCCBs shall
ensure operating of all the three phases in case of a fault in one
phase.
iii. Digital clock based timer with contactor shall be provided on
incoming panel of sub-distribution boards for automatic switching
ON/OFF of lights with a bypass arrangement. . Ammeter and
voltmeter with selector switch and ON/OFF indication lamp shall also
be provided on the front panel for incoming feeder.
iv. All the equipment shall be suitable for operation on restricted earthed
neutral system.
v. All the components and the boards shall conform to relevant Indian
Standards.
4.2.19.3 SPECIFICATION OF 70W HPSV/ MATEL HALIDE WELL GLASS LIGHT

FITTING
The luminaries shall consist of housing with reflector, glass cover, control
gear, lamp, igniters, capacitor, terminal blocks etc.
All the components of light fittings including bulbs shall confirm to relevant
Indian Standard or any other international standard.
The luminaries shall be suitable for mounting on the truss of conveyor
gantry at a height of 2 m (approx.) from floor level.
The luminaries shall be heavy duty, industrial type, dust, weather and
insect proof with control gear suitable for accommodating 70 W High
pressure sodium vapour/ Metal halide lamp for operation at 200 – 240 V
(L-L), 50 Hz supply system.
The luminaries shall have a housing of single piece and made of die-cast
aluminium. The inside of the house shall have a lamp holder and reflector
of high purity aluminium, electro-chemically brightened and anodized to
optimise light distribution. The lamp chamber shall accommodate the
required bulb.
The control gear box shall be made of suitable aluminium alloy and the
canopy shall be made of stove-enamelled sheet aluminium. The cover for
the bulb chamber shall be of high quality heat resistant glass with gasket
and will be protected with galvanized wire guard. The glass cover and
canopy shall be properly gascated to make the fitting dust tight and
weather proof. Proper locking arrangement of cover with the body shall
be provided.
JOB NO-730176 IV-177

The control gear housing shall be pre-wired with high quality, low-loss
heavy duty, copper wound ballast, capacitor to maintain minimum power
factor of 0.9 (lagging). Suitable electronic igniters, connector block shall be
provided.
The fitting should be provided with two brackets, which can be used for
top mounting or side mounting.
The housing shall be provided with cable entry box along with glands
suitable for required size of PVC insulated and PVC sheathed, single wire
armoured cable with 2 core Aluminum conductors.
4.2.19.4 SPECIFICATION OF 150W/ 250W/ 400W, HPSV/ MATEL HALIDE

STREET LIGHT/ FLOOD LIGHT FITTING
The luminaries consist of housing with reflector, glass cover, control gear
box, capacitor, terminal blocks etc.
All components of light fittings including bulbs shall confirm to relevant
Indian Standard or any other international standard.
The luminaries shall be suitable for mounting on structures, poles and
towers. The luminaries mounted on towers shall be of flood light fittings
and others are of street light fittings/flood light fittings.
The flood light luminaries shall be heavy duty industrial type, dust, rain,
weather, vermin and insect proof type suitable to accommodate 150W/250
W/400W high pressure sodium vapor/ Metal halide lamp for operation at
200-240V (L-L), 50 Hz., supply system.
The luminaries shall have a housing made of cast aluminum alloy with low
copper content for excellent corrosion resistance.
It should be provided with heat resistant glass cover to ensure insect free
performance without ingress of water. The glass cover shall be of plain
glass with good transparent properties. A felt gasket impregnated with
insecticide and water repellant chemical shall be provided between the
housing and glass cover. The housing should be closed from the front. It
shall have reflector of high purity aluminum, electro-chemically brightened
and anodized to optimized light distribution.
The control gear box shall be made of suitable aluminum alloy. An
aluminum lid shall be used to close the control gear compartment. The
control gear housing shall be pre-wired with high quality low loss heavy
duty copper wound blast, capacitor to maintain minimum power factor of
0.9 (lagging). Suitable electronic igniter, connector blocks shall be
provided.
Provision for varying the angle of mounting of luminaries shall be
provided.
The fitting shall be provided with brackets, which can be used for top
mounting or side mounting.
JOB NO-730176 IV-178

4.2.19.5 SPECIFICATION FOR FLOURESCENT TUBE LIGHT FITTINGS
The light fittings consist of housing, reflector, ballast, fluorescent tube rod,
terminal blocks, starter, condenser, rotor holder and rear wiring.
All components of light fittings shall confirm to relevant Indian Standard or
any other international standard.
The light fitting shall operate in the voltage range of 200-240V (L-L),
50Hz. supply system.
The tube light fitting shall be box type and suitable to accommodate two
nos. 1.2 m (4 feet) long 36/40 W or four nos. 2 feet long 18/20 W
fluorescent tube rods.
The housing shall be made from stove enameled and phosphotated
CRCA sheet steel not less than 20 SWG.
Provision shall be made on the base of the box so that the whole set can
be fitted on wall, on false ceiling or suspended from roof by conduit pipes.
The box shall be housed with electronic ballast, in-built capacitor if
required, starter along with its base and end holders for holding the tube
rods. The box shall house the required wires for connecting the various
components of the set.
Suitable in-built condenser may be provided to achieve minimum p.f. of
0.9 (lagging). Electronic ballast shall operator without humming and with
low losses.
Suitable sleeves shall be provided at the terminals of wires. Wire
termination arrangement shall be on terminal blocks.
4.2.19.6 SPECIFICATION FOR LIGHTING MAST
4.2.19.6.1 SCOPE
The scope of this specification covers the manufacture, installation, testing

and commissioning of complete lighting system, using raising and
lowering type of high mast towers, the civil foundation and all items
required for safe and efficient operation and maintenance of lighting
system including high mast light fittings and cables and any other items
stated in following pages also shall be included in the scope.
JOB NO-730176 IV-179

4.2.19.6.2 HIGH MAST
The high mast shall be continuously tapered, polygonal cross section

pleasing appearance and shall be based on proven in-tension design to
give an assured performance and reliable service. The structure shall be
suitable for wind loading as per IS: 875 part 3 and shall be measured at a
height 10m above ground level. The design life of the mast shall be at
least 25 yrs.
The mast shall be fabricated from special steel plate cut and folded to
form a polygonal section and shall be telescopically jointed and welded
and tested as per relevant standards. Mast shall be delivered in multiple
sections of effective length of 10 m (max.) The masts upto 20m height
shall be delivered in two sections and 30 m masts shall be supplied in
three sections. At site the section shall be connected together by slip and
stressed fit method. No site welding and bolted joint shall be done on the
mast. The minimum overlap distance shall be 1.5 times the diameter at
penetration. The dimensions of the mast shall be decided based on
design calculations shall be submitted for verification.
The mast shall be provided with fully penetrated flange, which shall be
free from any lamination or incursion. The welded connection of the base
flange shall be fully developed to the stress of the entire section. The
base flange shall be provided with supplementary gussets between the
boreholes to ensure elimination of helical stress concentration. For the
environmental protection of mast, the entire fabricated mast shall be hot
dip galvanised, internally and externally having a uniform thickness of
coat.
An adequate door opening shall be provided at the base of the mast and
the opening shall be such that it permits clear access of equipment like
winches, cables, plug and sockets etc. and also facilitate easy removal of
which. The door opening shall be complete with close fitting, vandal
resistant, weather proof door, provided with internal lock with paddle key.
The size of the door opening shall be such that can avoid bulking of mast
section under heavy wind condition.
A fabricated lantern carriage shall be provided for fixing and holding
required number of flood light fittings and control gearboxes. It shall have
a perfect self-balance. The carriage shall be able to accommodate wires
also. The carriage shall be so designed and have protective arrangement
so that no damage is caused to the surface of mast during the raising and
lowering operation of the carriage. The entire lantern carriage shall be hot
dip galvanised after fabrication.
A weatherproof junction box made of cast aluminum and other suitable
material shall be provided on the carriage assembly as required from
which the interconnections to the flood light luminaries and control gears
fixed on the carriage shall be made. The connections shall be by means
of PVC flexible cables of 3 cores 1.5 sq mm.
JOB NO-730176 IV-180

For the installation and maintenance of the luminaries and lamps it will be
necessary to lower and rise the lantern carriage assembly. To enable this
suitable wire rope winch along with head frame assembly shall be
provided.
A suitable terminal box shall be provided at base compartment of the high
mast for terminating the incoming cable. The electrical connection from
the bottom to the top shall be made by special trailing cable having
flexibility and endurance. This shall have inbuilt facilities for testing the
luminaries while in lowered position.
Suitable earthing terminals shall be provided at convenient location on the
base of the mast for lighting and electrical earthing of the mast.
4.2.20.0 SPECIFICATION OF CENTRAL REMOTE AND SEQUENCE CONTROL
4.2.20.1 GENERAL
The following requirements shall be applicable for all the equipment under
consideration in this document for centralized monitoring, centralized auto-
remote/semi-auto/manual sequence operation, inter-locking facilities, local
stop/start facility etc.
In order to have reliable, efficient operation of the proposed equipment in

pre-determined way, a centralized control system has been proposed for
the purpose of automatic monitoring and control of the different equipment
from a remote place.
All the equipment except vibratory feeders below truck loading hoppers,
electrical hoist blocks, dust suppression pumps & compressor and fire
fighting pumps will be sequentially controlled (starting/stopping) by using
programmable logic control (PLC) system with hot redundant from central
control rooms installed at a different places in the plant. The PLC system
will incorporate standard programs, software packages etc. The PLC
system consisting of CPU, control desk, mimic panel, annunciator etc. will
be installed in the control rooms. Provision shall be made to control the
equipment manually from the control desk in case of failure of sequence
control system.
The centralized auto remote and auto sequence control up-to bunker &
reclaim section of the CHP shall be operated from the Central control
room located at 1st floor of 3.3 kV substation- II near discharge end of the
bunker. The auto remote and auto sequence control of Silo loading
section will be done from the Silo control room itself.
Local control facility shall also be provided near each drive/equipment for
stopping and starting of equipment during repair and maintenance and
JOB NO-730176 IV-181

emergency. The tripper trolley drives shall also be provided with local
control facility so that the operator can operate as per convenience.
Equipment such as dust suppression pump, fire fighting pumps etc. shall
be controlled independently from central control desk. In addition local
control facility shall also be provided for operation of the pumps locally.
Requirement annunciation panel will also be provided in the central control

rooms for indicating the faults and their clearance.
4.2.20.2 SYSTEM REQUIREMENTS
The control system envisages sequence operation (starting/ stopping) of

all the technological equipment in coal flow line from a remote place in
auto/semi auto/ manual modes as described below :-
a. Auto mode - In Auto mode of control, one command through

keyboard or mouse of operating station (PC) will start the whole plant
except the loading equipment in silo complex equipment in
sequence interlocked mode through PLC system from central
control room. The equipment operating in the silo complex such
as loading chute etc. will be operated from silo control room.
b. Semi-Auto mode – In semi-auto mode, command for operation of

individual equipment in sequence will be given through keyboard
or mouse of the operating station, so the equipment can be
operated through PLC system.
c. Remote manual mode – In remote manual mode of sequence inter-

locked operation, start push button of individual drive will be
pressed sequentially on the control desk for operation of the
system through PLC provided as standby.
The control of the equipment in CHP and Silos shall be provided with dual
redundancy and automatic change over facility (not standby) to avoid
stoppage of equipment by using PLC system.
4.2.20.2.1 In order to have efficient sequence control of the technological equipment,

all the equipment working in have been divided into three sections namely
‘A’ flow, ‘B’ flow and ‘C’ flow. The details are shown in the enclosed
drawings.
i) A flow comprises
- 12 nos ( 6 nos on each conveyor) vibratory feeders below truck

receiving hoppers ( near tail end of conv.C2A, C2B)
- Belt conveyor C2A/ C2B
- Belt conveyor C3A/C3B
JOB NO-730176 IV-182

All the equipment in A-flow will be controlled from CD-1 located in CCR.
The coal flow diagram and sequence interlocking of A flow is shown in the
drawing R7/E&M/400170.
ii) B flow comprises.
- Belt conveyor C1
- Electrically operated flap gate in two-way chute at the discharge
pulley of conveyor C1
- Crusher CR1/CR2
chute of crusher CR1/CR2
All the equipment in B-flow will be controlled from CD-1 located in CCR.
The coal flow diagram and sequence interlocking of B-flow is shown in the
iii) C flow comprises.
- 4 numbers( 2 nos + 2 nos) Plough feeders below over ground

bunker
pulley of conveyor C7A/C7B
All the equipment in C-flow will be controlled from CD-2 located in CCR.
The coal flow diagram and sequence interlocking of C-flow is shown in the
The sequence of stopping and starting of the equipment shall be as shown

in the enclosed drawings and explained elsewhere in the report. However
provision shall be made for start/stop of the equipment from site during
maintenance/ repair by using push buttons. Emergency stopping of belt
conveyors can be done by pulling the pull chord switches. Belt sway
switches will stop the conveyor in case there is excessive sway of the belt
during operation.
The remaining equipment such as air compressors, Dust suppression/ fire
fighting/ plant cleaning pumps, tempt iron magnet, belt weigher, tripper
trolley of conveyor C6A/C6B, Metal detector on conveyor C3A/C3B will be
operated from the central control room (CCR) with a facility to operate
JOB NO-730176 IV-183

them locally. The electric hoist blocks will be controlled from the control
panel associated with the hoist blocks.
The sequence starting of the equipment shall be started with pre-start
warning signal / siren for which hooters will be located at suitable
locations. The indication shall also be shown in mimic panel.
In the sequence starting of different equipment in the system, the
equipment will be started in the reverse direction of coal flow to
avoid/minimize the spillage of material at transfer points. In this case each
machine next to be started shall be put in operation at a definite time lag
so that the preceding equipment has already picked up motion. In the
sequence stopping different equipment in the system will be stopped in the
direction of coal flow at a definite time lag to avoid clogging and spillage.
4.2.20.2.2 The loading equipment below the silo, track logic system, passenger lift,
lifting tackles will be controlled from the Silo control room. The loading
operation of coal from silo to wagons shall be started with pre-warning for
which hooters will be provided at suitable location. The automatic sampling
system will be controlled from the control room installed at 1st floor of 3.3
kV substation no-II.
i) The sampling system will be sequentially controlled from a central

control desk located in central control room to operate the system in
auto/semi-auto/manual mode as described above. However
emergency stop/start push buttons will be provided locally to stop
the equipment in case of emergency. In the sequence starting of
equipment in sampling system the equipment will be started in
reverse direction of coal flow to avoid/minimize the spillage of
material at transfer points. In this case each machine next to be
started shall be put in operation at a definite time lag so that
preceding equipment has already picked up motion. In the
sequence stopping of various equipment in the equipment will be
stopped in the direction of coal flow at a definite time lag to avoid
clogging and spillage. The primary sample cutter will be inter-
connected with belt conveyor C7A/C7B so that they will operate
only when the belt conveyors C7A/C7B are in operation. Sampling
unit will operate independently.
ii) The track logic system provided on the track will identify the rail
wagons and signal will be sent to the PLC system. After getting the
signal the hydraulically operated swing chute will be lowered and
placed in position. The flow control gate will be opened and then
the silo loading gates will be opened. When the wagon is nearing
the completion of the loading, the silo loading gate will be closed
first and then flow control gate will be closed. At the end of rake
loading the swing chute will be lifted and positioned in parking
place.
iii) The control units of weighing system, printers etc. will be located in
the silo control room
JOB NO-730176 IV-184

iv) The other equipment such as air compressor, hydraulic power pack
and associated accessories will be operated from the control desk
located in the Silo control room. The electric hoist blocks,
inspection winches, passenger lifts shall be controlled from the
control panels available at site.
The level (high and low) of coal inside the silo at any instant will be
monitored by independent continuous monitoring systems. The system
shall have remote and local display facility. The power to the monitoring
system shall be provided from auxiliary power distribution board.
High level indicators /limit switches will be provided in both silo 1 and silo-
2. Incase a predetermined high level is reached in any silo, the Plough
feeder below the main bunker shall stop. In case a predetermined low
level point (minimum 600 t. capacity is left in silo) is reached in any silo,
the silo loading gate shall be closed for which low
level limit switches will be provided in each silo.
The temperature in the silos, at different levels shall be continuously

monitored and give audio-visual signal at site and also in control room as it
reaches the preset value.
Interconnection of the PLC systems provided in both the control room with
the help of MODEM so that all the details of silo complex will be available
at Central control room.
Local control facility shall be provided to stop the equipment for

testing and for carrying out repair and maintenance work.
Provision shall be provided in the circuit to check before actual starting that
all the technological mechanisms are interlocked at the starting time. This
may be ascertained by depressing the inspection push button on the
control desk which lights up the pilot lamps in the circuit.
Emergency stop button may also be provided on the control desk for
stopping of the equipment.
4.2.20.3 CONSTRUCTIONAL FEATURES OF CONTROL SYSTEM

The control system shall consist of the following:-
a) Control desk-cum-mimic-cum-Annunciation part.
i. Auxiliary relay section
ii. Desk with Mimic and Annunciation panel
b) Programmable Logic Controller.
The details shall be as given below
JOB NO-730176 IV-185

4.2.20.3.1 CONTROL DESK-CUM-MIMIC-CUM-ANNUNCIATION PART.
i. The control desk shall be free standing, floor mounting, totally
enclosed, dust and vermin proof, IP-62 enclosure and designed to
have pleasing appearance. This may of back opening type. The
control desk shall be made of sheet steel of minimum 2mm thick
and adequately stiffened. The desk will have two faces (inclined
and vertical).
ii. On the inclined face the control devices such as push buttons
(start/stop/signalling), indicating lamps, selector switches, ammeter
(for motors 30 kW and above), digital temperature scanners for HT
drives, digital clock, auto telephone set, remote control switches for
the operation ON-OFF and trip indication, time totaliser for
recording actual operation of all the sections of plant, time recorder
for stoppages of all the sections of the plant, indication of all the
equipment not in sequence operation, all other facilities as
mentioned elsewhere in the document shall be neatly arranged so
that they are easily accessible to the operator for easy operation.
iii. On the vertical face the continuous graphic luminuous mimic panel
of acrylic sheet, representing the coal flow shall be provided. The
mimic will have inbuilt indicating lamps (LED or filament type) for
indicating the status of the equipment being controlled from that
particular desk. In the Central control room, the entire coal flow in
the CHP excluding loading section shall be shown in the mimic.
Similarly at Silo control room, coal flow in the loading section shall
be shown in the mimic.
iv. All necessary auxiliary contactors, relays, timers etc. required for
the purpose of field switch contact multiplication and inter-locking of
the equipment as required under sequence operation, will be
housed inside the desk in simplex/ duplex type control desk.
v. Control and selector switch shall be rotary type with escutcheon
plates clearly marked to show the function and position.
vi. Push buttons shall be spring return, push to actuate type with
silver contacts. All push buttons shall be provided with integral
escutcheon plates with its function clearly marked.
vii. Indicating lamps shall be filament type of low watt consumption with
series safety resistance. The lamps shall have escutcheon plates
marked with function.
viii. All auxiliary relays and timers shall be of proven design.
ix. All indicating instruments shall be of flush mounting type
x. All control wiring shall be done with PVC insulated cable of size of
not less than 2.5 sq mm copper. Wiring shall be grouped and
bunched so that tracing of connection will be easy. All the outgoing
cables will be terminated on a terminal block and ferruled. The
wiring shall be factory wiring.
JOB NO-730176 IV-186

4.2.20.3.2 PLC PART
i. Microprocessor based dual redundant (Hot standby) CPU
programmable logic controller (PLC) systems shall be provided in
the control rooms for Automatic/ semi-automatic/ remote-manual
control of the plant in sequence. There will be diagnostic packs for
self fault detection of PLC system and programming facility.
ii. The PLC will consist of a PC with CD and DVD writable drive with
VDU (Colour TFT / LCD monitor of 22”), with internet key board,
required software etc.
iii. The PLC system shall carry the following functions :-
a) Control of the sequential operation of the equipment in
CHP, loading system as described elsewhere in the
document
b) Alarm annunciation and reporting on visual display unit
(VDU)
c) Dynamic graphic display of the plant mimic, loading system
mimic on the VDU using different colours with variable
intensity to represent the different drives operational status.
d) On line data logging, digital/analogue display of the
following :-
1) Load current of motors above 30 kW
2) Loading details
3) Coal levels in silo
iv. Back up power system (UPS) for retention of memory in the event
of power supply shall be provided and this shall be of required
capacity.
v. The PLC system at silo control room shall have suitable print out
facility with memory to provide print out data of wagons such as
time of empty, time of exist of rake, tare weight of each wagons,
weight of coal loaded in the wagon, weight of coal loaded in each
rake, daily/ monthly/annual coal despatches. The PLC system shall
also be able to print the coal parameters such as grade, calorific
value, specific gravity, bulk density, moisture content, ash content
etc.
vi. There shall be one separate VDU mimic in the Engineer’s –in-
charge room at central control room.
4.2.20.3.3 LOCAL CONTROL

i. Local control shall be affected by means of a selector switch at site
and therefore no interlocking of the mechanism is provided while
operating in local mode.
JOB NO-730176 IV-187

4.2.20.4 REMOTE AND SEQUENCE CONTROL OPERATION
PLC system shall be capable of selecting the number routes of coal flow
from the respective central control room. This shall be achieved by
providing selector switches on the control desk.
At first, the healthiness of lamps and hooters of control desk and

annunciation panel is to be checked by pressing test bush button. After
checking the healthiness of lamps and hooters, the desired route for
material flow shall be selected and then particular mode of operation will
be selected.
Prior to starting the operation, the operator of the control room will transmit
and receive audio visual signals to / from all the concerned local stations
namely drive houses, transfer point, main bunker, crusher house, silo
loading point, truck loading hoppers etc. for assuring readiness of the
equipment of that particular route through ‘Two way communication
system’ (TWC). The two-way-communication system will have provision
for interlocking with route selection. When all start permissive signals for
starting of the particular route are received a ‘Route ready for operation’
lamp will be switched on control desks. The operator will then press the
‘pre-start’ warning push button, which starts all sirens located at strategic
points of selected route to give warning to the workmen for maintaining a
safe distance from the equipment. The sirens will blow 3 to 4 times with a
pre-set time delay (may be 15 seconds) and then switched off.
Immediately a slow blinking relay will be switched on to indicate that
system is ready for sequence starting and all the lamps in the mimic for
that particular route will start blinking slowly. The operator will then given
commands for sequence start operation depending on the mode of
operation selected. The starting of all the equipment in a particular route
shall be completed within a preset time as otherwise the cycle will have to
be repeated. After starting of each equipment mimic lamp will glow
steadily and the ON indicating lamps on control desk will be switched on.
The stopping of the system can be achieved by pressing the ‘Normal Stop’
push button on the control desk and in turn the material feed will
instantaneously stop and all subsequent down stream equipment will stop
with a preset delay so that all the equipment will stop on no load condition
which will enable to start the equipment subsequently in no load condition.
Local control station (LCS) consisting of stop push button will be used for
stopping the equipment from local place in case of repair/maintenance,
testing.
Operation of emergency stop push button (turn lockable type) provided on
control desk, should cut-off all control power supply and PLC commands
withdrawn and power supply can be restored after resetting the push
button.
The stoppages may be caused by
i. Operation of emergency push button of control desk
JOB NO-730176 IV-188

ii. Operation of protective devices viz. over oad, earth fault etc.
iii. Operation of local emergency stop push button
iv. Operation of safety devices viz. pull cord, belt sway, zero speed
switch
4.2.20.4.1 ANNUNCIATION PANELS
The annunciation panels shall be placed with control desks with

ACKNOWLDGE, RESET and TEST push buttons mounted on the control
desks.
During sequence interlocked running, whenever a fault occurs in the
system, the particular equipment is stopped instantaneously and
interlocking will stop all other equipment on up stream side to ensure
stoppage of material feed. A trip lamp of the faulty equipment will start
fast blinking and an audio alarm is also switched on simultaneously. The
lamp keeps on blinking and the alarm keeps on blaring until the fault
acknowledge push button is pressed. The lamp continuous to glow till the
fault is rectified and reset. From the mimic the equipment tipped and type
of fault can be determined before the pressing of the acknowledge button.
The annunciation scheme will be complete with Acknowledge, Test and
Reset push buttons. On pressing the test push button, all lamps will blink
and the audible alarm will sound which indicates the system is in order.
The windows shall be solid state /PLC driven. The indication shall be
engraved on translucent glass or plastic with black letters on white
background. It shall be clearly visible when the indication lamp glows.
Ten percent of spare windows shall be provided for future expansion.
The audio visual annunciation system will be suitable for annunciation of
the following group features of equipment working the CHP excluding the
loading section in silo complex. The details are as given below :-
i. Motor protection device operated

ii. Thermal over load relay operated
iii. Belt sway switch operated
iv. Pull cord switch operated
v. Zero speed switch operated
vi. Local emergency stop push button operated
vii. 3.3 kV motor winding temp. high
viii. 3.3 kV motor bearing temperature high
ix. 3.3 kV circuit breaker tripped
x. 415V ACB tripped
xi. Earth leakage relay operated
JOB NO-730176 IV-189

xii. Transformer bucholz relay operated
xiii. Transformer winding temperature high
xiv. Transformer oil temperature high
xv. Emergency stop push button on control desk operated
xvi. AC control supply failure
xvii. Fire pump failure
xviii. Dust suppression pump failure
xix. Fire control alarm
xx. Sampling system hydraulic circuit fault
The audio visual annunciation system will be suitable for annunciation of

the following group features of equipment working in the loading section.
The details are as given below:-
i. 3.3kV circuit breaker tripped

ii. 415V ACB tripped
iii. Earth leakage relay operated
iv. Transformer Buchloz relay operated
v. Transformer winding temperature high
vi. Emergency stop push button on control desk operated
vii. AC control supply failure
viii. Motor protection device operated
ix. Thermal overload relay operated
x. Continuous bin level annunciation in silo level high
xi. Continuous bin level annunciation in silo level low
xii. Silo internal temperature high
xiii. Hydraulic power pack / air compressor motor tripped
xiv. Fire alarm pump failure
xv. Rapid loading system hydraulic circuit fault
xvi. Formation of arch in silo
JOB NO-730176 IV-190

4.2.21.0 SPECIFICATION FOR LOCAL MOTOR STARTER (E - 10)
The Local Motor Starters shall be provided for manual switching of

3300V/415V, 3 phases and squirrel cage motors.
The starters shall be metal enclosed, suitable for outdoor/indoor mounting

on wall or steel structures. The enclosure shall be die cast aluminum or
cold rolled sheet steel of at least 1.6 mm thickness. The enclosure shall be
provided with a hinged guard at the front, covering full length, to avoid
adverting operation of push buttons. The starters shall be painted to shade
no. 692 of IS: 5 in accordance with relevant code and shall be dust &
Vermin proof and shall have a degree of protection of IP 52 as per
relevant code.
The starter shall be suitable for both top & bottom cable entry (either of
which may be used depending on cabling convenience) and shall be
provided with removable undrilled gland plates or knockouts. Adequate
space shall be available inside the starter enclosure for terminating
external cables directly on push button terminals. Overall size of Starters
shall be subject to Purchaser’s approval.
Each Starter shall comprise of:
i) A 3:pole contactor, mechanically latched type

ii) Start Push Button, colored GREEN
iii) Stop Push Button, colored RED
iv) Local Switch
v) Auto Switch
The start push button when pressed shall preferably remain in depressed
position and shall be released along the contactor when the stop push
button is pressed or when thermal overload relay operates. Local starters
shall be suitable for loop-in and loop-out of incoming cable and for one
outgoing cable to a motor.
Motor protection relay & Earth leakage relay shall be provided in HT & LT
motor starters as per system requirement.
JOB NO-730176 IV-191

4.2.22.0 SPECIFICATION OF POWER, CONTROL AND SPECIAL CABLES
The following are the broad requirement and shall be applicable to the
power, control and special cables furnished under these specifications.
The bidder shall however submit detailed specification for all type of
cables.
Cables shall be designed and manufactured so that damage will not result
from transportation, installation and operation under all the climatic and
operating conditions to which they may be subjected.
3300 volt power cable shall be of stranded aluminum conductor, cross

linked polyethylene insulator fire retard low smoke type in outer sheathing,
suitably insulated and sheathed, single layer armoured suitable for
restricted earthed neutral system.
415 volt power cable should be of 1100 volt grade, stranded aluminum
conductor, fire retard low smoke type in outer sheathing, suitably PVC
insulated and PVC sheathed single layer armoured suitable for earthed
neutral system.
Control cable shall be of 650 volt grade, stranded copper conductor, fire
retard low smoke type in outer sheathing, PVC insulated and PVC
sheathed, single layer armoured having a minimum size of 2.5 sq.mm.
The individual cores of cable shall be identified by different coloring of

insulation. For control cables having more than 4 cores, it is preferable to
provide the core number embossed on each individual core.
No. of cores of control cables shall be as per requirement.10 % extra

cores are to be provided for control cable.
4.2.22.3 SIZES AND LENGTHS
The cable size and type of 3300 volts and for 415 volts system should be
selected in accordance with the clause of specification and
customer/consultants approval.
Bidder shall indicate the size and length of cables necessary to tie up all
the equipment under their scope of supply. However, during erection if it is
found that the quoted lengths are not adequate, the Bidder shall have to
supply the additional quantities to complete their erection at no extra cost.
JOB NO-730176 IV-192

The selection of power and lighting cables shall be on the basis of the
following parameters:
a) Short circuit withstand for 1 second.

b) Voltage drop – the maximum allowable voltage drop from the
substation to motor terminal shall not exceed 5% of 415 volts/3.3
k.V under full load normal working condition and 15% under
starting conditions for the highest and/or most distant located
motor.
Length of cables shall be ascertained from the layout drawing so that

straight through cable joints are avoided.
Derating factors for various conditions of installation including the following

for all type of cables shall be considered while choosing the conductor
sizes.
a) Variation in ambient air temperature

b) Variation in ground temperature
c) Depth of laying
d) Soil resistivity
e) Grouping of cables
Derating factors selected shall be based on factors recommended by

reputed cable manufacturers/IS. The factors considered shall be clearly
brought out in the offer, if it is found that the derating factors considered
are not adequate, the Bidder shall have to revise the cable sizes at no
extra cost to the customer satisfaction. The overall derating factor shall not
exceed 0.6 in any case.
4.2.22.4 CABLE TRAYS AND TRENCHES
Cable trays shall be made of Galvanised Iron. The cables shall be laid
along fabricated trays and be properly grouped as power cables, control
cables etc. spaced from each other and clamped. 3300 volt and 415
power cables shall be grouped separately.
Cables shall, preferably, be run on fabricated cable trays. Concrete

trenches are only permitted for out side connection. There shall not be
any cable trench in side substation buildings. In place of cable trenches
cable vaults of suitable height shall be provided above ground.
JOB NO-730176 IV-193

4.2.22.5 FLEXIBLE TRAILING CABLE
4.2.22.5.1 L.T POWER & CONTROL
Flexible cable shall be annealed, tinned stranded copper conductor, EPR

insulated. EPR inner sheathed/nylon braded unarmored and flame
retardant heavy duty PCP/CSP outer sheath conforming to IS: 9968.
HT Flexible cable shall be annealed tinned copper conductor, insulated

with EPR, conductor and insulation shielded with silicon EPR, cores
screened with ATC wire braiding, cores laid up, proof cotton taped and
HDCSP sheathed overall conforming to IS:9968.
4.2.22.5.2 SPECIAL CABLES
Special cables including but not limited to the following
a) Temperature detectors to the selector switches,

b) Temperature indicators, from coal bunker level
c) Indicator temperature detectors to associated electronic enclosure
etc.
These cables shall be heavy duty fire retard low smoke type, self
extinguishing, color coded; shielded, armoured copper conductor
650/1100 volts grade coaxial screwed compensating mineral insulated etc.
4.2.23.0 WELDING SETS AND SOCKETS
4.2.23.1 GENERAL
The following broad requirements shall be applicable for all the equipment
for key operated industrial type power sockets and switches furnished and
erected under these specifications
Key operated, industrial type socket cum switch for welding purposes shall
be provided at 50 metre intervals along the conveyor length, Bunker, silos,
hopper house, Crusher house, drive houses and at all transfer points. The
successful Bidder shall give the quantity, location and specification of the
socket cum switch. The location of socket shall be such as to facilitate
welding at any point in this project.
4.2.23.2 KEY OPERATED PUSH BUTTON TYPE, INDUSTRIAL TYPE WELDING

SOCKET CUM SWITCH.
Plug and socket and switch shall receive welding power from the welding
machines. It shall be totally enclosed, dust and vermin proof having a
hinged cover. There shall be provision to insert/connect the welding cable
JOB NO-730176 IV-194

with holder for welding purpose. Socket shall have provision for
interlocking so that switch can be put in ON position only when the
connector of the welding cable is in complete alignment and is completely
housed in. The hinged cover shall be provided with a caution notice.
Approved type of connector suitable for connection of aluminum/copper

conductor shall be provided.
4.2.23.3 PORTABLE TRANSFORMER WELDING SETS
Air cooled single operator aluminum wound arc welding transformers of

adequate rating have been envisaged for this purpose. The transformers
shall be suitable for 415V ± 10% 3 phase 50 Hz AC supply system of
suitable output current. However the exact values according to 80 & 100V
open circuit shall be provided by the bidder. Provision shall be kept for
easy lifting of the welding set.
The welding sets shall be complete with accessories like electrode,

ground cable, leather hand gloves, earthing clamps, face shield with lens
etc.
4.2.24.0 SPECIFICATION OF 3.3kV OFF LOAD ISOLATOR
4.2.24.1 SCOPE
The specification covers requirements for 3.3 kV off load isolator suitable
for use in outdoor.
The switch shall comply with the latest revision of IS 9921 & IS 13947
specified here in shall be deemed to be included.
The isolator shall be gang operated, single centre break, tinned leaf spring
loaded contacts with contact pressure not less than 16 kg per ampere of
rated current. The contacts shall be high conductivity copper or copper
alloy heavily tinned.
The isolator shall be manually operated and shall have two separate
earthing terminals on the opposite corners.
4.2.24.3 TEST CERTIFICATES & IDENTIFICATIONS
The isolators shall be Type tested for insulation level, fault withstand
capacity and breaking capacity in accordance with relevant codes. Results
of Routine Test for power frequency voltage shall be supplied by the
manufacturer before consignment of the units. The results of the test
JOB NO-730176 IV-195

certificate shall also indicate the identifications like manufacturer’s name
and the serial number of the product which should also appear printed or
embossed on the body.
4.2.24.4 TECHNICAL PARAMETERS FOR 3.3 kV OFF LOAD ISOLATOR
Applicable code - IS 9921 (amended up to date)

Rated Current- As per design confirming relevant IS
Operation - Manual, Off Load, Gang Operated
Mounting - Pole Mounted
Type of Break - Single/Centre
No. of poles - Three
Contacts - High Conductivity copper/ copper
alloy heavily tinned
Accessories - 1) Base channel of hot dipped
galvanized steel
2) Operating down rod complete
with mechanism & pad lock system
for manual isolator
4.2.25.0 SPECIFICATION FOR 3.0 kV LIGHTNING ARRESTOR
4.2.25.1 SCOPE
The specification covers the requirements for lightning arrestors for

nominal system voltage of 3.3 kV.
The arrestors shall comply with the latest version of IS 3070
Any other component or accessories not specifically stated in the

specification but necessary for trouble free operation shall be deemed to
be included.
IS: 3072 (Amended up to date) Code of practice for installation of switch

gear
The arrestors shall be composed of units of non linear resistors made of

zinc oxide
4.2.25.4 TESTS & CERTIFICATES & IDENTIFICATION
The units shall be tested for insulation level, discharge current & residual
voltage in accordance with relevant codes.
JOB NO-730176 IV-196

4.2.25.5 TECHNICAL PARAMETERS FOR 3 kV LIGHTNING ARRESTOR
Applicable Code - IS 3070

Rated Voltage - 3 kV
Nominal Discharge Current - 5 kA
Type - Gapless non linear resistor
type
Class - Line Type
Mounting - Bracket/Post Insulator
Other Requirement - copper braided strap for
connecting the arrestor with
earthing strip
4.2.26.0 EARTHING & LIGHTNING PROTECTION
Sub-station earthing shall conform to the requirements of Indian Electricity

Rules and the IS Code of practice for earthing, IS: 3043 of 1966 (latest
revision). The earthing system shall consist of required numbers of earth
pits. The equipment as elaborated below shall be connected to the earth
pits as per IS and the earth pits shall be interconnected by 50mm x 6mm
GI flats. The overall resistance to ground shall not exceed one Ohm.
The primary requirements of the system shall be as follows:
Each set of lightning arrestor shall have independent earth which shall, in
turn, be interconnected to the station grounding mat.
Equipment frame work and other non current carrying metal works
associated with the system shall be effectively connected to the earth mat.
Extraneous metal frame work not associated with the power system shall
have provision for earthing. It shall be ensured that the step and touch
potentials shall be within safe limits, as mentioned hereunder:
a) The step potential shall be less than 165+Ps

T0.5
b) The touch potential shall be less than 165+0.25Ps
T0.5
'Ps' shall be the soil resistivity in Ohm meters and 'T' is the time in seconds
to clear the fault. It may be ensured that permissible values are based on
'T' of not less than 3 seconds and 'PS' of not more than 40 Ohm mtr. in the
present case. The earth pits shall confirm to IS: 3043 amended up-to date.
Each electrode shall preferably be made of G.I. pipe not smaller than
50mm. internal diameter. The buried length of the pipe electrode shall not
be less than 3 meters. Electrodes shall preferably be embedded below
JOB NO-730176 IV-197

permanent moisture level. Each electrode shall be buried vertically in an
earth pit of minimum 300mm x 300mm. area and 3meters deep in
alternate layers of charcoal and salt. The inter spacing of the electrodes
shall not be more than 6 meters.
The size of the earthing conductors shall be determined by consideration

of potential difference and temperature rise. The current carrying capacity
shall be consistent with fault current. However, in no case the cross-
section of the conductors shall be less than 165 mm2 for main connections
and 65mm2 for branch connections. It is recommended that anti-corrosive
galvanized steel strips shall be used in grounding grids.
The joints shall be riveted, sweated, brazed, bolted or welded. For rust
protection the welds shall be treated with barium chromate. Welded
surfaces shall be painted with red lead and aluminum paint in turn and
afterwards coated with bitumen. Joints in the earthing conductor between
the switchgear units and cable sheaths, which may require to be
sufficiently broken shall be bolted and the joint faces tinned. All joints in
the earthing shall be welded except the points for separating the earthing
mat for testing purposes, which shall be bolted. These points shall be
easily accessible for supervision. All exposed steel conductors shall be
protected with bituminous paint.
The earth mat shall be buried at a depth of more than 600mm. below the
ground level.
Each motor, transformer, panel and other electrical equipment should be

earthed by two separate earthing strips. In addition all the motors will be
earthed through the armoring of the connecting cable. Size of earthing
strip and electrodes shall be as per requirement, as per relevant IS, to be
finalized by the bidder during detailed engineering stage. However, the
size of main earth bus strip shall not less than 65 mm x 5 mm where as
that of the connecting earthing strip shall not less than 25 mm x 5 mm. The
value of earth resistance shall not exceed one ohm in all the time through
out the year. Earth pits shall be located near substation/switch stations,
ground bunker, silos, transfer houses, crusher house, hopper house, drive
houses, intermittent points along conveyor gantries etc.
Adequate care shall be taken towards earthing of light fittings, welding

sockets etc. Air Termination network shall be provided for buildings,
conveyor gantries, switching stations / substations and silos. Proper
Lightning protection shall be provided for protecting the buildings and
structures against direct stroke of lighting conforming to relevant IS.
Lightning masts for protecting the buildings and structures against direct
stroke of lighting shall be earthed separately by digging separate earth
pits.
JOB NO-730176 IV-198

4.2.27.0 COMMUNICATION SYSTEM
4.2.27.1 PROJECT ADMINISTRATION SYSTEM
Required nos. of automatic dial type telephone sets shall be provided at

various locations along CHP and CHP administrative building as stated
below:
(i) Truck receiving hopper Complex - 2 Nos.
(ii) Office - 3 nos.
(iii) Bunker - 2 nos.
(iv) Crusher House - 1 no
(iv) Substation - 4 nos.(One for each S/S)
(v) Central control room - 1 no.
(vi) Silo control room - 2 No
These telephone sets shall be wired and brought to a common junction

point and from there these shall be connected to the main auto exchange.
4.2.28.0 SPECIFICATIONS FOR MISCELLANEOUS ITEMS
The following general requirements shall be applicable to all the

miscellaneous items furnished under these specifications.
4.2.28.1 Metal Enclosed Non-segregated Phase Bus Duct
Metal enclosed non-segregated phase bus duct assemblies shall be

supplied for incoming connection from the transformers to MCCs if
required.
The enclosure shall be made of aluminum alloy. The section of the bus
duct shall be rectangular. The design of the bus duct enclosure shall be of
sturdy construction such that it will withstand the internal or external forces
resulting from the various operating conditions. The enclosure sheet shall
not be less than 3 mm thick. The bus duct shall be divided into sections of
suitable length for easy transport and individual sections will be connected
by flanges.
The entire duct shall be designed for dust, vermin and weather proof
construction. A suitable aluminum sheet hood shall be provided to cover
all outdoor bus duct enclosure joints to facilitate additional protection
against rainwater ingress. Bus duct enclosure in the indoor portion shall
have a degree of protection not less than IP-52 and that in the outdoor
portion shall have a protection not less than IP-55 in accordance with IS
2147.
JOB NO-730176 IV-199

The inside of the bus enclosure may be treated with black paint to enable
efficient heat dissipation. The matt paint used shall be suitable for
temperature experienced during continuous loading of the bus conductor.
Flexible expansion joints for the enclosure shall be provided wherever
deemed necessary by the Bidder. Necessary bonding shall be provided at
the expansion points if made of insulating material.
Enclosures shall be provided with flanged ends with drilled holes to suit
the flanges at the switchgear and transformer terminals. The flanges shall
be provided with gaskets, nuts, bolts, etc. Details of the flanges provided
on transformer/switchgear ends shall be properly co-ordinated with bus
duct flanges.
Suitable inspection doors shall be provided for periodic inspection of
insulators. Handles shall be provided on each inspection doors to
facilitate easy lifting.
The synthetic/neoprene gasket shall be provided so as to satisfy the
operating conditions imposed by temperature, weathering, durability etc.
Flange gasket shall be provided at the equipment terminal connections.
The bus duct shall be properly supported on ground wall/structure.
Suitable arrangement shall be provided inside the duct for installing
insulators which in turn will be used mounting bus bars on them.
Bus duct enclosure shall be connected to station earth grid at both ends.
Necessary earthing arrangement as applicable shall be provided with
clamps to receive station earthing bus. All accessories and hardware
required for the earthing arrangement shall be provided by the bidder.
Suitable G I earth strip shall run all along the bus duct and shall be bolted
to each section of bus duct enclosure at least at two places.
4.2.28.2 Bus bar
The material of the conductor shall be copper. The bus bars shall be
rated in accordance with the service conditions and rated for continuous
and short circuit current ratings.
Bus bars shall be adequately supported on insulator to withstand dynamic
stresses due to short circuit current, without permanent deformation.
Successful bidder shall furnish calculations establishing adequacy of bus
bar for specified current rating shall be mentioned during detailed design.
All bus bar joints and bus tap joints shall be either silver faced or
thoroughly cleaned at the joints, and a suitable no oxide contact grease
applied before making a joint. Plain and spring washers shall be provided
to ensure good contacts at the joints and clamps.
Flexible connections for terminations at transformer bushing and
switchgear shall also be included in the bidder’s scope of supply.
Expansion joints made of copper strips shall be provided, wherever felt
necessary by the Bidder, to take care of expansion and contraction of the
bus bars under normal operating conditions.
JOB NO-730176 IV-200

All the above joints shall be tested for temperature rise to prove the
adequacy of the design. The maximum temperature rise at the joints
when carrying rated current shall not exceed 50oC with silver plated joints
and 40oC with all other type of joints, over an outside ambient
temperature of 50oC.
The bus bar clamps at insulators shall be designed to withstand the forces
developed during expansion and contraction due to momentary circuit
current the bus bar. The material of the clamps shall be copper. Suitable
copper spacers shall be provided, wherever necessary.
All bolts, nuts and lock washers used in the bus assembly shall be of high
tensile steel, plated for corrosion resistance. Spring washers/Belleville
washers shall be used.
Bus bar support insulators shall be made of non-hygroscopic, non-
combustible, track resistant and high strength type porcelain or polyester
fibreglass mounted material and shall be suitable to withstand the dynamic
stress due to specified short circuit currents.
Facility shall be provided for supporting the indoor bus duct from ceiling,
floors or beams. The outdoor bus ducts shall be supported from the floor
T-shaped steel structures.
All steel structures required for bus duct support shall be hot dip
galvanised.
4.2.28.3 BUS DUCT SPACE HEATERS
Space heaters shall be provided in the bus ducts, wherever they are
necessary for preventing harmful moisture condensation.
The space heaters shall be suitable for continuous operation on 240v AC,
50 Hz, single-phase supply, and shall be automatically controlled by
thermostats.
4.2.28.4 PULL CHORD SWITCH
Pull chord switches shall be provided along the entire length of conveyor
for emergency stopping of the conveyor.
Spacing shall be at an interval of 50m (app.) along with the conveyor and
at least one switch should be provided for small conveyors near drive
heads & tail ends.
It shall have cast/metal clad and weather proof enclosure.
The pull chord shall be of adequate length and shall be of standard flexible
galvanized wire.
Pull chord switch shall have operating signal facility
4.2.28.5 BELT SWAY SWITCH
(a) Belt sway switches shall be provided in pairs to keep the belt sway
within permissible limit.
JOB NO-730176 IV-201

(b) The spacing shall be at an interval of 50m (approx.) with a minimum
of two pairs to each belt conveyor.
(c) It shall be provided with common bridging by pass switch at the
central desk which may be required to be used during starting and
also during emergency.
4.2.28.6 ZERO SPEED SWITCH
a) Zero speed switch shall be provided at the tail end or preferably on

the drive end of each conveyor to keep the operational speed within
a set limit.
b) It shall stop the conveyor if the speed exceeds or falls below the
preset limit.
c) It shall have cast / metal clad dust and weather proof enclosure.
4.2.28.7 PRESSURISATION AND AIR CONDITIONING:
(a) Design of the building of the substation/switch stations shall be done

in such a manner that the entry of dust from outside is totally
prevented and at the same time proper temperature and humidity is
maintained inside for proper working of equipment and operating
personnel.
(b) Air conditioning of silo control room & PLC room shall be done by
split type unit air conditioner and Air conditioning of Engineer in
Charge’s room shall also be done by split type unit air conditioner.
The total number of units shall be as per requirement.
(c) Requisite numbers of exhaust fan and ceiling fans shall be provided
in all rooms to ensure proper working conditions for equipment &
personnel in the rooms in case of failure of pressurization and air
conditioning.
(d) MCC rooms shall be pressurized with conditioning of inlet air
(number of air changes not less than 15 in an hour) and control of
humidity to ensure proper working of equipment and operating
personnel inside the room.
4.2.28.8 COMPLIANCE WITH STANDARDS
All electrical design, installation and commissioning shall comply

with relevant Indian standard and codes of practice including the
following:
• IS 3043 : Code of practice for earthing

• IS 4961 : Degree of protection provided by enclosure for
rotating electrical machinery.
• IS 6362 : Designation of method of cooling of rotating electrical
machine.
• IS 3202 : Code of practice for climate proofing of electrical
equipment.
JOB NO-730176 IV-202

• IS 4729 : Measurement and evaluation of vibration of rotating

electrical machinery.
• IS 4722 : Specification for rotating electrical machines.
• IS 6381 : Construction and testing of electrical apparatus with
type of protection.
• IS 5572 : Classification of hazardous areas for electrical (Part:I)
installations.
• IS 8623 : Specification for switch gear and control gear for
voltage up to and including 1000VAC/1200VDC.
• IS 4237 : Control requirements for switch gear and control gear
for voltages not exceeding 1000V.
• IS 2147 : Degree of protection provided by enclosures for
voltage switch gear and control gear.
• IS 3072 : Code of practice for installation and maintenance of
switchgear.
• IS 8544 : AC motor starters of voltage not exceeding 1000V.
• IS 2516 : AC circuit breakers (Part: I & II Sec.: I)
• IS 4064 : Air break switches, Air break disconnectors, and fuse
combination units for voltage not exceeding 1000V
AC/1200 VDC.
• IS 2705 : Current transformers.
• IS 3156 : Voltage transformers.
• IS 3231 : Electrical relays for power system protection.
• IS 1248 : Electrical indicating instruments.
• IS 722 : AC electricity meters.
• IS 375 : Marking and arrangement for switchgear, busbars,
main connections and auxiliary wiring.
• IS 9224 : HRC cartridge fuse (Part: II)
• IS 6875 : Switches and push buttons.
• IS 6005 : Code of practice for phosphating iron and steel.
• IS 5082 : Wrench Aluminium and aluminum alloys for electrical
purposes.
• IS 5819 : Recommended short circuit rating of HV PVC cables.
• IS 1554 : PVC insulated (heavy duty) electric cables.
• IS 5831 : PVC insulation and sheath of electric cables.
• IS 1753 : Specification for aluminium conductors for insulated
cables.
• IS 3961 : Recommended current rating for PVC insulated and
PVC sheathed heavy duty cables.
• IS 3975 : Mild steel wires, strips and tapes for armoured cables.
• IS 434 : Rubber insulated cables with copper conductor.
• IS 5 : Colours for ready mix paints.
• IS 694 : PVC insulated cables.
• IS 2959 : Contactors.
• IS 2208 : HRC fuses.
• IS 2419 : Indicating instruments.
• IS 3427 : Metal enclosed switchgear.
• IS 2544 : Porcelain post insulator, 3.3kV and above.
JOB NO-730176 IV-203

• IS 732 : Electrical wiring installation.

• IS 5561 : Specification for electrical power connectors.
• IS 5216 : Guide for safety procedure and practices in
electrical work.
• IS 1633: Specification for conduits.
• IS 2309: Code of practice for protection against
lighting.
• IS 1851: Welding transformer (Part: I).
• IS 2026: Power transformers.
The list given above is indicative but not exhaustive. The contractor shall
give complete list of latest revisions/standards, needed for design,
installation erection commissioning of all electrical electronic signaling,
communication etc. equipment/items. The contractor shall submit all the
standards for reference as required by the Employer at the detailed
engineering stage.
JOB NO-730176 IV-204

CHAPTER - V
DATA TO BE FURNISHED BY THE TENDERER
5.0.0.0 The following data are required along with the offer failing which the
offer may be treated as incomplete
5.0.1.0 GENERAL
Plant description as envisaged

• System drawings of the plant
• Sample GA drawing of conveyor system indicating plan,
elevation, belt profile with idler location & switches,
foundation plan.
• System drawings of other associated systems like dust
suppression, fire fighting & plant cleaning, power supply ,
illumination , control , communication etc.
• Scope of supply
• List of spares forming part of scope of supply
• Deviations from the NIT, if any
• Manufacturer’s pamphlet of different equipment indicating
technical details
• List of spares for next one year operations
• Any additional alternative provisions.
5.1.0.0 MECHANICAL
5.1.1.0 BELT CONVEYORS
5.1.1.1 DRUMS (ALL TYPES)
The details of the drums required shall be furnished for all types of
drums for any one of the conveyor here for initial assessment
• Diameter (OD)
• Shell thickness
• Bearing centers
• Material of shaft
• Plummer block type, make
• Type of construction of drums
• Details of ribs & stiffeners provided inside the drum shell along with
thickness
• Type of shaft and hub connections
• Type of sealing for the bearings / Plummer blocks.
• Lubrication arrangements
• Bearing life guaranteed for (hours)
• Out of roundness of the drums
• Type of lagging on drive drums and details
Job No. - 730176 V-1

• Approx. Weight of each drum

• Whether statically balanced or not
5.1.1.2 IDLERS (ALL TYPES)
The details asked below shall be furnished for all types of idlers.
• Diameter (OD)
• Length of roller
• Wall thickness of tube
• Diameter of shaft & its length
• Material of shaft
• Size & Type of bearings
• Details of sealing arrangement
• Approximate capacity of grease cavity
• Bearing life guaranteed for (hours).
• Eccentricity / Ovality of the idler
• Idler tube construction -
• Weight of idler set
• Weight of moving parts/ idler
• Shore hardness of rubber disc for impact idlers
• Spacing for different types of idlers
• Make
• Friction factor
5.1.1.3 IDLER BRACKET
• Sample detailed dimensioned drawings

• Details of fixing of brackets showing allowance for shifting the idler
sets.
• Material of construction
• Minimum thickness of steel plate used
• Structural steel section used for fixing the idler brackets
5.1.1.4 DRIVE UNIT MOTOR
• Kilo Watt
• Make
• Starting torque
• Full load torque
• Starting current
• Full - load current
• Power factor
• Insulation class
• Type of enclosure
• Voltage
Job No. - 730176 V-2

5.1.1.5 GEAR BOX
• Make
• Type & size
• Speed ratio
• Output transmitting capacity
• Service factor used
• Efficiency
5.1.1.6 COUPLING (LOW SPEED)
• Type
• Make
• Size
• Service factor
5.1.1.7 FLUID COUPLINGS (HIGH SPEED)
• Type
• Make
• Size
• Rating
5.1.1.8 ANTI-ROLL BACK DEVICE
• Type
• Make
• Size
• Capacity in kilogram-meters
5.1.1.9 PULL CHORD SWITCHES
• Type
• Make
• Spacing & number
5.1.1.10 BELT SWAY SWITCHES
• Type
• Make
• Spacing & number
5.1.1.11 TRIPPER (FOR TRIPPER CONVEYOR)
• Tripper construction
• Drum diameter
• No. of wheels for tripper carriage
Job No. - 730176 V-3

• Wheel bearings
• Type of rail clamps
• Type of tripper drive
• Drive motor rating
• Power supply system
• Operation Platform and cross-over ladder provided.
• Size of railing considered
5.1.1.12 WEIGHT OF THE FOLLOWING
• Drive unit consisting of motor, reduction gear, drive drums,

couplings and anti-roll back device, common bed and frame etc.
• Head drum assembly
• Tail drum assembly
• Take-up assembly
• Tripper carriage
• Weight per Meter run of conveyor excluding belts.
5.1.1.13 DRAWINGS WITH OFFER
The following drawings in triplicate shall accompany the offer failing which it
may be passed over. All drawings shall conform to the IS: 696 and all
dimensions shall be in millimeters.
• General arrangement dimensioned drawings of complete

conveyor indicating idler arrangement, nos and type provided for
each conveyor, location of pull chord and other switches
curvatures provided for each conveyors.
• Drive unit and discharge drum assembly indicating plan & front
views complete with all important dimensions and clearances
including bolt hole centers for foundation.
• Tail drum arrangement
• Take-up arrangement
• Construction drawing of typical idlers showing all important
details
• G.A. of Tripper arrangement along with rail, rail clamp, breaking
and power supply details.
• Number offered of each conveyor.
• G.A drawing of sampling system
• G.A drawing of magnetic separator
• G.A drawing of metal detector
• G.A of Chute with flap gate
Job No. - 730176 V-4

5.1.2.0 BELTING
• Width in mm
• Type & make
• Total length in meter
• Construction
• Type of jointing
• No. of plies
• Factor of safety assumed for belt strength
• Breaking load per warp & weft:
• Thickness of belting in mm
• Belt weight per metre run in Kg./cm width/m
• Cover Thickness in mm
• Top
• Bottom
• Grade of cover & its abrasive value
• Belt length in meter
• Roll diameter in mm
• Trough ability of belt
• Compliance with standard
• Manufacturer’s descriptive pamphlets and sectional
5.1.3.0 SECONDARY ROLL CRUSHER

• Type & make
• Width in mm
• Diameter in mm
• Total length in meter
• Construction
• Holding bolts
• Gap setting detail
5.1.4.0 ROTARY PLOUGH FEEDER
5.1.4.1 GENERAL
• Type/size/no
• Make
• Capacity – Nominal & variable
• Arrangement detail to get variable discharge
• General specification including constructional feature details
5.1.4.2 DISCHARGE WHEEL ASSEMBLY
• Discharge wheel diameter (mm)

• Speed of discharge wheel (max.) (RPM)
• Range of speed variation
• Arrangement provided for speed variation
Job No. - 730176 V-5

• Method of reclaiming material

• Number of Arms
• Recommended type of carrying idlers & spacing of the same for
the reclaim belt conveyors
5.1.4.3 FEEDER CARRIAGE ASSEMBLY
• Feeder carriage speed along the bunker

• Variation in speed
• Arrangement for varying the travel speed
• Track gauge
• Type of drive, speed reducers and couplings
• Details of discharge chute and the liner provided.
• Dia of wheels
5.1.5.1 CHUTES OF IN FEED CONVEYOR INTO SILO
• Chute material
• Thickness of mother plate
• Type and material of liner
• Thickness of liner
• Slope of chute
• Inside dimension of chutes
• Number of discharge chutes
• Hood cover thickness
• Method of fixing of liner plate
• Details of dust sealing arrangement
5.1.5.2 SILO
• Inside dia of silo (M)

• Height of silo roof top from rail top (M)
• Struck volume of silo and its self flowing capacity (Cu.m.)
• silo side slope
• Constructional material details
• Number of holes provided for fitting of pneumatic arch
breaker and other accessories
• Thickness and size of steel liner mm
• Method of fixing of steel liners
• Material of liner
• Thickness and height of ferrosite lining
• Other technical features
• Details of bottom support
Job No. - 730176 V-6

• Material handling system provided for replacement of

liner plates.
• Approx. wall thickness
5.1.5.3 LEVEL INDICATORS
• Type of level indicators provided

• Name of the manufacturer
• Model
• Number of level sensors
• Type of control
• Audio-visual alarms
• Level measuring devices (Construction/ Operational
features)
5.1.5.4 PRE WEIGH HOPPER
• Struck volume (m3)

• Self flowing volume (m3)
• Slope angle of side plates in conical portion with
horizontal (degree)
• Material and Thickness of steel plates used in the hopper
(mm)
• Liner material
• Thickness of liner material (mm)
• Method of fixing liner plates
• Load cell
i) Make
ii) Type
iii) Capacity
iv) Quantity
• Pre Weigh System Calibration

i) Type of calibration system
ii) Calibration weights (t)
iii) Number of calibration weights and denomination
provided
iv) Description of the calibration system
v) Details of jacking system
vi) Make
Job No. - 730176 V-7

vii) Details of automatic calibration system

• Time required to fill the weigh hopper
• Time required to empty the weigh hopper
5.1.5.5 PNEUMATIC ARCH BREAKER
• Type and size

• Numbers provided and their level
• Name of the manufacturer
• Volume of air discharged (Cu.M.)
• Type and size of air compressor & capacity of air receiver
recommended
5.1.5.6 SILO OUTLET GATES & MAINTENANCE GATE
• Type of gates
• Number of gates
• Opening size of gates
• Number of hydraulic cylinders used for each gate
operation
• Minimum opening time of each gate (Sec.)
• Minimum closing time for each gate (Sec.)
• Hydraulic cylinder, operating pressure (BAR)
• Maximum closing force at above pressure (Tonnes)
• Type and size of cam followers used and their numbers
• Expected flow rate (TPH)
5.1.5.7 LOADING CHUTE
• Inside dimensions of chute

• Type/ thickness of material and liner used
• Number of hydraulic cylinders used for positioning the
chute
• Hydraulic cylinder operating pressure (BAR)
• Complete chute retraction time (Seconds)
• Type of Pivot/Support
• Maximum & minimum height of loading chute from rail top
• No. of inter locks and signaling including positioner (Brief
write up)
• Make and any other relevant constructional and
operational details
5.1.5.8 FLOW CONTROL GATE
• Inside opening of the chute

• Thickness of steel plates for gate wall & blade
• Type of liner material for gate wall & blade
Job No. - 730176 V-8

• Thickness of liner material (mm) for gate wall & blade

• Method of fixing liners
• Type and size of bearing used
• Shaft material & size
• No. of hydraulic cylinders used for gate opening and
closing
• Hydraulic cylinder operating pressure (BAR)
• Minimum closing and opening time (Seconds)
• Inter locks and signaling
5.1.5.9 TEMPERATURE / HEAT SENSORS
• Make
• Type
• Qty. per each silo
• Location of installation
• Control system details
• Signalling system
• Operation and construction details
5.1.5.10 HYDRAULIC POWER PACK
• No. of hydraulic power pack

• Name of manufacturer
• Model and size
• Reservoir capacity (litres)
• Type of hydraulic pump
• Pump capacity (Litres/Min.)
• Oil flow (Litres/Min.)
• Type of the hydraulic oil
• Properties of hydraulic oil
• Approx. life of hydraulic oil
• Type of gauges provided
• Drive motor power
• Oil closing system
• Constructional & operational features
5.1.5.11 HYDRAULIC ACCUMULATOR
• Type of accumulator
• Volume of accumulator
• Description of accumulator, operating system and other
constructional details
Job No. - 730176 V-9

• Operating pressure
• Make and model
5.1.5.12 HYDRAULIC CYLINDERS
• Bore & stroke of hydraulic cylinders (mm)

• Operating pressure (BAR)
• Test pressure (BAR)
• Make and model
5.1.5.13 PASSENGER/ FREIGHT LIFT
• Name of the manufacturer :

• Capacity - Number of persons :
• Freight capacity (kg) :
• Speed of the lift (m/sec) :
• Travel (m) :
• Number of floors served :
• Location of machine room :
• Location of counter weight :
• Size of car platform :
• Type and size of landing door
• Type and size of landing door :
• Constructional feature of car body :
• Type of operation :
• Type of locking devices for landing doors :
• Type of indictors provided :
• Rope construction details including :
• Rope size and make :
• Drive motor / other motor power :
5.1.6.0 MOTORISED HOIST
• Capacity and number offered.

• Locations
• Lifting and lowering height
• Lifting speed
• Traversing distance
• Traversing speed
• Motor power
• Type of power feeding arrangement
• Type of structural support
• Make & Maker’s illustrative pamphlets
Job No. - 730176 V - 10

5.1.7.0 TRAMP IRON MAGNET/MAGENTIC SEPERATOR
• A brief description of tramp iron magnet with its technical

parameters.
• Type of input power i.e., whether A.C. or D.C. is to be
used.
• Specified controls provided.
• Type and composition of metals where it can be
effectively used.
• If DC power input is required, method of conversion from
AC to DC
• Maximum weight and volume of foreign metal which can
be lifted from the conveyed material.
• Type and make of the equipment.
• A general arrangement drawing of tramp iron magnet
• Maker’s illustrative pamphlets and literature and the
details of past supply.
• Method of suspension and arrangement for sideway
movement and disposal
5.1.8.0 BELT WEIGHERS
• Specification in detail in respect of various accessories and

systems provided with the belt weigher including the features
are to be elaborated
• General arrangement drawings of the belt weigher giving
broad dimensions and indicating its various functions :
• Manufacturer's descriptive pamphlets giving details of
various constructional features of the equipment and of
various individual components :
• Weighing range for each unit :
• Percentage accuracy over the entire weighing range:
• Provision of zone adjustment detail :
• Type of totaliser and details :
• Type of sensing equipment and details :
• Speed sensing device details :
• Weigh bridge type and details & weighing length :
• Rate indicator type and details : :
• Power supply required
• No. offered
• Calibration device provided :
Job No. - 730176 V - 11

5.1.9.0 METAL DETECTOR
• A brief description of detector with its technical

parameters.
• Type of input power i.e., whether A.C. or D.C. is to be
used.
• If DC power input is required, method of conversion from
AC to DC
• Specified controls and hooter provided.
• Type and composition of metals where it can be
effectively used.
• Minimum weight and volume of foreign metal which can
be detected over conveyor bed.
• Type and make of the equipment.
• Material used to be dropped for the metal identification
• A general arrangement drawing of detector .
• Maker’s illustrative pamphlets and literature and the
details of past supply.
5.1.10.0 CHAIN PULLY BLOCK
• Capacity and number offered.
• Lifting and lowering height
• Type of structural support
• Make & Maker’s illustrative pamphlets
5.1.11.0 FIRE FIGHTING SYSTEM
• Water Hydrant system description

• Type/make of water hydrant
• Water requirement
• envisaged (cum/hr)
• Terminal head (m)
• Pump Capacity (cum/hr)
• Type of pumps provided
• Drive motor power of pump (kW)
• Pipe size used
• System descriptions and line diagram
• or the water hydrant system
• Portable extinguishers
• Type of fire extinguishers
Job No. - 730176 V - 12

• Capacity and number of each type and their location

• Make
• Manufacturer's descriptive pamphlet
• Smoke/Fire Detection
• Type and make
• Specific technical features
• Operating principles
• Quantity location wise
• Manufacturer's descriptive technical pamphlets
5.1.12.0 DUST SUPPRESSION SYSTEM
• A line diagram of the suppression arrangement (showing

location of nozzles, pumps / compressors and layout of
pipeline from reservoir to various distribution points ) :
• Details of piping, fittings, pumps and nozzles. The material
construction for nozzles, pipes and reservoirs :
• The details of water storage tanks used. Pressure and quantity
of water required for nozzle :
• Details of chemicals to be used, its consumption availability
and approximate price :
• Details of chemical storage tank, its mixing arrangement and a
line diagram of flow :
• Illustrative literature for dust suppression plant in general
• Make of different items like pumps / compressors, fittings,
nozzles, pipes etc.
5.1.13.0 CHUTES AND LINERS
• Chute material
• Thickness of mother plate
• Type and material of liner
• Thickness of liner
• Slope of chute
• Inside dimension of chutes
• Number of discharge chutes
• Hood cover thickness
• Method of fixing of liner plate
• Valley angles of chutes :
• General arrangement drawings along
with maker's illustrative pamphlets,
literature for lining material :
Job No. - 730176 V - 13

5.1.14.0 SAMPLING SYSTEM

5.1.14.1 PRIMARY SAMPLING MACHINE
• Type and make of cutter type sampler

• Cutter opening mm
• Cutter speed (m/sec.)
• Number of cuts/hour
• Kilograms/Cut
• Total quantity of sample/hour (Kgs.)
• Type of cutter drive
• Drive power
• General construction features
5.1.14.2 SAMPLE BELT FEEDER
• Capacity (TPH)
• Belt width and length
• Belt speed
• Material size
• Drive power
• Make
• No offered
5.1.14.3 SAMPLER COLLECTING UNIT
• Size of sample collector

• Number of sample collectors
• Material of collector
• Capacity of each collector (Kg.)
5.1.15.0 MISC EQUIPMENT
5.1.15.1 FLAP GATE
• Quantity and location

• Thickness of plate in mm
• Thickness of liner plate in mm
• Motor power in kW
• Drive unit details
• Type of limit switches
Job No. - 730176 V - 14

• Qty. of limit switches for each flap gate

• Position of limit switches
• Construction and operation details
5.1.15.2 BELT VULCANISING MACHINE
• Make
• Type
• Duty and rating of vulcaniser
• Temperature to be maintained.
• Size and material composition of Heating plates.
• Details of Hydraulic pressure system
5.1.15.3 VIBRATORY FEEDER
• Make
• Type
• Capacity
• Detail of mounting arrangement.
Job No. - 730176 V - 15

5.2.0.0 ELECTRICAL
5.2.1 TECHNICAL PARTICULARS TO BE FURNISHED BY THE TENDERER

FOR 30kV LIGHTNING ARRESTOR
1. Manufacturer's name :
2. Type and Designation :
3. Nominal Voltage Rating :
4. Rated discharge current
(8/20 microsecond) :
5. Type of mounting :
6. Maximum impulse spark over voltage :

FOR 33 kV OFF LOAD ISOLATORS
1. Name of the Manufacturer :

2. Governing Standard :
3. Class (Outdoor/Indoor) :
4. Rated Voltage and Frequency :
5. Type & Designation :
6. Rated current in Amps :
7. No. of Poles :

FOR 33 kV VACUUM CIRCUIT BREAKER
1. Name of Manufacturer :
2. Rating applicable as per standard :
3. Rated Voltage & Frequency :
4. Current rating
a) Normal :
b) Continuous as per site condition :
c) Short time rating for 3 second kA :
5. Reference Ambient Temperature :
6. Maximum rise of temperature
Job No. - 730176 V - 16

over reference ambient for

current rating as per site conditions. :
7. Derating factor for 50oC

ambient temperature. :
8. Rated operating duty :
9. Breaking capacity based on

duty Cycle as per clause 6
a) Symmetrical at rated voltage :

b) Asymmetrical at rated voltage :
10. Type of contacts
a) Main :
b) Arcing and arc control device :
11. Material of contacts
a) Main :
b) Arcing :
c) Whether contacts silver faced :
12. Whether circuit breaker is

trip free or fixed trip
5.2.4 TECHNICAL PARTICULARS TO BE FURNISHED BY THE TENDERER 33

KV DROPOUT FUSE
The characteristics of the insulator fitted for mounting D.O. fuse should also
be furnished as given below:
1. Name of manufacturer :
2. System Voltage :
3. Type of Insulator :
4. No. of Units per stack :
5.2.5 TECHNICAL PARTICULARS TO BE SUPPLIED BY THE BIDDER FOR

33/3.3 kV POWER TRANSFORMER
2. Service :
3. kVA rating
a)HV winding : kVA
b)LV winding : kVA
4. Rated voltage
Job No. - 730176 V - 17

kVA rating
a)HV winding : kV
b)LV winding : kV
5. Rated frequency :
6. Number of phases :
7. Connections
a)HV winding :
b)LV winding :
8. Connection symbol
a) HV-LV :
9. Tapings
a) Range :
b) Number of steps :
10. Reference Ambient temperatures
0
a) Maximum ambient air temperature : C
0
b) Minimum ambient air temperature : C
11. Type of cooling :
12. Temperature rise
0
a) Top oil : C
0
b) Windings : C
13. Total loss at rated voltage at principal taping : kW
and rated frequency
14. Impedance voltage at rated current for the
principal taping
a) HV – LV : Percent
15. Efficiencies at 75oC at unit factor
a) At full load : percent
b) At ¾ full load : percent
c) At ½ full load : percent
16. Regulation at full load at 75oC
a) At unit power factor : percent
b) At 0.8 power factor lagging : percent
17. Terminal arrangement
a) High voltage :
b) Low voltage :
d) Neutral
5.2.6. TECHNICAL PARTICULARS TO BE FURNISHED BY THE TENDERER

FOR 3.3 kV SWITCH BOARD PANEL
1. General
Maker's name
Enclosure degree of protection
Thickness of sheet steel, mm
Standards to which the various equipment conform
2. Main Bus bars
Job No. - 730176 V - 18

Material
Size
Type of support insulators
3. Earth Busbars
Material
Size of earth bus bar
Fault current rating in K Amps.
4. Vacuum Circuit Breaker

Maker's name
Rated voltage (Nominal/Highest), kV
Standard to which the equipment conforms
Rated current Amps, rms
Thermal rating, 1 sec., kA.
Temperature rise over ambient temp
Symmetrical Breaking capacity MVA/kA.
Number of breaks per phase
Type and material of contacts
Type of operating mechanism
Closing
Tripping
Spring charging motor
Type and make
Number of auxiliary contacts furnished
Normally open
Normally closed
Whether operation counter provided
Whether mechanical safety interlocks provided
Whether electrical and mechanical anti-pumping features provided.
Any other special features
5. Current Transformer
Maker's name and type
Rated voltage, kV
Rated secondary current, Amps
Accuracy class
Class of insulation
6. Voltage Transformer
Maker's name and type
Primary and secondary rated voltage, kV
Job No. - 730176 V - 19

Accuracy class
Class of insulation
burden.
7. Vacuum Contactors
Makers name and type
Standards to which the contactors conform
Rated voltage of coil in volts
Rated duty
Rated current, Amps
Rated breaking capacity, kA
Duty class
5.2.7. TECHNICAL PARTICULARS TO BE FURNISHED BY THE TENDERER 33

kV CURRENT TRANSFORMER

2. Type :
3. Rated System Voltage :
4. Application :
5. No. of Phases :
6. Frequency :
7. Rated Transformation Ratio :
8. Rated Burden of each Core :
9. Class of Accuracy of each Core :
10. Accuracy limit factor of each Core :

33 kV POTENTIAL TRANSFORMER
1. Name of the manufacturer :

2. Type :
3. Rated System Voltage :
4. Application :
5. No. of Phases :
6. Frequency :
7. Rated Transformation Ratio :
Job No. - 730176 V - 20

8. Rated Burden of each Core :

9. Class of Accuracy of each Core :
10. Accuracy limit factor of each Core :
5.2.9 TECHNICAL PARTICULARS TO BE SUPPLIED BY THE BIDDER

FOR 3.3/0.415kV DISTRIBUTION TRANSFORMERS
2. Service :
3. kVA rating
a)HV winding : kVA
b)LV winding : kVA
4. Rated voltage
kVA rating
a)HV winding : kV
b)LV winding : kV
7. Connections
a)HV winding :
b)LV winding :
a) HV-LV :
9. Tapings
a) Range :
0
0
0
a) Top oil : C
0
b) Windings : C
and rated frequency
principal taping
Job No. - 730176 V - 21

a) High voltage :
b) Low voltage :
d) Neutral
5.2.10 50/100/250 KVA, 3300 V/230V (L-L) LIGHTING TRANSFORMER
2. Service :
3. kVA rating
a)HV winding : kVA
b)LV winding : kVA
4. Rated voltage
kVA rating
a)HV winding : kV
b)LV winding : kV
7. Connections
a)HV winding :
b)LV winding :
a) HV-LV :
9. Tapings
a) Range :
0
0
0
a) Top oil : C
0
b) Windings : C
and rated frequency
principal taping
a) High voltage :
b) Low voltage :
d) Neutral
Job No. - 730176 V - 22

5.2.11. CENTRALISED REMOTE AND AUTO SEQUENCE CONTROL
a. Whether block diagram showing sequence control and interlocking

arrangement for CHP and Silo loading system furnished.
Control desk, Annunciation Panels, Local control Station
5.2.11.1 CONTROL DESK
a. Maker’s name
b. Standard to which the equipment conforms
c. Mounting details
d. Type of enclosure
e. Whether mimic panel is included in the offer
f. Paint shade
g. Ground-box material, size, size of connector, fault current rating etc.
h. Internal wiring
i. Voltage grade
ii. Insulation
iii. Conductor material
i. CONTROL SWITCH
i. Maker’s name & type

ii. Standard to which the equipment conforms
iii. contact rating
iv. Whether key interlock furnished
j. Push button

iii. Nos. of contacts furnished
k. Ammeter/Voltmeter selector switches

iii. Contact rating
l. Lamps

ii. Standard to which the lamp conforms
iii. Rated voltage, volts
iv. Rated power, watt
v. Mounting details
Job No. - 730176 V - 23

m. Space heaters

ii. Rated voltage, volts
iii. Mounting details
iv. Whether thermostat provided
n. Terminal blocks

ii. Standard to which the lamp conforms
iii. Rated voltage grade, volts
iv. Whether 20% spare terminal furnished
o. Instruments and meters

iii. Range
p. Facilities provided on the control desk as per specification
(list to be furnished )
q. Annunciation Panel
a. Maker’s name
b. Type of annunciation system
c. Number of windows
d. Type of panel construction
e. Materials and thickness
f. Any other special feature
5.2.12 PROGRAMMABLE LOGIC CONTROLLER:
I. CENTRAL PROCESSING UNIT (CPU) SUBSYSTEM COMPRISING

POWER SUPPLY, PROCESSOR AND MEMORY
a. Power supply
b. Processor
II. INPUT/OUTPUT SUBSYSTEM

a. Chassis with power supply
b. I/O count and distribution
( inclusive of 10% spares)
i. Analogue input ( 4 to 20 mA DC )
ii. Analogue output ( 4 to 20 mA DC )
iii. Digital input ( potential free contact )
Job No. - 730176 V - 24

iv. Digital output ( potential free contact )

c. Type of I/O modules
d. Capacity per module
i. ( Analogue input 4 to 20 mA DC )
ii. (Analogue output ( 4 to 20 mA DC )
iii. Digital input ( potential free contact )
iv. Digital output ( potential free contact
e Expn. Chassis for housing I/O modules
f CPU rack along with local I/Os
g Remote I/O stations
h I/O status indication
III. CONSOLE SUB SYSTEM
(a) The operator station – Main control room & Silo Control Room
Function:
Plant operation and display of status of Input & output at the
field interface modules, Process Dynamic graphics on Monitor,
Data log record.
(b) THE Engineering (programming) station - 1 no.
Function:
On and Off line programming of PLC by the user during
development of programme, start up, Fault diagnosis ( trouble
shooting) & preparation of user5 doc. Etc.
(c) Personal computer with printer
Communication cable
Computer cable
IV SOFTWARE PACKAGES
a. For operator station and mimic station

b. For programming station
V UPS SYSTEM WITH CABINET
VII COMPUTER MIMIC IN THE ENGINEER’S/OFFICER IN CHARGE OF

CHP’S ROOM
VIII. LAPTOP FOR RELOADING THE SOFTWARE IN PLC / PC
Job No. - 730176 V - 25

IX. HOUSING PANELS/CABINETS
a. For housing CPU rack with local I/Os and power distribution
accessories.
b. For housing remote I/O racks and power distribution accessories
c. General
d. Fabrication material
e. Cabinet finish
f. Enclosure protection
g. Inside cabinet wiring
h. Illumination
5.2.13. COMMUNICATION
TELEPHONE SYSTEM
a. Maker's name and type :

b. Standard to which the equipment conforms :
c. Number of sets provided :
d. Operational range of frequency :
e. Facilities :
f. Output level :
5.2.14 EARTHING
a. Number of earth electrodes

b. Size and material of earth strip/wire for
i. Main earthing grid
ii. Main earth bus
iii. Equipment earthing
iv. Earthing of light fittings, welding sockets,pull chord switch, belt
sway switch, zero speed
v. Earthing for protection of buildings & structure from lightning
5.2.15 EARTHING
a. Details protection system

b. Type of protection system provided over silo/ Bunker & others
c. Size and height of the spies
d. Size of the flat used for connection
e. Standards to which the system conforms
5.2. 16 MISCELLANEOUS ITEMS
1. Inverter sets for emergency lights
Job No. - 730176 V - 26

a. Maker’s name and type

b. Rated KVA
c. Rated voltage, volts
d. Phase
e. Frequency
f. Current, Amps
g. Whether automatic switching ON facility has been provided in case of
power failure
5.2.17. DETAILS OF AIR CONDITIONING & PRESSURISATION SYSTEMS
PRESSURISATION
a. Make
b. Pressure
c. Temperature
d. No. of air charges
e. Other details
AIR CONDITIONING
a. Make
b. Type
c. Temperature
d. Humidity
e. Other details
5.2.18 MOTOR CONTROL CENTRE
Note: The tenderer shall furnish the complete details for all the MCCs. Some
details are given below
5.2.18.1 GENERAL
a. Maker’s name
b. Enclosure degree of protection
c. Standard to which the various equipment conform
5.2.18.2 AIR CIRCUIT BREAKER

a. Maker's name
c. Rated voltage (Nominal/Highest), kV.
d. Number of phase and frequency
Job No. - 730176 V - 27

e. Rated current, Amps rms.

f. Symmetrical Breaking capacity, MVA/kA.
g. Making current, kA
h. Total interrupting time, cycle
i. Closing time
j. Number of auxiliary contacts provided
k. Whether operation counter furnished
l. Whether mechanical safety interlocks furnished
m. Whether Electrical and Mechanical anti pumping feature provided.
n. Instruments provided
o. Protections provided
p. Whether remote control facility from control desk provided.
q. Whether ON, OFF, TRIP indications have been carried over to the
control desk
5.2.18 .3 MAIN BUS BAR
a. Material and size

b. Type of support insulator
c. Maximum working voltage, volts
d. Continuous maximum current rating at 500C ambient, Amps
5.2.18 .4 GROUND BUS BAR
a. Material and size

b. Maximum withstand fault current rating in kA and it’s duration
5.2.18 .5 MCCB/ SWITCH FUSE UNIT
a. Maker’s name
c. Rated breaking capacity in kA
5.2.18.6 ISOLATORS
a. Maker's name
b. Type
c. Standard to which the isolators conforms
5.2.18.7 FUSES
a. Maker's name and type
b. Standard to which the fuses conforms
c. Maximum symmetrical rms fault current interrupting capacity, kA.
Job No. - 730176 V - 28

5.2.18 .8 CONTACTORS
a. Maker’s name & type

c. Rated voltage of coil in volts
d. Rated duty
e. Rated currents in Amps
5.2.18 .9 OVER LOAD RELAYS

5.2.18 .10 CURRENT TRANSFORMER

c. Rated voltage in KV
d. Rated secondary current in Amps
5.2.18 .11 VOLTAGE TRANSFORMER
a. Maker’s name
c. Rated voltage primary and secondary
d. Accuracy class
5.2.18 .12 INSTRUMENTS AND METERS
a. Maker’s name
b. Type and range
c. Standard to which the equipment conforms
d. Rated voltage in Volts
e. Instrument accuracy class
5.2.18 .13 INDICATING LAMPS

b. Standard to which the lamp conforms
c. Rated voltage in Volts
d. Rated power in watts
5.2.18 .14 PUSH BUTTONS AND CONTROL SWITCH

c. No. of contacts furnished
d. Mounting details
Job No. - 730176 V - 29

5.2.18 .15 POWER WIRING
a. Conductor material
b. Area of cross-section of conductor
c. Voltage grade
d. Insulation material
5.2.18 .16 CONTROL CIRCUIT BREAKER

c. Rated voltage ( Nominal/ Highest ) in KVolts
5.2.19. POWER, CONTROL AND SPECIAL CABLES
NOTE: The tenderer shall furnish the complete details for each size of
cable and of different voltage grades. Some of details are as
follows:
a. Maker's name
b. Standard to which the cable conforms
c. Voltage grade, volts
d. Suitable for earthed or unearthed system
e. Short circuit current
i.Short circuit current, kA

ii.Duration short circuit
iii.Conductor temp. allowed for the short circuit duty.
f. Conductor
i) Material
ii) Nominal cross sectional area, sq.mm
iii) Number and diameter of wires.
g. Insulation
i) Material
ii) Thickness
iii) Composition
h. Armour-material, type
i. De-rating factors for the following shall be indicated
5.2.20. REQUIREMENT FOR ILLUMINATION SYSTEM
NOTE: The tenderer shall furnish the complete details for each type
of the equipment and accessories furnished. Some of the details are
given below:
Job No. - 730176 V - 30

LIGHTING FIXTURES
a) Maker's name and reference type

b) Description of the fixture
LAMPS
a) Maker's name and reference type

b) Min. luminous flux
BALLAST
a) Maker's name and type

b) Standard to which the equipment conforms
c) Rated voltage, volts
CAPACITOR
a) Maker's name
b) Rated voltage, volts
STARTER
LIGHTING CABLE
a) Maker's name
b) Standard to which the cable conforms
c) Voltage grade, volts
d) Size of conductor, sq.mm
e) Conductor material
LIGHTING DISTRIBUTION BOARD (MAIN/SUB)

a) Maker's name
b) Type
c) Standard to which the various equipment conform
d) Details of enclosure
e) Rated voltage frequency
f) Rating and make of moulded case circuit breaker (MCCB)
g) Rating and make of miniature circuit breaker (MCB)
h) Fault withstand cap. for 1 sec, kA.
i) Make and type of timer
j) Make and type of Contractor
Job No. - 730176 V - 31

JUNCTION BOX
RECEPTACLES AND PLUGS

b) Rated volts
c) Current rating, Amps
SWITCH

b) Rated voltage, volts
c) Current rating Amps
Details of lighting towers

Details of emergency lighting and safety lighting
5.2.21. WELDING SOCKET
Welding plus Socket Cum Switch

(Industrial Type Key Operated Push Button Type)
a) Maker's name and type :
b) Standard to which the equipment conforms :

c) Rated voltage, volts :
d) Current rating, Amps :
e) Number of pins :
:
5.2.21.3 CAPACITOR
Note: The tenderer shall furnish the complete details for capacitors
required, some of the details are as follows:
a) Maker's name and type :

b) Standard to which the capacitor conforms :
c) Capacity provided kVAr :
5.2.22 TECHNICAL PARTICULARS TO BE FURNISHED BY THE TENDERER 3kV

LIGHTNING ARRESTOR
1. Manufacturer's name :
2. Type and Designation :
3. Nominal Voltage Rating :
Job No. - 730176 V - 32

5. No. of sections per pole :
5.2.23. TECHNICAL PARTICULARS TO BE FURNISHED BY THE TENDERER

FOR 3.3 kV OFF LOAD ISOLATORS

2. Governing Standard :
3. Class (Outdoor/Indoor) :
4. Rated Voltage and Frequency :
5. Type & Designation :
6. Rated current in Amps :
7. No. of Poles :
a) Type :
b) Material :
Job No. - 730176 V - 33

5.2.24. CIVIL AND STRUCTURAL WORKS
5.2.24.1 FOUNDATIONS
a) Type of foundation envisaged
5.2.24.2 STRUCTURAL OF FABRICATION
a) Cross Section of conveyor gantry-- Single/ Double

b) Size of the drive house, transfer houses for belt
conveyor showing the minimum clearance provided
around the equipment
c) Details of flooring used
d) Supporting details of Vibratory feeder
5.2.24.3 SILO
a) Design principle
b) Total height of silo
c) Internal dia. of silo
d) Details of liners used in the conical portion of the silo
e) Details of liners used in the vertical portion of the silo
f) Number of floors
g) Provision of stairs in between the floors
h) Lift shaft details
i) Shaft details for carrying cables, pipes etc.
j) Type of floor finish
5.2.24.4 SERVICE BUILDINGS
a) Size and details of all service buildings
5.2.24.5 MISCELLANEOUS
a) Details of plant cleaning system

b) Details of approach road , internal road , drains & culverts.
c) Details of facilities provided at site for testing of construction
materials.
d) Details of plantation
e) Details of water supply & sanitary arrangement.
5.2.25. ANY OTHER DETAILS
Job No. - 730176 V - 34

TENDER DOCUMENT
FOR
NEAR
LINGARAJ OCP
LINGARAJ AREA

भाग -2ए
VOL II A
(DRAWINGS)
िदस बर - 2011
ू
TENDER DOCUMENT
FOR
NEAR
LINGARAJ OCP
LINGARAJ AREA

भाग -3
VOL III
(PRICING FORMAT)
िदस बर - 2011
ू
INDEX
ITEM DESCRIPTION PAGE NO
1 SUPPLY ITEMS VOL-III-1
1.A MECHANICAL PLANT AND MACHINERY VOL-III-1
1.A.1 CONVEYORS VOL-III-1
1.A.2 MECHANICAL EQUIPMENT VOL-III-2
2 ELECTRICAL PLANT & MACHINERY VOL-III-3
3 MANDATORY SPARES VOL-III-5
4 OTHER ITEMS VOL-III-6
5 WOTK & SERVICES VOL-III-6
5.1 SURVEY, SOIL TESTING & DESIGN

ENGINEERING
VOL-III-6
5.2 CIVIL & STRUCTURAL WORKS VOL-III-8
5.2.A CIVIL & STRUCTURAL WORKS VOL-III-8
5.2.B DEVELOPMENTAL WORK 7 VOL-III-8

INFRASTRUCTURE
5.3 ERECTION, INSTALLATION & VOL-III-9
COMMISSSIONING
5.4 MAINTENANCE OF PLANT VOL-III-9
6 WEIGHT & VOLUME FOR CIVIL & VOL-III-10

STRUCTURAL WORKS,DEVELOPMENT
& INFRASTRUCTURE
7 INSTRUCTIONS VOL-III-11
Job No 730176
PROFORMA FOR PRICE BID
METHOD OF PRICING
The Bidders may quote their bids either item wise or broad head wise i.e.
1.0.A-1, 1.0.A-2, 2.0,3.0, 4.0, 5.1, 5.2A & 5.2B, 5.3, 5.4 and grand total i.e. 1.0
to 5.4 as per the following format in separate sealed envelope .As indicated in
clause 6.0, it is mandatory to fill up the quantities..
The price should be quoted inclusive of all taxes and duties.
1.0 SUPPLY ITEMS
A. MECHANICAL PLANT AND MACHINERY:
SL.NO. PARTICULARS Unit Qty UNIT TOTAL

PRICE PRICE
A-1 CONVEYORS
1.1 Conveyors 1200/1600mm wide m
for N-N belt
1.2 Conveyors 1800mm wide for N- m
N belt
1.3 Conveyors 1800mm wide for m
Steel chord belt
1.4 Extension of existing conveyors m
1200mm wide
1.5 N-N Belting1200/ 1600 mm m
1.6 N-N Belting1800 mm m

1.7 Steel chord Belting1800 mm m
1.8 N-N Belting1200 mm for m

extension of existing belt from
feeder breakers.
SUB-TOTAL1.0.A-1
Job No: 730176 VOL-III - 1


PRICE PRICE
A-2 MECHANICAL EQUIPMEMT
1.1 Rapid loading system-4000 te NO
capacity silo, 5000-6000 tph ,
including ,arch breaker .air cannon,
Air compressor, hydraulic system
.test weights pipes & fittings with
electrical ,printer , display facility etc.
1.2 Pre weigh hopper for silo NO
1.3 Passenger lift NO
1.4 Rack & pinion chute gates NO
1.5 Electro mechanical vibro feeder NO
cap.600 tph
1.6 Automatic coal sampling system Set
1.7 Plough feeder, capacity 0 - 3600 tph, NO

complete with electrical and in built
dust extraction system
1.8 Twin shaft sizer / Secondary roll NO
crusher for Secondary crushing,
1600 tph, Feed size (-)250mm,
product size (-)100mm, .
1.9 Chain pulley blocks 10 t NO
`1.10 Motorised hoist, NO
1.11 Manual hoist,
1.12 In motion rail weigh bridge 100 t cap. NO
With printer, digital display etc.
1.13 Belt weigher NO
1.14 Tramp iron magnet for 1800mm wide NO
1.15 Metal Detector for 1800 mm belt NO
1.16 Motorised flap gate NO
1.17 Belt cleaner. NO
1.18 Belt pulling device NO
1.19 Special tools & tackles LS
1.20 Vulcanizing M/c NO
1.21 Chute assembly with liner NO
1.22 Dust suppression system with piping SET
& other accessories.
1.23 Pressurisation system SET
1.24 Ventilation system SET
1.25 Safety & fire fighting system and SET
Plant cleaning system
1.26 Safety equipment LOT
1.27 Any other items required for

successful completion of the job
SUB-TOTAL 1.0.A-2

2.0 ELECTRICAL PLANT AND MACHINERY:
S.NO PARTICULARS Unit Qty UNIT TOTAL

PRICE PRICE
ELECTRICAL EQUIPMEMT
2.1 33kV substation at existing project LOT
substation as described in scope
of supply in Annexure-III.2A (Sl
no 1) and System description
2.2 Two sets. 3.3 KV double circuit LOT
overhead lines (wolf conductor)
on separate rail poles from 33kV
substation upto 3.3 kV substations
including DP/4-pole structures for
power receiving arrangement at
Sub stations- I, II & III and other
accessories. as described in
scope of supply in Annexure-
III.2A (Sl no 2) and System
description
2.3 3.3kV substation - I as described LOT
in scope of supply in Annexure-
description
2.4 3.3 kV substation - II as described LOT
description
2.5 3.3 kV substation - III as LOT
described in scope of supply in
Annexure-III.2A (Sl no 5) and
System description
2.6 Power cable 3.3 kV, XLPE, 1.1kV, LOT
PVCSWA Aluminum & copper
cable for Control, communication
& signaling cable of different sizes
having FRLS properties in outer
sheathing along with all
accessories such as cable tray,
cable rack etc. as described in
scope of supply in Annexure-
description


PRICE PRICE
2.7 Illumination system comprising LOT
of Lighting sub distribution
boards, light fittings, poles,
lighting towers, emergency
lighting, lighting cables, junction
boxes, cable tray, cable rack
etc. . as described in scope of
supply in Annexure-III.2A (Sl no
7) and System description
2.8 Welding Set & Welding LOT
Receptacles including
transformer welding set, power
sockets, 1.1 kV , PVCSWA
Aluminum conductor cable
having FRLS properties in outer
sheathing along with all
accessories such as cable tray,
cable rack cable hangers etc.
as described in scope of supply
in Annexure-III.2A (Sl no 8) and
System description
2.9 Plant earthing system including LOT
earth pits, earth strips ctc. . as
System description
2.10 Lightning protection including LOT
spikes, earth pits, earth strips
ctc. . as described in scope of
10) and System description
2.11 Control system including control LOT
desk, mimic panel, annunciation
panel, PLC, audio visual
signaling, computer, VDU,
printer, hooters etc for CHP and
Rapid Loading system. as
System description
2.12 Communication system for CHP LOT
and Rapid Loading system. as
System description


PRICE PRICE
2.13 Pressurisation for Switchgear LOT
rooms of Substation I, II & III &
Air conditioners for Silo Control
room, PLC room, Engineer-in-
charge’s room etc as described
description
2.14 Other items such as ceiling fans, LOT
exhaust fans, insulation mat,
signaling system, testing and
safety equipment, fire fighting
equipment, Aviation light at silo
etc. as described in scope of
14) and System description and
mentioned elsewhere in this
document.
2.15 Any other items required for
successful completion of the job
SUB-TOTAL 2.0
3.0 MANDATORY SPARES

PRICE PRICE
3.1 Mandatory spares , tools & LOT
tackles for Mechanical items
3.2 Mandatory spares , tools & LOT
tackles for Electrical &
electronics items
SUB-TOTAL 3.0

4.0 OTHERS ITEM

PRICE PRICE
4.1 Drinking water system 1lot
consisting of tanks, pipes,
valves, taps etc
4.2 Plant cleaning system As per
requirement
4.3 Any other item left out for
completion of the project
SUB-TOTAL 4.0
5.0 WORK AND SERVICES
5. 1 SURVEY,SOIL TESTING & DESIGN ENGINEERING
SN. PARTICULARS QUANTUM UNIT AMOUNT

OF WORKS PRICE
5.1.1 Detailed survey of the area, within the Complete
battery limits and submission of reports. works as per
tender
document
5.1.2 Sub soil exploration, field and laboratory Complete
testing of samples and submission of works as per
reports. tender
document

SN. PARTICULARS QUANTUM UNIT AMOUNT

OF WORKS PRICE
5.1.3 Design Engineering cost
a)Preparation of system engineering As per
drawing submission. requirement
b)G.A and detail engineering designs &
drawings of all civil and structural included
in system and scope of work, site
development drawings etc.
c)G.A and detailed basic engineering
designs & drawings
i)All Individual equipment,Electrical and
Mechanical.
ii)Dust suppression system
iii)Fire fighting system.
iv)Chutes and liners
v)Power supply system
vi)Illumination system
vii)Control system
viii)Earthing system
ix)Lightning protection system
x)Air conditioning and pressurization
system
xi)Plant cleaning system
xii)Water supply arrangement
xiii)Manual sets.
xiv)Inspection& maintenance of SILO
xv)Drainage system, road and sewerage
disposal.
d)Control, monitoring & tele
communication system
5.1.4 Documentation as per tender specification
SUB-TOTAL 5.1

5.2 CIVIL AND STRUCTURAL WORKS
ITEM NO. ITEM DESCRIPTION AMOUNT

A Civil and structural work (Silo, Overhead Bunker, Truck
receiving hoppers, Conveyor Gantry, Drive & Transfer Houses,
Sampler House, etc.)
5.2.1 Earthwork in cutting in all types of soil and rock
5.2.2 a) Earthwork in filling
b) Sand filling
5.2.3 PCC at all levels as per system requirement
5.2.4 RCC (excluding reinforcement) at all levels as per system
requirement
5.2.5 Supply, bending, binding and placing of Tor steel in position
5.2.6 Supply, fabrication and erection of structural steel at all levels as
per system requirement
5.2.7 a) Pre-coated galvanized iron profile sheeting at all levels including
supply.
b) Perspex sheeting at all levels including supply.
5.2.8 Stainless steel liner as per requirement
5.2.9 Ironite liner as per requirement
TOTAL OF 5.2.A
B Developmental work and infra-structure
5.2.1 Internal road(PCC) of 7.50 m
5.2.2 WMM Pavement around truck receiving hopper complex
5.2.3 Drains with average size 30cmx40cm
5.2.4 Leveling, dressing of vacant area
5.2.5 Arboriculture
5.2.6 Service building with floor area
5.2.7 Water supply pipe line
5.2.8 Ground water reservoir
5.2.9 Boundary wall withfencing
5.2.10 Misc. items of works such as painting on civil works, land scaping
etc.
TOTAL OF 5.2.B
ABSTRACT OF COST ESTIMATE
ITEM NO. ITEM DESCRIPTION AMOUNT
1 Civil and Structural work
2 Development work and infra-structure
SUB TOTAL OF 5.2 (A+B)

5.3 ERECTION, INSTALLATION & COMMOSSIONING
SL.NO. PARTICULARS UNIT QTY UNIT TOTAL

PRICE PRICE
5.3.1 Erection of mechanical Lot
equipment
5.3.2 Erection of electrical equipment Lot
5.3.3 Erection of other plant and Lot
machining etc.
5.3.4 Trial run and commissioning of Lot
the plant
SUB-TOTAL 5.3
5.4 MAINTENANCE OF PLANT
SL.NO. DESCRIPTION QUOTED AMOUNT

5.4.1 Training for operation and maintenance of staff/ personal
( As per the description given in the tender document)
5.4.2 Maintenance of whole plant for one year
SUB TOTAL OF 5.4
GRAND TOTAL (1.0 to 5.4)
( Rupees ………………………………………………………………………………..) in words

6. WEIGHT AND VOLUME FOR CIVIL AND STRUCTURAL WORKS
ITEM ITEM DESCRIPTION UNIT QUANTITY

NO.
Civil and structural work (Silo, Overhead Bunker, Truck

receiving hoppers, Conveyor Gantry, Drive & Transfer
Houses, Sampler House, etc.)
1 Earthwork in cutting in all types of soil and rock cum
2 Earthwork in filling cum
3 PCC at all levels as per system requirement cum
4 RCC (excluding reinforcement) at all levels as per system cum
requirement
5 Supply, bending, binding and placing of tor steel in position MT
6 Supply, fabrication and erection of structural steel at all levels MT
as per system requirement
7 Pre-coated galvanised iron pofile sheeting at all levels sqm
including supply.
WEIGHT AND VOLUME FOR DEVELOPMENT WORK AND INFRASTRUCTURES

(Broad quantities within a limit of +/- 10% of actuals on completion)
ITEM
NO. ITEM DESCRIPTION UNIT QUANTITY
1 Internal road (PCC) of 7.50 m m
2 WMM Pavement around truck receiving hopper complex sqm
3 Drains m
4 Service building (Floor area) sqm
5 Boundary wall (2.0m height ) with top 0.61m concertina coil m
fencing

7. INSTRUCTIONS:
1) Quantity should be as per scope defined in the tender document and should
cover all the requirement of the system.
2) ±10% clause based on civil and structural quantities of works as given by the
bidder in the above table, the short fall in total quantity of all civil & structural
works shall be allowed up to 10% only to every individual items. For shortfall of
quantities exceeding 10%, there shall be proportional reduction in the price of
the individual items resulting in the reduction in the award value by the same
amount. Upward variation in quantity of individual items for civil & structural
works should be absorbed by contractor unless specifically stated otherwise in
the document.
3) The above items of work are to be executed strictly as per IS provisions.

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NOTICE INVITING TENDER

MAHANADI COALFIELDS LIMITED

A Subsidiary of Coal India Limited

Office of The General Manager(E&M)

NOTICE FOR PRE-NIT MEETING

REF NO.: E&M/2011-12/PRE-NIT/97 Dt. 16 / 12 /2011

Name of the job : : Planning, Design, Engineering, Construction, Fabrication, Supply,

Value of Work : Rs. 25680.00 Lakh

NAME OF WORK : Planning, Design, Engineering, Construction, Fabrication, Supply,

ELCTRICAL & MECHANICAL DEPARTMENT

LINGARAJ CHP & SILO 1

Erection Conditions of Contract 72 - 87

LINGARAJ CHP & SILO 2

NOTICE INVITING TENDER

LINGARAJ CHP & SILO 3

COMPANY : MAHANADI COALFIELDS LIMITED

TENDER NOTICE NO: E&M/2011-12/PRE-NIT/ DT. / / 2011

Name and description of work Location Estimated Expected date of Period of

3.0 Application fee for Tender Documents:

LINGARAJ CHP & SILO 4

4.1 Complete tender documents are also available on website http://tenders.gov.in /

5.0 General Instructions for Submission of Tender:

A Bidder should strictly comply with the following instructions:

Part I- Full details of the firm, information on the supplies of equipment to

Part II – Technical offer along with technical specifications of equipment / know-

7.0 Validity period of Offer:

8.0 Receipt of tenders:

(a) Office of General Manager (E&M),

LINGARAJ CHP & SILO 5

(c) Office of the General Manager

9.0 Opening of Tenders:

10.0 Deputation of representatives for negotiation:

Shri S.K. Chatterjee,IPS (Retd.),

1. D.T.( P&P), MCL for kind information

LINGARAJ CHP & SILO 6

LINGARAJ CHP & SILO 7

2.0 ELIGIBLE BIDDERS:

3.0 QUALIFICATION OF THE BIDDER:

a) copies of original documents defining the constitution of legal status, place of

LINGARAJ CHP & SILO 8

3.4 To qualify for award of the contract :

LINGARAJ CHP & SILO 9

LINGARAJ CHP & SILO 10

Assessed available bid capacity = (A x N x 2 – B)

(ii) In case of Consortium Route, their collective qualifications/eligibility -

a) made misleading or false representations in the forms, statements and attachments

LINGARAJ CHP & SILO 11

5.0 COST OF BIDDING

6.0 SITE VISIT:

7.0 CONTENT OF BIDDING DOCUMENTS:

8.0 CLARIFICATION OF BIDDING DOCUMENTS

LINGARAJ CHP & SILO 12

10.0 LANGUAGE OF BID

11.0 DOCUMENTS COMPRISING THE BID

12.0 BID PRICES

LINGARAJ CHP & SILO 13

13.0 CURRENCIES OF BID AND PAYMENT

14.0 BID VALIDITY: