CNG COCO Station Tender

GAIL GAS LIMITED

{A wholly owned subsidiary of GAIL (India) Limited}
BENGALURU, KARNATAKA (INDIA)
CITY GAS DISTRIBUTION PROJECT AT BENGALURU

BID DOCUMENT
FOR
COMPOSITE WORKS OF CNG COCO STATIONS & CNG STATIONS IN OMC

ROS FOR CITY GAS DISTRIBUTION PROJECT IN BENGALURU
OPEN DOMESTIC COMPETITIVE BIDDING
Bid Document No.: MEC/23RT/01/51/D2/T51/ER/0016
E-Tender no.: 6000001380

PART – III
PREPARED AND ISSUED BY
MECON LIMITED
(A Govt. of India Undertaking)
Bengaluru, India
OCTOBER’2018

GAIL GAS LIMITED

COMPOSITE WORKS FOR CONSTRUCTION OF CNG COCO
STATIONS & CNG STATIONS IN OMC/ROS
E-Tender no. MEC/23RT/01/51/D2/T51/ER/0016
Bid Document No.: 6000001380

CONTENTS
LIST OF SPECIFICATION/STANDARDS
PART-I : Civil, Structural and Architectural Work
PART-II : Electrical and illumination Work
PART-III : Mechanical Work
PART-IV : Instrumentation Work
PART- V : Typical CNG station

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SPECIFICATION FOR CIVIL & ARCHTECTURAL WORK
PART-I
TECHNICAL SPECIFICATION
FOR
CIVIL, STRUCTURAL AND
ARCHITECTURAL WORK
1. CIVIL, STRUCTURAL AND ARCHITECTURAL WORKS
1.1. GENERAL
The scope of work to be performed under this contract shall include complete civil, architectural
and steel structural works as per plans, equipment layout, drawings & technical specifications for
the ‘CNG Stations.

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1.2. SCOPE OF SUPPLY
Contractor shall procure & supply to site all the materials including cement, reinforcing
steel, steel sections, plates, pipes, MS Y Angle Posts, Concertina coil, RBT fencing wire, Chain
link fencing, chequered plate, Colour coated steel sheets, False ceiling, mesh and other
accessories, other masonry materials, bitumen/asphalt, admixtures & bonding agents, sealants,
kerb stones, paver block, sand, boulder, etc., and any other construction material / item required
to complete the civil & structural works.
All costs towards testing/inspection of materials/goods shall be borne by the Contractor.
1.3. SITE WORK

Complete construction work including supply of labour, construction materials, construction
equipment, survey, tools & tackles, dismantling & modification / strengthening, supervision,
testing etc. required to complete all the structures, foundations, roads, drains, pavements,
finishes, supply, fabrication, erection of steel structures, Canopy, hoarding, Loading unloading
platform, LCV Platform, cat ladder, welded wire mesh fencing and gates, pre cast compound wall
etc, painting, including site grading/earthwork in cutting & filling etc. as specified and required to
complete the civil & road works in all respect.
All enabling works e.g. construction of water tank, casting/fabrication yard, electricity, site stores &
office, safety and security measures, coordination with other contractors working at site etc. shall be
Contractor’s responsibility.
1.4. SCOPE OF WORK
The scope of work shall be broadly, but not limited to, the following:
a. Site grading of the plot by removing 150 mm top soil, , stacking it properly and reusing it for
planting purpose, including plot development by filling good quality earth as required.
b. Earth filling in embankments for external roads wherever required with providing of
RCC Culverts/ Pipe Culvert.
c. Clearing the site, removal of bushes and trees etc as per site requirement.
d. Construction of a 3 m high boundary wall with pre cast RCC panels, PCC Coping, MS Y
Angle Posts and Concertina coil with RBT fencing etc as per drawing.
e. RCC cable trenches: complete civil works for cable trench including providing inserts,
conduits (GI, PVC or HDPE etc.) and PVC coated MS Chequred cover plate / Pre cast
concrete covers as per requirement.
f. Construction of single and double S.S.tube trench as per drawing.
g. Construction of compressor foundation as per drawing.
h. Construction of Green belt etc as per drawing.

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i. Construction of Dispenser foundation, canopy foundation etc. as per relevant drawings.
j. Construction of fore court, approach roads etc. as per drawing.
k. Construction of cable pit, drain pits etc as per requirement.
l. Construction of Septic Tank along with Soak Pit and connections.
m. Storm water drainage system in RCC/brick drains with complete civil works as per
requirement.
n. Laying of Hume pipes for drainage as per drawing and requirement of site.
o. Construction of Utility/Office building - Control room, Office room, Store Room, UPS and
Battery Room, Electrical Room etc as per relevant architectural drawings.
p. Construction of Refreshment Centre with ATM as per relevant architectural drawings.
q. Construction of Bore well as per supplier specification and direction of Engineer in
charge.
r. 80 mm thick PCC paver block over sand cushion over ground/on a PCC base (Grade M-
10) at locations as specified.
s. Laying PCC kerb stones 125mm x 300 mm over 75 thk PCC base (Grade M- 10) as
specified.
t. Grouting of all base plates/frames of equipment foundations and structural bases.
u. Providing of all inserts, conduits, pre-cast covers, fixing of free issue items into permanent
works etc.
v. Providing of approved quality sand for back filling as per requirement.
w. Clearing all construction debris and handing over completed work site.
x. Any other work not specifically mentioned but required to make the station functional.
y. Making as-built details/drawings on one set of construction drawings and return to owner.
2. PREAMBLE TO SCHEDULE OF RATES
The Preamble to Schedule of Items is an integral part of the schedule of quantities and rates and
this is to be considered incorporated into the description of items themselves. The Contractor’s
rate for any item of work in the schedule of item shall, unless stated otherwise be held to include
the cost of all materials including wastage, conveyance and delivery, unloading, storing,
fabrication, all consumable materials, like MS bolts, washer, electrodes, putty, gases, splices
paints, tools and plants, power fuel, consumables, all taxes, royalties, other revenue expenses,
temporary facilities
like roads etc.
The item shall include all the safety provisions listed below:

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 The site should be cordoned off on all sides by way of 3 Mt. High corrugated GI
sheet fixed on metal pipes/angles, leaving space for only a Gate. This fencing
should be fixed such that it is not possible for anyone to enter the site from any
other location other than the Gate.
 The gate should be made in metal with metal sheet cladding. A guard
restricting entry of all unauthorized person/material on site should man the gate.
The guard shall also maintain a register of all persons visiting site.
 All persons including all labor, supervisors, visitors etc. on site must wear hand
gloves, helmet and safety shoes. The responsibility of this shall rest with the main
contractor.
 All workmen while working on height shall wear safety helmets and safety belts.
 All workmen such as welders/ fitters etc. shall wear protective gloves,
protective glasses etc. and as per the requirement and demands of the trade.
 All excavated pits/holes shall be cordoned off with red tape with warning notice.
 All inflammable material shall be kept in non-inflammable containers that are fixed
with screwed on caps at all times. The containers should be marked with danger
sign and the name of the material shall be marked on the outside. There should
be at least one person who should be responsible for the safe custody of these
materials.
 All areas of work shall have appropriate safety signage depending on the nature
of work, prominently displayed to prevent any mishap, particularly signs in
fluorescent paint for night vision. These signs should be visible from a
reasonable distance for a vehicular traffic at designated speed limits for a given
road/ location. All necessary city traffic rules and signage specifications shall be
observed with strict adherence.
 All gadgets must have required safety devices in working conditions as per the
manufacturers’ recommendations and the law of the country.
 All the persons on site must be insured against injury and death due to

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accidents.
 The contractor shall not use the site for any activity other than what it is
authorised for.
 Children below the age of 16 shall not be allowed to work on site. The
contractor shall prepare a secured crèche adjacent to the site, for the children of
labor working on site and there shall be at least one person dedicated to look after
the safety and other needs of these children at all time.
 All persons working at site shall be physically and mentally fit. The contractor shall
ensure that no illegal activity takes place on site and that no person with doubtful
past shall be engaged on site.
 The contractor shall be responsible for the safety of all persons at site.
 Consumption of liquor and smoking shall not be permitted on the site.
 The site shall be illuminated at night when there is work in progress.
 The contractor shall maintain a First-aid box at site to take care of any minor injury.
 The storing of all inflammable/explosive material shall be done as per the laws of
the country and best common practice.
 All temporary electrical connections shall be done with the help of insulated
connectors to prevent any sparking etc.
 Contractor shall keep the Owner and Consultant completely indemnified by

ensuring a completely safe working, keeping a third party insurance cover on site.
2.1. SITE CLEARANCE
Complete works for the site clearing so that the site is suitable for construction activity. Brief
description of major items shall be as follows:
a. Dismantling of all existing structures in brick masonry/stone masonry/

RCC /PCC, road, fence, sheds, cladding, sheets etc. so that the site becomes suitable for

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construction activity.
b. Disposal of all material to be cleared from the site to any authorised disposal site/ storage
yard.
c. Removal of trees up to and above 30cm girth as per respective SOR items.
d. Provide all assistance/co-ordination/liaison between any and all government/

semi government agencies connected with the scope mentioned and also with the body
owning/maintaining the access road to the site.
Note:
1. Site Clearance including removal of vegetation shall be measured in m2.
2. Demolition of RCC/PCC/Brick Masonry and road will be paid in M3.
3. Trees shall be counted in numbers for more than 30 cm girth.
2.2. EARTHWORK IN SITE GRADING, EXCAVATION & BACKFILLING FOR PLOT

DEVELOPMENT, ETC.
Brief description of major items shall be as follows:
a. Taking pre-work and finished levels.

b. Stripping and grubbing the top soil of 150 mm and preparation of sub-grade.
c. Excavating excess soil and soft rock if any to develop the plot.
d. Dewatering of excessive water.
e. Backfilling with serviceable earth in layers of 150 mm thickness in controlled way.
f. Watering and compaction up to ‘95% or as per direction of Engineer in charge of its MDD
with mechanical means.
g. Disposal of unserviceable and surplus earth/rock to a suitable dumping ground to any lead.
h. Actual work shall be carried out as per certified construction drawings to be issued to
successful tenderer.
Note:
i. For all these items only net excavated quantity in CuM shall be measured for payment.
ii. No separate payment for excavation for foundation / sewerage forecourt or Road
work/other items where earthwork is included (since cost of earthwork is included in
respective items).

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iii. Measurement for rock breaking shall be done by stacking. 35% of stack measurement
shall be deducted as voids.
Earthwork shall be done as per approved detailed construction drawings to be issued to the
successful tenderer. Offer to be prepared by the tenderer based on the enclosed drawings and
on lump sum unit rate (per M3).
2.3. EARTH WORK IN FILLING
Complete earthwork in filling with borrowed earth is included in the scope. Brief description of
major items shall be as follows:
a. Taking pre-work and finished levels.

b. De-watering of excessive water.
c. Strutting and shoring to retain the earth.
d. Borrowing of approved quality good earth from any lead.
e. Filling in layers of 150 mm.
f. Watering and compaction up to ‘95% or as per direction of Engineer in charge’
of its MDD with mechanical means.
Note:
Payment for item earthwork in filling shall be paid for compacted net volume of filling after
deductions of foundations, culverts, etc
2.4. SAND FILLING AND STONE SOLING
Complete works in filling is included in the scope. Brief description of major items shall be as
follows:
a. Taking pre-work and finished levels

b. Borrowing of approved quality sand/stone from any lead.
c. Filling in layers of 150 mm.
d. Providing and laying stone ballast 40-63 mm size in layers of 150 mm with spreading
blinding material like murum, bajri, stone grit and compaction with road roller etc.
complete the surface as per specifications including cost of material.
e. Watering and compaction by 10 T rollers.
Note:
i. Payments to be done on completed work profiles by considering the plan dimensions only.

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Sand filling and Stone soling shall be done as per approved detailed construction
drawings to be issued to the successful tenderer. Offer to be prepared by the tenderer
based on the enclosed drawings and on lump sum unit rate (per M3).
2.5. PCC WORK
Providing and laying PCC M 7.5 (1:4:8) / M 10 (1:3:6) / M15 (1:2:4) in all positions, in foundations,
substructure, superstructure and under floor, etc. (at locations where the same is not included in
respective SOR items, eg RCC in Substructure, Brick work, Concrete pavement etc.) complete in
all respects as per scope of work, detailed construction drawings, technical specifications and
direction of Engineer-in-charge.
Following works shall be inclusive in the rate of PCC item:
a. Earth Work in excavation including back filling (including disposal of surplus earth).
b. Preparation of bed including cleaning, levelling, compacting/tamping of surface and
providing support from bottom and sides.
c. Providing shuttering and strutting of all types (If necessary).
d. Providing inserts, pockets, recesses, holdfast etc.
e. Curing, rendering, finishes to match with adjoining surfaces etc.
Note:
i. For all these items only net PCC concrete quantity in M3 shall be measured for payment.
The construction of PCC work shall be done as per approved detailed construction drawings to
be issued to the successful tenderer. Offer to be prepared by the tenderer based on the enclosed
typical drawings and on lump sum unit rate (per M3) of PCC work done.
2.6. REINFORCED CEMENT CONCRETE - SUB STRUCTURE

a. Earth Work in excavation including back filling using serviceable surplus/ borrow
material, disposal of surplus earth (wherever required), including bailing out water
(where ever required), shoring / strutting etc.
b. 100 mm thk. PCC M-10 in mud mat.
c. Providing shuttering and strutting of all types.
d. RCC M25 as per drg. & specification including supply of cement, coarse aggregate, fine
aggregate and placement of concrete at all levels and depths,all inclusive & testing of
concrete and other materials.
e. Providing and fixing of all anchor bolt and nuts into permanent works etc.

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f. Providing and fixing of all inserts, conduits, precast covers into permanent works etc.
g. Provision of chequered plates, gratings into permanent works as per SOR item of Structural
works.
h. Grouting of all base plates/frames of equipment foundations as per requirement.
Note:
i. For all these items only net RCC quantity in M3 shall be measured for payment.
ii. Providing shuttering, shoring, strutting, staging etc. shall be inclusive in RCC Item.
iii. Earth work with borrowed earth shall be paid vide respective SOR item.
iv. Anchor bolts and nuts shall be paid vide respective SOR item.
v. Grouting with non shrinkable compound shall be paid vide respective SOR item
2.7. REINFORCED CEMENT CONCRETE - SUPER STRUCTURE
a. Providing shuttering and strutting of all types

b. RCC M25 as per drg. & specification including supply of cement, coarse aggregate, fine
aggregate and placement of concrete at all levels, all inclusive & testing of concrete and
other materials.
c. Grouting of all base plates/frames of equipment foundations and structural bases as per
requirement.
d. Providing and fixing of all anchor bolt and nuts into permanent works etc.
e. Providing and fixing of all inserts, conduits, precast covers into permanent works etc.
f. Provision of chequered plates, gratings into permanent works as per SOR itemof Structural
works.
Note:
i. For all these items only net RCC quantity in M3 shall be measured forpayment. The RCC
quantity of building superstructure is included in the Building Works item. Providing
shuttering, staging etc. shall be inclusive in RCC Item.
ii. Anchor bolts and nuts shall be paid vide respective SOR item.
iii. Grouting with non shrinkable compound shall be paid vide respective SOR item.
2.8. REINFORCEMENT STEEL
a. Supplying , fabricating and fixing in position HYSD steel reinforcements / TMT grade Fe-500
conforming to IS 1786-1985 at all levels and positions.
b. Straightening, cutting, bending, cranking, binding, welding, provision of necessary chairs and

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spacers for reinforcement bars as per drawing and construction requirements.
c. Preparation of bar bending schedule drawings and getting the same approved by site
engineers as directed by EIC.
Note:
i. Rate to include cost of all labour, tools, tackles, equipment, hire charges, supply of all
materials such as steel reinforcement, binding wire and other minor construction materials,
testing etc. all bye works and sundry works complete in all respects.
ii. Chairs, laps, spacers, wastage etc. shall be to contractor’s account.
iii. Only net reinforcement bars as per approved BBS / as laid at site shal be considered for
payment.
2.9. BRICK WORK IN SUB STRUCTURE / CC BLOCKS (200mm thick)
Complete works in brick masonry sub structure is included in the scope.
Brief description of major civil items shall be as follows:
a. Earthwork in excavation including back filling using serviceable surplus material or approved
borrow material and transportation of excess earth beyond plot limits. Preparation of sub-
base including de-watering and compaction.
b. CC block work for sub structure and super structure with not less than M7.5 grade, minimum
compressive strength 75 kg/sqcm in 1:4 cement sand mortor (in coarse sand.)
c. Brick work for SS tubing trench with not less than M-5 grade bricks/ minimum comp. Strength
of 50 kg/cm2 in 1:6 cement sand mortar (in coarse sand).
d. 150 mm thk. PCC (M-10) in levelling course.
e. DPC 50 mm with cement concrete M-15 (1:2:4) as per requirement with water proofing
compound and application of bituminous paint
f. 15 mm thk. plastering in CM (1:4) (in coarse sand) on exposed brick surfaces.
g. Making weep holes of 150 mm x 150 mm with stone filter pack at 1.0 m intervals in both the
directions.
Note:
i. Only net brick masonry quantity excluding plaster thickness shall be measured in M3 for
payment purpose.
ii. Earth work in backfilling with borrowed earth shall be paid vide respective SOR item.
The construction of brick work shall be done as per detailed construction drawings to be
issued to the successful tenderer. Offer to be prepared by the tenderer based on work
described above.

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2.10. BRICK WORK IN SUPER STRUCTURE /CC BLOCKS
Complete works in brick masonry super structure is included in the scope.

Brief description of major civil items shall be as follows:
a. CC block work for sub structure and superstructure with not less than M7.5 grade , minimum
compressive strength 75 kg/scm in 1:4 cement sand mortar (in coarse sand).
b. Brick work for ss tubing trench with not less than M-5 grade bricks/minimum comp. strength
of 50 kg/scm in 1:6 cement sand mortar (in coarse sand).
c. 15 mm thk plastering in CM (1:4) (in course sand) on exposed brick surfaces.
d. All niches, offsets, pockets etc shall be considered part of the work.
e. Providing shuttering / supports etc. as per requirement.
f. Applying Lime wash / Cement based paint / Weather proof paint / oil bound distemper
/Acrylic paint on plastered faces in super structure as specified in drawings.
Note:
i. Only net brick masonry quantity excluding plaster thickness shall be measured for payment
purpose.
The construction of brick work shall be done as per detailed construction drawings to be
issued to the successful tenderer. Offer to be prepared by the tenderer based on work
described above and payment will be made on rate (per M3) of brickwork done.
2.11. SOAK PIT AND SEPTIC TANK

Complete works for the making and proper functioning of soak pit and septic tank is included in
the scope:
a. Earth work in excavation, back filling, and disposal of surplus earth.
b. P.C.C. M-15 (1:2:4).
c. Brick work of M-5 grade in 1:5 cement mortar.
d. Plaster 12 mm thick 1:3 in coarse sand, finished with floating coat of neat cement inside and
rough plaster outside.
e. Brick bat filling in soak pit.
f. Honey comb brick work in soak pit.
g. RCC M-25 including reinforcement, shuttering etc in top slab.
h. Making all types of connections for sewerage collection and disposal.
i. Providing and fixing cast iron vent pipe up to required height as per drawing.
Note:

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Soak pit and septic tank shall be provided inclusive of all related works, as per approved detailed
drawings to be issued to the successful tenderer. Offer to be prepared by the tenderer based on
the enclosed drawings and on lump sum unit rate (per installation).
2.12. PAVER BLOCK (80 mm THK) PAVEMENTS IN SPECIFIED AREAS
Brief description of major works to be considered in this item is as follows:
a. Earthwork in excavation including back filling upto required level (including using borrow
earth and disposal of surplus earth).
b. Filling in layers of 150 mm thickness in controlled way.
c. Watering and compaction up to 95% of modified dry proctor density of soil with mechanical
means.
d. Providing and laying / fixing 80 mm thick M-30 Paver Blocks over 75 mm thk. sand cushion
over well compacted sub grade / PCC as specified.
e. Filling joints between the blocks with fine River sand.
f. Making slopes, finishing edges, leaving pockets for pedestals & sleepers.
g. Actual work shall be carried out as per certified construction drawings to be
issued to successful tenderer.
Note:
i. Complete civil works for Paver Block Pavement including, earth work in excavation,
preparation of base i.e., compacted sub grade, 100mm thk. sand filling and compaction, etc.
are included in the works & payment shall be made under Paver Block Pavement item. Only
net laid quantity shall be considered for payment purpose.
ii. PCC under the Paver Block Pavement wherever specified shall be paid under separate
PCC item.
2.13. KERB STONE IN SPECIFIED AREAS
Brief description of major works to be considered in this item is as follows:

a. Earth Work in excavation including back filling up to required level (including using borrow earth
and disposal of surplus earth).
b. Supplying and fixing M-25 Kerb Stone Blocks 125 mm x 300 mm over 75 mm thk. PCC - M 10
grade.
c. Filling joints between the blocks with cement mortar (1:3) (in coarse sand).
d. Actual work shall be carried out as per certified construction drawings to be issued to successful
tenderer.
Note:
Complete civil works for Kerb Stone including, earth work in excavation,preparation of
base i.e., compacted sub grade, 75 mm thk. PCC, etc. are included in the works & payment

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shall be made in RM. under Kerb Stone item.
2.14. BUILDING WORKS
Complete civil and architectural works for the buildings is included in the scope:
Utility/Office building - Control room,Office room,Store Room, UPS and Battery

Room,Electrical Room etc
Brief description of major civil and architectural under the item is as follows:
i. Site grading of the plot by removing 150 mm top soil stacking it properly and reusing it for planting
purpose, including plot development by filling good quality earth as required in the new areas to be
developed.
ii. The building shall be RCC framed structure with cladding and partitions of masonry walls.
iii. Construction of all sub-structures and superstructures.

iv. Anti-termite treatment to be applied to the building foundations, plinth and under flooring inside the
building and under Apron. .
v. All underground concrete/ masonry structure in contact with earth shall be given two coats of hot
bitumen application.
vi. All structural concrete for RCC elements shall have a minimum strength of 25 MPa at 28 days.
Grade of concrete in R.C.C. works shall be M-25.
vii. Masonry shall be in cement mortar 1:4 (in coarse sand) and with CC blocks of strength not
less than 7.5 MPa.
viii. Plastering on masonry structures shall be of thickness 15 mm on either faces, and 6 mm on

concrete faces. The cement mortar shall not be leaner than 1:4 in coarse sand.
ix. All chhajja/ canopy projections shall have drip mould grooves underneath all along periphery.
x. Entrance door/door for office/officer, control room of the building shall be anodized aluminium
/powder coated of approved shade fully / partially glazed , 6 mm thick float
glass(ASAHI/MODI/TUFF) panels fixed with necessary gaskets and aluminium beading strip or
panelled (double sided) with pre laminated board, double leaf / single leaf doors with floor springs.
All windows/ ventilators shall be aluminum glazed min. 6mm thick glass (ASAHI/MODI/TUFF)
withanodized aluminum/powder coated hardware with aluminum grill. The windows / ventilators
shall be partially/ fully fixed or openable, casement or slidingwindows as per requirement and
drawing. The fixtures like handles, stoppers,stays, etc., shall also be anodized aluminium/powder
coated and shall be of approved make. All aluminium sections shall be of standard make like

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Jindal, Hindalco or approved equivalent. Aluminium alloy used in the manufacture of extruded
sections shall correspond to IS Designation H E 9 WP of IS 733. Hollow aluminium alloy sections
used shall conform to IS Designation HV9 WP of IS 1285. The sections shall be polished and
anodized with approved colour. The average thickness of anodic coating shall not be less than 20
microns as per IS: 1868-1982. All work shall be fitted and shop assembled to a first job, and
ready for erection. EDPM performed profiles shall be used for inserting into extruded pockets of
sections. Glazing beads shall also be of EDPM performed profiles to hold the glass in frame under
pressure. Non metallic setting blocks shall be used to centralize the glass in frame. All work
shall be adequately braced and reinforced as necessary for strength and rigidity. Stainless steel
ball bearings, housed in nylon type nylon rollers, shall be used. All mechanical connections shall
be sealed with silicon sealant. Around all windows, approved quality sealants shall be run down to
make sure of total weather/water sealing.
xi. Windows shall have aluminium grills (Diamond Window Grill from Decogrill or approved
equivalent).
xii. Toilet doors shall be of high grade PVC (Sintex or approved equivalent) with suitable frames.
xiii. Flush doors, wherever required, shall have shutters conforming to IS:2202 (Part I) decorative
type, core of block board construction with frame of 1st classhard wood and well matched teak 3
ply veneering with vertical grains or cross bands and face veneers on both faces of shutters,
35mm thick including ISImarked stainless steel butt hinges with necessary screws. Frames shall
be
pressed steel single/double rebate door frames conforming to IS: 4351 manufactured from
commercial mild steel sheet of 1.25 mm thickness including hinges jamb, lock jamb, bead, etc.
xiv. Inside walls and ceilings of rooms/ buildings shall be finished with acrylic washable distemper
on Birla Putty or JK Putty and outside with weather resistant paint “Weather shield” of ICI or
“Apex Ultima” of Asian Paints of approved color on Birla Putty or JK Putty.
Rain water pipes of pvc shall be provided. Only approved make shall be used. RCC channels
for cables, pipe trenches etc. shall have provision of MS chequered plate / PVC coated
MS Chequred cover plate/ electrical room (as per equirement) and payment for chequred plates
shall be paid as per SOR item of Structural works.
xv. Inserts shall be provided to suit the technological requirements.
xvi. All exposed flat roofs shall be treated with “Aquashield APP” of STP or “Davco Armour shield” of
Chryso over a layer of screed concrete as per suppliers specification.
xvii. If sloping roof is provided as per design drawing, the same shall be finished with decorative
plaster.
xviii. Grade slab in flooring shall be of 150mm thick RCC of M-25 grade, 100 thick P.C.C. (M-10) over a
compacted sand layer of 250mm on well-prepared sub base.

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xix. Flooring & skirting in SCADA room, Office/ Control room, Verandah shall be provided with
10mm to 12 mm thick vitrified ceramic tiles (600 x 600) mm of make Asian/Kajaria/Johnson /
Somany etc.) on a bed of 20mm thick cement mortar of 1:4 proportion be provided. Skirting height
shall be 150mm.
Flooring and skirting in Electrical room shall be heavy duty vitrified tiles (600X600) mm.
Flooring and Dado in UPS / Battery room shall be provided with Acid proof tiles Pavigres of Kajaria
(size 300X300mm).
The height of dado in UPS/Battery room shall be 2400 mm with respect to finished floor level.
Eye/Face wash, model no.7001 pedestal mounted from Tobit Engineers shall be provided in
UPS/Battery room.
xx. Flooring & dado of Fire Protection room, store shall be of polished Kota stone.
xxi. All M.S. doors/window & louvered door for electrical room etc., wooden doors & leafs shall be
painted with 3 coats of synthetic enamel paint on pink/zinc chromate primer.
xxii. All finishes, painting, locking arrangement, etc. any other works not specifically mentioned but
required for completion and handing over of premises, complete in all respects.
xxiii. Apron 0.90M/1.0 m wide (as per drawing) of PCC M-10 grade and peripheral Storm water drains
in Brick around building (as per requirements).
xxiv. Electrical work including lighting inside the building and outside shall be under the scope of this
contract. The quantity of fixture etc. shall be covered under Electrical SOR for the terminal.
xxv. Mineral fibre false ceiling of “Armstrong” or equivalent make of approved pattern shall be
provided in Scada, Telecom and Electrical Rooms, office room, engineers room, discussion room
etc. as mentioned in working drawings. The tiles shall be beveled/ tegular tiles of size (600 x
600 x19) mm with 95% humidity resistance, light reflectance >80%, 0.7 NRC, thermal
conductivity k=0.052-0.057 w/m0c, class O/class1(BS 476 classification) fire performance or
equivalent .Tiles to be laid on 24XL-hot dipped galvanised steel suspension system having rotary
stitching on the main runner, 1200mm & 600mm cross tees making regular cut out for light fittings,
fire spinklers, etc., fixing & finishing. Ceiling to be finished neat and complete so that no
irregularities are visible after finish, including providing caps to the cut outs after fitting the fire
sprinkler nozzles.
xxvi. One or more 1000 liter overhead Sintex tank with necessary GI incoming and outgoing pipes and
fittings along with 0.5 HP pump for pumping water shall be provided for supplying water in toilets /
other areas.
xxvii. Toilets and pantry fixtures shall be provided as follows: EWC no. 20024 of

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Hindware, Flat back urinal no. 60002 of Hindware, Pedestal type Wash Basin no. 10010 of
Hindware, Stainless steel Sink of size 410X410 of Nirali, unless mentioned otherwise in
architectural drawings.
xxviii. Toilets to have first quality chromium plated fittings - taps, faucets, stopcocks, etc. of Jaqaur/
Parryware/ Cera, liquid soap dispenser, towel rail, deodorant holder, coat hook, china recessed
toilet paper holder, anti cockroach chilly trap, etc.
xxix. Toilets and pantry shall have anti-skid ceramic tiles flooring and ceramic tiles dado upto +1500
mm height from FFL.
xxx. Cutouts for exhaust fans to be made at beam bottom in Battery Room and Electrical Room in
required numbers.
xxxi. M.S. Cat ladder to be provided for roof approach.
xxxii. M.S. railing, wherever required, shall consist of handrail of 63X32X3.2 mm M.S. hollow section,
16X16 mm M.S. sq. bar balusters @ 250mm c/c and 2 nos. 25X6 mm M.S. plate running
horizontally at equal distances.
xxxiii. Water supply piping with GI pipe complete with all fittings and jointing,pipe work, bronze valves
with overhead tanks with high pressure ball cock,level indicator,level control and all its
connections and platform,anti-mosquito over flow grating etc.
xxxiv. A backlit signage hoarding in approved design including GAIL GAS logo of 5.0m x 1.0m
prepared in aluminum framework with flexible sub strata and approved colored translucent
vinyl to be provided on rooftop.(refer point no.- 2.25) (for payment refer separate SOR item).
xxxv. G.I. conduit to be fixed in concrete as per detail drawing shall be supplied and fixed in position.
xxxvi. Clearing all construction debris and handing over completed work site .
xxxvii. Making as-built details on one set of construction drawings and return to Owner.
xxxviii. Any other item not covered above but required for proper functioning of the building.
2.16 Canteen Table:
1. Canteen table 4 Seater with PU Coated size shall be 1022 Width mm x 1022 Depth mm x 750
Height mm. Top shall be made out of 25 mm thick MDF board and on top has to be PU painted of
minimum 2H hardness with 75% glass as per approve colour by IOCL .
2. There should be provision of combination colour graphics on the centre of the work surface and
below the table top there shall be dark colour Laminate on bottom specially profiled edges.

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3. The Under structure shall be having bend pipe structure of MS powder coated.
4. Pipe dia has to be 38 mm and 2 mm thick.
5. The under structure shall be fitted with top by SS machine screws.
6. Legs shall be of MS powder coated and 38 mm dia and 2 mm thick. Pipe legs should be fixed with
under structure and table top.
7. Glide shall be of Plastic fixed at the under structure to prevent the damage of table top during
stacking.
2.17 Canteen Dining Chair:
1. The seat and back of the dining chair shall be made out of injection moulded high impact strength
polypropylene polymer compound with indoor grade UV Resistance material.
2. The seat size will be 52.5 cm. (W) x 53.2 cm. (D) and the back size shall be 51.6 cm. (W) x 40.5
cm. (H).
3. The powder coated ( DFT 50±10 microns ) welded tubular frame shall be made out of 02.22 ± 0.03
cm x 0.16 ± 0.0128 cm and 3.5 ± 0.03 cm x 1.5 ± 0.03 cm x 0.16 ± 0.0128 cm M.S. E.R.W tube.
4. The tubular welded frame will be made out of Dia 2.22 ± 0.03 cm x 0.12 ± 0.0128 cm and 3.5 ± 0.03
cm x 1.5 ± 0.03 cm x 0.12 ± 0.0128 cm Stainless Steel 202 grade tube.
5. The tubes shall be buff polished to give shiny finish. The powder coated ( DFT 50±10 microns )
welded Beam M.S. Structure is made from 5.08 ± 0.03 cm x 5.08 ± 0.03 cm x 0.16 x 0.0128 cm.
6. The 0.315 ± 0.008 cm thk HR steel plate is welded to beam for fixing seat and back frame. The
powder coated ( DFT 50±10 microns ) welded Leg M.S.
7. Structure is made from 5.08 ± 0.03 cm x 5.08 ± 0.03 cm x 0.16 x 0.0128 cm and 5.08 ± 0.03 cm x
2.45 ± 0.03 cm x 0.16 ± 0.0128 cm.
8. The shoes will be made of high impact strength Polypropylene polymer compound with indoor grade
UV resistance and pressed fitted with tubular frame.
2.18 High back Chair:
1. High Back Chair seat shall be made up of 1.2 ± 0.1cm thick hot pressed plywood and upholstered
with leather and moulded polyurethane foam.
2. The back foam should be designed with contoured lumber support for extra comfort. The back size
shall be 530 W x 954 H seat size shall be 546 W x 490 D. the HR polyurethane foam should be
moulded with density = 45 +/-2 kg/m³ and hardness load 16 ± 2 kgf for 25% compression the seat
and back should be arrested together with spine made of 0.8 ±0.05 cm thk HR steel and should be
black powder-coated ( dft 40-60 microns ).
3. armrest shall comprise of three parts viz. the armrest support tube and p.u. armrest and the armrest
top. The armrest tube assy. should be made of 2.54±0.03cm x 0.16±0.0128cm m.s. e.r.w. support
tubes and chrome plated. The p.u. armrest should be made of black integral skin polyurethane with
50-70 shore hardness and reinforced with m.s. insert. The armrest top should be made of abs &

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upholstered with foam & leather the mechanism should be designed with the following features:
360° revolving type.
4. Seat back tilting ratio of 1: 1.5 front pivot for tilt with feet resting on ground ensuring more comfort.
Tilt tension adjustment.5-position locking with anti-shock back mechanism, which prevents the
backrest from impacting the user when the lock should be released.
5. Static seat depth adjustment = 5.0 ± 0.5cm with 5 position locking. it has an adjustment stroke of 9.0
± 0.3cm the bellow should be 1 piece and blow moulded in black polypropylene the pedestal should
be made of die-cast aluminium with buffing finish. it should be fitted with 5nos. twin wheel castor.
the pedestal should be 67.0 ± 0.5cm pitch-centre dia. (77.0 ± 1.0cm with castors) the twin wheel
castors should be injection moulded in black nylon.
2.18 Mid back Chair:
1. Mid Back Chair Cushioned seat shall be made of Injection moulded Plastic outer & inner. Plastic
Inner is upholstered with leatherette and moulded High Resilience (HR) Polyurethane foam of
Density 45±2 kg/m3, and hardness load 16 ± 2 kgf as per IS: 7888 for 25% compression.
2. The seat size shall be 470 W x 480 D mm. The Cushioned back has to be made out of PU Foam
with insitu moulded MS E.R.W Round Tube of size 1.9±0.03 cm x 0.16 ±0.0128 cm.
3. It should upholster with Leatherette. The high back size shall be 477 W x 76.4 D mm. The armrest
top should be moulded from polyurethane (PU) and mounted on to a drop lift adjustable type tubular
armrest support made of 03.81±0.03 cm x 0.2±0.01 cm thk M.S. E.R.W tube having chrome plated
finish.
4. The armrest height should be adjustable up to 6.5 ± 0.5cm in 5 steps. The adjustable tilting
mechanism shall be designed with the following features: 360' revolving type, Front-pivot for tilt with
feet resting on ground and continuous lumbar support ensuring more comfort, Tilt tension
adjustment can be operated in seating position, 5-position Tilt limiter giving option of variable tilt
angle to the chair, Seat & back tilting ratio of 1: 2 the mechanism housing is made up of HPDC
Aluminium black powder coated.
5. The Seat depth adjustment has to be integrated in the seat through a sliding mechanism. Seat
depth adjustment range is will be of 6.0 ± 0.5 cm. The Back Frame should be connected to the Up
Down mechanism housed in Plastic T spine.
6. It shall be adjusted in the range of 7.42 ± 0.5 cm for the comfortable back support to suit individual
need. The pneumatic height adjustment has an adjustment stroke of 10.0±0.3 cm.
7. The pedestal is High Pressure Die cast polished Aluminium and fitted with 5 nos twin wheel castors.
The pedestal shall be 65.0 ± 0.5cm pitch-centre dia.(75.0 ± 1.0cm. with castors.

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2.19 Workstation:
1. Size of workstation shall be 1500 x 1500 x 1200 mm H. Frame 50 mm thk. and 1200 mm ht.
2. Frame finish below Worktop shall be of approved pre laminated board and above worktop shall be
of approved fabric, one marker and one soft pinup board shall be provided.
3. Every workstation shall have one magnetic pinup board. Steel frame cap of approved colour shall
be provided.
4. Worktop made of approved prelam particle board of 25mm thick with 2mm thick PVC lipping of
750mm table height with the provision of wire management including keyboard tray, steel paper
tray, steel CPU trolley complete as per the specification and direction of Engineer in Charge.
2.20 L-Shaped Executive Table:
1. The size of L Shape Executive table shall be of 1800mm L x 750 mm D and side table 1200mm L x
750mm D with steel legs with 25mm thick prelam particle board along with Steel powder coated
Keyboard tray, Steel CPU trolley, wire management system and steel powder coated two drawer
pedestal of size 360mmW x450mm D x 560mm H, complete as per the specification and direction of
Engineer in Charge.
2.21 Steel Storage:
1. Steel storage unit shall be of size 750(W)x450(D)x1200(H) and 900(W)x450(D)x1350(H).

2. Body of storage unit shall be made of CRCA (minimum 0.8mm thick) with powder coating
(minimum 40-50 micron) Steel conforming to IS: 513 Gr.D in welded construction made of
approved colour with lock and key.
2.22 UPVC Windows:
1. UPVC frame shall be of white colour sliding with 6.0mm thick clear float glass upto 1.50 m in height.
2. Dimension comprising of uPVC multi-chambered frame with in-built roller track and sash extruded
profiles duly reinforced with 1.60 ± 0.2 mm thick galvanized mild steel section made from roll
forming process of required length (shape & size according to uPVC profile), appropriate dimension
of uPVC extruded glazing beads and uPVC extruded interlocks, EPDM gasket, wool pile, zinc
alloy(white powder coated) touch locks with hook, zinc alloy body with single nylon rollers (weight
bearing capacity to be 40 kg), G.I fasteners 100 x 8 mm size for fixing frame to finished wall and
necessary stainless steel screws etc.

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3. Profile of frame & sash shall be mitred cut and fusion welded at all corners, including drilling of
holes for fixing hardware's and drainage of water etc.
4. After fixing frame the gap between frame and adjacent finished wall shall be filled with weather
proof silicon sealant over backer rod of required size and of approved quality, all complete as per
approved drawing & direction of Engineer-in-Charge.
2.23 Venetian Blinds:
1. Venetian Blinds shall be 100mm wide of' approved make, shade, texture, colour with supporting
framework and assembly complete in working order as per manufacturers specifications and
directions of the Architect.
2. Venetian Blinds shall be vertical as per approved design.
2.24 Glazed Door:
1. Glazed door shall be made of Aluminium alloy used in the manufacture for extruded sections for this
work shall correspond to I.S 733 and shall be anodized before incorporating in the work. The rate
quoted for these items is deemed to include the cost of anodizing also.
2. The frame work, style, mullions, beadings, transome and handles etc. shall be of aluminium
anodized sections as shown in the detailed drawings.
3. All sections and hard ware shall have minimum anodic film of thickness not less than 15 microns.
Anodising quality shall be of type B-3, Decorative quality as per IS 1868. Sealing shall be done with
hydration tratment of anodic oxide coatings to reduce porosity.
4. Stainless steel or Cadmium plated brass counter sunk screws, nuts, bolts, washers, rivets and other
miscellaneous fastening devices shall be of approved brass cadmium plated or stainless steel as
specified in the drawing.
5. Approved shade of glass transparent sticker shall be fixed in the door as per approved design etc.
2.25 Name Display Board:
1. Name display board shall be of size 300 mm X 200 mm made of stainless steel, at least 2 mm thick.

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2. Name shall be printed as per the approved design complete as the drawings or as direction by the
engineer in charge.
3. Display board shall be fixed on wall surface as per the direction of the engineer incharge.
Note:
1. The construction of the building shall be done as per detailed construction. drawings to be issued
to the successful tenderer. Offer can be prepared by the tenderers based on the enclosed
architectural and standard drawings and on lump sum unit rate (per sqm) for complete building
work.
2. The payment for completed works shall be made as follows:
a. For superstructure all items (above Plinth Beam Level) as listed above shall be payable as
per enclosed drawing No.MEC/05/11/STD/CNG/001.
b. Centerline measurement for building shall be considered for payment purpose.
c. For substructure e.g. foundations, plinth beam etc. and other items such as
apron, peripheral drains, steps etc. respective SOR items shall be payable.
3. For electrical wiring, illumination and fixtures refer relevant parts of specification for Electrical
Works. All Electrical works shall be paid under respective Electrical Items. However, all
required civil works for electrical, instrumentation/ are in contractor’s civil scope of work.
2.26 FORECOURT
Complete civil works and other finishes in the fore court are included in the scope. Brief description
of major civil items shall be as follows:
a. 100 mm thick PCC M-10 (1:3:6).
b. Laying of all required conduit, cables, pipes etc. and fixing them securely (payable under separate
item).
c. Making of cable and steel tube trench with precast covers with lifting arrangement (payable
under separate item but area of trench will be deducted from forecourt).
d. Making dispenser islands including Granite/Vitrified tile top fixing and all its finishes (payable

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under separate item).
e. Providing and laying / fixing 80 mm thick M-30 designed coloured Paver Blocks over 75 mm thk.
sand cushion over well compacted sub grade / PCC as specified.
f. Fixing of concrete kerb stone blocks. Kerb stone blocks shall have niche with reflective material
fixed in it (payable under separate item).
g. Manhole, gully trap including precast covers.
Note:
a. Only area of completed forecourt shall be measured for payment.
b. The construction of fore court shall be done as per approved detailed construction drawings
to be issued to the successful tenderer. Offer to be prepared by the tenderer based on the
enclosed architectural drawings.
2.27 CULVERT
Complete works for the construction of culvert is included in the scope.
Brief description of major civil work items shall be as follows:-

a. Excavation of earth and back filling/disposal of the same.
b. 350 mm thick PCC M-10 (1:3:6).
c. CC Block of M-7.5 grade in 1:4 cement mortars as per design.
d. 12 mm thick plaster in 1:3 on exposed brick surface.
e. Laying of RCC pipe, joining the pipe lengths and encasing the same with 350 thick PCC M-15
(1:2:4).
f. Diversion of existing drainage (if any) during construction and its restoration to original position
after smooth joining of existing with new construction.
Culvert shall be made as per approved detailed construction drawings to be issued to the
successful tenderer. Offers can be prepared by the tenderers based on the enclosed drawings
and on lump sum unit rate (per RM) of pipe dia. basis.
Note:
In case a R.C.C. box culvert is provided - the payment shall be made under R.C.C.
composite rate.

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2.28 EXTERNAL SEWERAGE & STORM WATER PIPING
Complete works for the installation and proper functioning of external sewerage and drainage is
included in the scope.
a. Earth work in excavation and back filling.
b. PCC M-15 (1:2:4).
c. Laying pipes (SW, RCC pipe 150 / 300 mm dia).
d. Connection to Municipal manhole.
e. Restoration of site and clearing the debris.
External sewerage shall be provided inclusive of all related works, as per approved detailed
drawings to be issued to the successful tenderer. Offer to be prepared by the tenderer based on
the enclosed drawings and on lump sum unit rate (per RM) pipe laid.
2.29 ROADWORK
Complete works in making of road over well-compacted sub grade (CBR 4.0 - 5.0 in soaked
condition) is included in the scope.
a. Preparation of sub grade including dressing to camber, making good all undulations,
re-rolling with power road roller of 8 to 12 tons capacity etc.
b. Supply, stacking, and laying two layers of 115 mm thick WBM with 90 mm to 45 mm graded
stone aggregate stone screening and blending material including screening, sorting,
spreading to template and consolidation with power roller of 8 to 10 tons capacity etc. using
kankar, murum and red bajri etc.
c. Supply, stacking and laying one layer of 75 mm thick base course WBM with 63 mm to 45 mm
graded stone in the same fashion as above.
d. Supply, stacking and laying one layer of 75 mm thick base course WBM with 53mm to 22.4 mm
graded stone in the same fashion as above.
e. Providing and applying 75 mm thick Bitumen macadam with tack coat.

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f. Providing and applying tack coat using hot straight run bitumen of grade 80/100 by spraying
with mechanically operated spray unit fitted with boiler, after cleaning and preparing the
WBM surface @ 0.75 Kg/Sqmt.
g. Providing two layers of 25 mm thick premix carpet surfacing with 2.25 cum. and 1.12 cum. of
stone chipping of 13.2 mm and 11.2 mm size respectively per 100 sqmt and 52 kg and 56 kg
of hot bitumen per cum of stone chipping of 13.2 mm and 11.2 m size respectively including
a tack coat with hot straight run bitumen including consolidation with road roller of 6 to 9
tons capacity etc. complete with paving asphalt 60/70 with no solvent.
Road making shall be done as per approved detailed construction drawings to be

issued to the successful tenderer. Offer to be prepared by the tenderer based on the enclosed
drawings and on lump sum unit rate (per SqM) of premix carpet surface laid.
2.30 PRE-CAST SLAB
Brief description of main items shall be as follows:
Heavy duty 600mmx550mmx70mm thick precast Slab in trenches shall be provided and fixed as
per instruction of Engineer-in-charge.
2.31 PROVIDING AND LAYING FLOOR HARDENER
Heavy duty non- metallic hardener compound of STP, Roff, Fosroc, CICO of approved
manufacture or equivalent laid in panels at all locations over well compacted concrete bed
complete with all works, with minimum coverage as per manufacturers’ specifications, drawings
and as directed by EIC shall be provided and laid. All preparation and laying to be done under
specialist supervision and a performance guarantee be furnished for a long term service life.
2.32 GROUTING WITH NON-SHRINKABLE COMPOUND
Ready mix non-shrink cementitious grout of compressive strength 30N/mm2 / 45 N/mm2 as per
SOR shall be provided and laid manually or by pumping at all positions. This shall include
shuttering, compacting, edging, repairing, sealing and curing for shutdown repairs, base
grouting of rotating equipment and other installation complete. This shall be as per
specifications, site sketches/ drawings and direction of the EIC.
Minimum coverage as per manufacturers’ recommendations shall be applied in absence of
actual field consumption data.

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2.33 PROVIDING AND LAYING CAPCELL BOARD
CAPCELL board sealing in expansion joints of 12 mm/25 mm thickness and required depth shall
be provided and laid. All preparation, protection, sealing and sand bed separation will be part of
the work.
2.34 SPECIFICATION-PRECAST PANELLED COMPOUND WALL
The compound wall shall consist of RCC cast in situ concrete columns of cross section 400
mmX450mm at 3.0 M c/c(as per drawing) having grooves of required size so as to receive precast
RCC panels of 100 mm thick. Panels shall be reinforced with hard drawn steel wire fabric 8 mm
dia. 100X100 mesh as per IS: 1566 on both faces (as per drawing). The RCC for precast panels
shall be of M-25 grade. RCC Pre cast panels for compound wall shall be procured from a
reputed/approved vendor duly approved by EIC.
Note:
Complete civil works for precast panelled compound wall including, earth work in excavation,
backfilling, shuttering, RCC, PCC, reinforcement, transportation and erection of posts, panels, etc.
are included in the works & payment shall be made as stated below:
1. All works of compound wall up to fore court level shall be paid in respective SOR Items.
2. All works of compound wall above fore court level shall be considered as a composite item
and shall be payable in Rm which shall include all items for compound wall as per
drawings and specifications The items shall be mainly, but not limited to the followings:
a) Pre cast RCC Panels with hard drawn steel wire fabric complete in all
respect (as per drawing).
b) Hire and running charges of crane etc., for fixing, loading and
unloading.
c) The cost of ISMC 125 and fixing including necessary inserts to be

provided for the groove for fixing RCC Pre cast panels complete in
all respect as per drawing.
d) RCC Columns up to desired height (as per drawing) complete in all

respect. Reinforcement of columns shall be paid separately in
respective SOR Item.
e) RCC beam above fore court level.

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f) Coping (including 6 mm plaster) and Y angle including grouting,
complete in all respect (as per drawing).
g) Concertina coil, RBT complete in all respect as per drawing.
h) Fabrication and fixing of GAIL GAS Logo complete in all respect as

per drawing.
i) Acrylic paint on wall. Colour scheme shall be approved by EIC.
j) Painting of Y angle.
k) Preparation of expansion joints including cap bell armoured board,

sealant, bitumen etc. all complete.
l) Procurement, transportation, of all items as above including

necessary testing charges.
m) Shuttering, staging etc. all complete.
n) Any other item(s) necessary for successful completion of compound

wall.
2.36 TSS-1.0 TECHNICAL SPECIFICATION FOR 9.5/9.0/8.0 M LONG RCC POLE

WORKING LOAD OF 150/145/115 KGS.
The specification covers manufacture, curing, testing and supply of 9.0 and 13 mtrlong RCC
poles, are generally as per drawing enclosed with the specification and are intended to be
used on 11 kV over head electric distribution lines. The materials
manufactured shall conform strictly to the requirement of relevant INDIAN
STANDARDS and latest addition of IS using the best quality of materials and
workmanship. The Cement used in the manufacture of RCC Poles shall be of good quality
and confirming to the relevant ISS either ordinary or rapid hardening Portland cement
conforming to IS: 269. Aggregate used for the manufacture of RCC Poles shall confirm to
IS: 383. Reinforcing bars and wires used in the manufacture of RCC Poles shall be as
below:-
i) Mild steel and medium tensile steel bars and hard drawn steel wire confirming to
IS-432/1960.
ii) The steel of Tor-50 grade conforming to latest edition of IS: 1786.
iii) Quality of MS Rounds used for stirrups shall comply with the requirements of

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IS:226.
The reinforcing bars used shall be of required length as per drawing and no joint shall be
allowed. All joints and stirrups shall be welded properly. If no welded, the lap length shall
not be less than 40 times the diameter of the bars. The cover of concrete over the
reinforcement shall be 30mm under normal working conditions and shall not be under any
circumstances less than 20mm.
The sand shall be of the quality fit for use in RCC works i.e., river sand and sieved and free
from alkaline/acidic materials.
The ratio of cement concrete shall be 1:2:4 and shall comply with the requirements of
IS:456.
The standards adopted for various materials manufacture shall be as follows:

i) The RCC poles shall conform to the requirement of IS:785/1964.
ii) The quality of concrete shall be to the requirements of IS:456/1964.
iii) The testing of proto-type poles shall be as per requirements of IS:2905/1966.
The RCC Poles shall be manufactured as per the enclosed drawing and as noted below:
i) 9.5 M long Poles – Drawing No. KEB/CPL/RCP-2/19-9-1974.
ii) 9.0 M long Poles – Drawing No. KEB/CPL/RCP-2/19-9-1974.
iii) 8.0 M long Poles – Drawing No. KEB/CPL/RCP-2/19-9-1974.
The poles shall take working load of 150 kgs for 9.5mtr. 145 Kgs, for 9.0 mtr, and
115 Kgs for 8.0 mtr, long RCC pole acting at 0.6 M from top with factor of safety of 2.5
respectively and
The tests for transverse strength, torsion strength, measurement of cover and uprightness
shall be carried out in the presence of a representative of OWNER.
1.0% of the total number of poles ordered and selected at random shall be tested as per
thestandard referred to above.
No payments will be made for the poles, which fail or tested to destruction.
Earthing shall be provided for the poles. By having a continuous separate length of SWG GI
wire embedded in concrete during manufacture and the ends of wire left projecting from the
narrower end of the poles and 150mm below the ground level. The arrangements for
termination of the earth wire to the bolt and nut shall be as indicated in the concerned
drawing. The G.I. Wire used for embedding shall comply with requirement of IS: 2141/1968.
The poles shall be clearly and indelibly marked with the following particulars, during
manufacture but before testing at a position so as to be easily seen after erection in

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position.
a) Month and year of manufacture.

b) Maker’s Sl. No. and marking.
c) Purchase order No. and date.
d) A line to indicate the depth of planting.
e) KRWSSA engraved (letters – OWNER).
f) Lines to show the level of cross arms.
Provisions for holes for fixing the cross arms and other fixtures shall confirm to drawing
and/or the construction practice adopted by the KPTCL/ ESCOM. The same shall be got
confirmed by the Executive Engineer El., of the Division, before taking up the manufacture
and supplies.
LIST OF RECOMMENDED MAKES & MANUFACTURERS
Sl.No Description Manufacturers

M/s. HR Johnson; M/s. Kajaria Tiles,
Glazed tiles / Ceramic tiles / M/s. Somany Floor & Wall Tiles,
1
Vitrified ceramic tiles Bell-Ceramics, M/s.NITCO,
M/s. Murudeshwar Ceramics Ltd.
2 FLOOR HARDENR CICO, Fosroc,Sika
3 STEEL DOORS, ROLLING M/s Shakthi Met-Door, M/s. Madhu

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SHUTTERS & PRESS STEEL Industries, M/s. Deccan Structural
DOOR FRAMES Systems Pvt. Ltd., M/s. NCL Seccolor
Ltd.,
ALUMINIUM DOORS, Indal , Bhoruka, Hindalco, Jindal
WINDOWS, CURTAIN WALLS / M/s. ALFAB Products.
4 STRUCTURAL GLAZING USING
INDAL / JINDAL / HINDALCO
SECTIONS
GLASS : M/s Modigaurd, M/s Saint-Gobain,
5 (Plain/Frosted clear / tinted float M/s Asahi, M/s. Hindusthan Safety Glass
glass) Works Ltd
M/s Shalimar Hardware.
M/s Everite,
M/s Hardwyn,
HARDWARE FITTINGS & M/s Earl Bihari,
6
FIXTURES: M/s Godrej & Boyce, Secur Industries.
M/s EBCO:
M/s Godrej & Boyce mfg. Ltd.
M/s CROWN
M/s Shalitex; M/s Tiki Tar industries;
M/s STP Ltd. (Ms Shalimar Tar
EXPANSION JOINT AND Products);
7
TARFELT WATERPROOFING M/s Lloyd Insulation (I)
M/s Pidilite
M/s IWL
INTEGRAL WATER: Accoproof, Cico; Impermo Lafarge,
8
PROOFING COMPOUND Fosroc, Roffe,Sika,
Sika, Fosroc, Roffe, Overseas water
9 WATERPROOFING proofing corporation, Chowgule
TREATMENT Texsa, Pidilite,
CEMENT PAINTS, EXTERIOR
M/s Asian Paints;
EMULSION PAINTS,
M/s Berger Paints;
10 DISTEMPER, ACRYLIC
M/s Goodlass Nerolac;
EMULSION PAINTS, ENAMEL
M/s Jenson Nicholson;
PAINTS & FLAT OIL PAINTS
India gypsum, Armstrong, Lafarge boral
11 FALSE CEILING / PARTITION
gypsum limited, Luxalon , GYPROC
Decolam,National, Formica, Greenlam,
12 DECORATIVE LAMINATES
Century (merino)

Page 31 of 378

GAIL GAS LIMITED


DOOR CLOSERS, FLOOR Everite, Garnish, HARDWYN, DORMA
13
SPRING
Ge Silicon, Dow corning,
14 SEALANTS
Bostik, Pidlite Industries
Basant Beton, Pavestone marketing
15 CONCRETE PAVER BLOCKS Designers Pavings& Tiles Pvt. Ltd.,
Bessers Concrete Paver Blocks.
Parryware,Hindustan Sanitary Ware &
16 SANITARY APPLIANCES
Industries ltd., Neycer.
CP BRASS FITTINGS, WASTE Jaquar, Essco, Nova, Gem, Marc,
17
COUPLINGS, BOTTLE TRAPS Essess, Jupiter aqua , Grohe.
18 PVC flushing cisterns Parry ware, Hindware, Neycer
Saint Gobain, Modigaurd, Atul glass
19 Mirror
works,
20 Plastic seat and cover Commander,
Nirali, Diamond, Jaquar
21 Stainless Sink
Dayana,Amc, etc.
Tata, Jindal
22 GI Pipes
23 GI Malleable fittings Unik, Zoloto pec,MJM, Bimal
24 GM gate/ Globe valves Neta, Sant, New, Leader

Perfect Kashmira, South India
25 SW Pipes & Gulley traps
Corporation, TACEL, INDO PIPES
Prince, Finolex, Supreme, Kitec,
26 HDPE/UPVC Pipes & fittings
Oriplast, Polyfab,
27 CPVC pipes & fittings Flowgaurd (ASTRAL), Finolex
28 CI manhole covers Neco

Sintex, Infra, ICP (India) Pvt. Ltd.
29 PVC storage tanks
Century, Polycon
ACC, Ambuja Cement.
30 CEMENT
Ultra Tech, Birla super
31 REINFORCEMENT STEEL SAIL, TATA STEEL, RINL

Page 32 of 378

GAIL GAS LIMITED

32 ADMIXTURES FOSROC,SIKA,ROFF
33 PVC PIPES SUPREME, INFRA, PRINCE, FINOLEX

PEST CONTROL INDIA LTD,
MYSODET LTD., ASHOK PEST
34 ANTI TERMITE TREATMENT CONTROL – HUBLI, PEST CONTROL –
PUNE, CHRISLINE MARKETING
AGENTS- Bangalore
APP modified bitumen water STP, BITUMAT, SIKA, IWL, PIDILITE
35
proofing membrane TEXSA
Wall care putty for base Birla Wallcare putty, Berger, Johnson
36
preparation and Nicholson, JK white
37 Polysulphide Sealant Cico, Fosroc, Pidilite, Sika
38 Chain link fencing Tata

PRELAMINATED PARTICLE
39 Archidply
BOARD
NUTEK, M/s SASICON, M/s RBBR
Infrasture, For any other make,
40 PRECAST RCC COVER SLAB contractor has to obtain prior approval
from MECON/GGL based on their
credentials.
INTERARCH, JSW Colour coated sheet,
41 CANOPY FALSE CEILING
For any other make, contractor has to
obtain prior approval from MECON/GGL
42 CANOPY ROOF SHEETING based on their credentials.
ALSTONE, For any other make,

ACM SHEETING FOR FACIA, contractor has to obtain prior approval
43
SIGNAGES from MECON/GGL based on their
credentials.
RMX (Magadi road), SCC READYMIX
44 RMC CONCRETE PLANT (Kumblagod, Kengeri Hobli), NEXGEN
CONCRETE (Hennur)
45 STRUCTURAL STEEL SAIL, TATA STEEL, RINL

Page 33 of 378

GAIL GAS LIMITED


M/S SASICON, M/s RBBR
Infrastructures
PRECAST CONCRETE PANELS
46 For any other make, contractor has to
FOR COMPOUND WALL
obtain prior approval from MECON/GGL
based on their credentials.
Godrej , Featherlite . For any other
make, contractor has to obtain prior
47 FURNITURE
approval from MECON/GGL based on
their credentials

Page 34 of 378

Page 35 of 378

QUALITY ASSURANCE & QUALITY CONTROL
SITE QUALITY PLAN
CIVIL ENGINEERING DIVISION

Page 36 of 378

MECON LIMITED
13 FLOOR, SCOPE MINAR, NORTH TOWER
th
LAXMI NAGAR, DISTRICT CENTRE,

DELHI-110 092
Doc. No. Mec/05/11/SQP R0

Issued in - Nov' 2016
QUALITY ASSURANCE CIVIL ENGINEERING DIVISION

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
ANNEXURE - 1 MATERIAL TESTS FOR SITES
SL. Component/ Sampling plan with Type Instru- Refer- Acceptance Format Testing Remarks
No Operation basis of ment ence Norm of agency
and check docu- Record
Description ment
of test
A: MATERIALS
1.0 COARSE AGGREGATE
1.1 Specific Once in 12 weeks or Labora Weigh IS:2386 Package These test will be
Gravity, change of source tory balance, Part III, Contractor carried out while
Density, Voids whichever is earlier Test Oven, Jar IS:456, establishing design mix.
IS:383

Page 37 of 378

1.2 Sieve Analysis For Industrial Projects: Field Sieve set & IS:383 As per L-04 -do- Mandatory Site Test
One sample per 200 M3 Labora weigh requirement of
(or part thereof) or tory balance design mix
change of source Test within the limits
whichever is earlier. specified in
For Building Projects: relevant IS
One sample per 45M3 (or Codes.
part thereof)
1.3 Petrography To be done once per Visual/ - IS:2386 - -do- Test will be carried out
examination source Checki Part IV, while establishing mix
including visual ng IS:383 design
inspection (for
acceptanc
e limits)
Prepared By: Checked By: Approved By: QUALITY ASSURANCE PLAN NO.
J PRABHAKAR AGM (Civil) P.Sivanandam DGM (Civil) K.N.Raju DGM I/c (Civil) MEC/05/11/QA&QC/SQP-01 - R0
Date of Issue 13-08-2015

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test

Page 38 of 378

1.4 Deleterious To be done once per Lab Balance IS:2386 -do- Test will be carried out
Chemicals source Test Sieve & Part III, while establishing mix
Container IS:383 design
(for
acceptanc
e limits)
1.5 Soundness To be done once per -do- Sieve IS:2386 -do- Test will be carried out
source Scales & Part V, while establishing mix
Drying IS:383 design
Oven (for
acceptanc
e limits)
1.6 Acid & Alkali To be done once per Lab Weigh IS:2386 -do- Test will be carried out
Reactivity source Test balance Part VII, while establishing mix
IS:383 design
1.7 Flakiness To be done once per -do- - IS:2386 -do- -do-
source Part-I,
IS:2386
Part VII,
IS : 383

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test

Page 39 of 378

1.8 Bulk Density One Sample per 200 m3 Oven, Jar & IS:2386 -do- -do-
or part thereof Weigh
balance
2.0 FINE AGGREGATE
2.1 Bulkage One sample per 20M3 (or Routin Oven, Jar IS : 2386 -do- Mandatory Site Test.
Moisture part thereof) e and weigh Part-III, Volume of sand and
Measu balance IS : 383 weight of water shall be
rement adjusted as bulkage &
moisture contents.
2.2 Sieve Analysis For Industrial Projects. Routin Sieve Set, IS : 2386 As per L - 03 -do- Mandatory Site Test.
One sample per 200 e Weigh Part-I, IS : requirement of
m3(or part thereof) or balance 383 design mix
change of source within the limits
whichever is earlier. specified in
For Building Project. relevant IS
One sample per 40 M3 (or Codes
part thereof)
2.3 Particle Size To be done once per Routin -do- IS : 2386 Particle size -do- To be carried out during
and Shape source and to be repeated e Part-I, IS : shall be mix design.
if source is changed 383 maximum 4.75

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

Page 40 of 378

Description ment
of test
mm. Grading
shall be within
the limits of
grading zone -
III for concrete
work and for
mortar and
grout within the
limits of grading
zone III & IV.
2.4 Deleterious -do- -do- Balance, IS : 2386 -do- To be carried out during
Chemicals sieve & Part-III, mix design.
Container IS : 383
2.5 Soundness -do- -do- Sieve, IS : 2386 - -do- To be carried out during
Scales & Part-V, IS mix design.
Drying : 383 ( for
Oven acceptanc
e limit)

Page 41 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test
2.6 Acid and Alkali To be done once per -do- Weigh IS : 2386 - -do- To be carried out during
Reactivity source and to be repeated Balance Part-VII, mix design.
if source is changed IS : 383
2.7 Mortar Making -do- Compressio IS : 2386 - -do- To be carried out during
Properties n testing Part-VI, IS mix design.
machine, : 383
7.06 cm
cube
moulds
2.8 Petrographic -do- Visual/ - IS : 2386 -
Examination Physic Part-VI, IS
including visual al : 383 ( for
inspection acceptanc
e limit)
2.9 Specific Once in 12 weeks, change Measu Weigh IS : 2386 These tests will be
Gravity, of source whichever is rement Balance Part-III carried out while
Density, Voids earlier establishing design mix.
2.10 Check Silt and Every 20M3 (or part Measu Jar & Oven IS : 2386 Deleterious - Mandatory Site Test
Clay Content thereof) rement Part-II, IS material not to
: 383 exceed 5%

Page 42 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test
3.0 LIME
3.1 Chemical and Every 10 MT (or part Labora IS: 6932 -do- Optional Test if
Physical thereof) tory (Part I to required.
Properties Test X)
4.0 CEMENT
4.1 Fineness For each consignment of Labora IS : 4031, Manufactur Manufacturer’s
100T (or part thereof). tory IS : 269, er/ certificate to be
Test IS : 1489, Package furnished.
IS : 455 Contractor
4.2 Normal -do- Labora Vicat IS : 4031, Manufactur -do-
consistency tory needle IS : 269, er/
Test IS : 1489, Package
IS : 456 Contractor

Page 43 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test
4.3 Initial and -do- Labora Vicat IS : 4031, Depending on Manufactur -do-
Final setting tory needle IS : 269, the type of er/
Test IS : 1489, cement and as Package
IS : 457 per relevant IS Contractor
4.4 Soundness, -do- Labora IS : 4031, Manufactur -do-
Specific tory IS : 269, er/
Gravity Test IS : 1489, Package
IS : 458 Contractor
4.5 Compressive Every fortnight for each Measu Compressio IS : 4031, Depending on Package Mandatory Site Test
Strength consignment. rement n Testing IS : 269, the type of Contractor
Machine IS : 1489, cement and as
IS : 459 per relevant IS
5.0 CONCRETE

Page 44 of 378

5.1 Workability, Once a day for each Measu IS : 456, Degree of Package Mandatory Site Test
Slump test batching/ mixing plant rement IS : 1199, workability Contractor
and Client’s adopted
compaction specificati depending on
factor test on the type of
structure and
type of

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test
compaction
equipment.
5.2 Crushing One set of 6 cubes of 150 Measu Compressio IS : 516, Shall be as per Package Three specimens shall
Strength cm. Size per 35 Cum. of rement n Test IS : 1199, IS: 456 Contractor be tested at 7 days and
concrete or part thereof Machine IS : 416 remaining at 28 days.
for each grade of concrete and Mandatory Site Test.
per 8 hours of work or Client’s
portion thereof. specificati
on
5.3 Water Cement At random at the time of Measu Visual As per Package
Ratio batching rement observation approved Contractor
design mix

Page 45 of 378

5.4 Check cement -do- Measu IS : 3025, Package

content rement IS : 456 Contractor
/ by and
weigh approved
batche design
r mix.
6.0 WATER

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test
6.1 Tests for Once for each source of -do- Lab Test IS : 3026 Package During mix design stage
ascertaining supply and Soil Contractor
limits of solid investigati
on record.
6.2 Test of pH -do- -do- PH meter IS : 456 PH value shall Site log -do-
value be less than 6. book
7.0 BRICK

Page 46 of 378

7.1 Compressive For designation 100, Compr Compressio IS: 1077 As per brick Mandatory Site Test
Strength Every 50,000 or part essive n Testing designation.
thereof. strengt Machine
For designation up to 75, h
Every 100,000 or part
thereof.
7.2 Shape, Size, -do- Visual IS: 3495 Mandatory Site Test
Colour &
measu
rement
for
size.

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test

Page 47 of 378

7.3 Water One test for each source Routin IS: 3495 Water Mandatory Site Test
absorption and of manufacturer and every e absorption: a)
efflorescence lot of 200,000. after 24 hours
not less than
20% by weight
b) after 6 hours
not less than
10% by weight.
c) moderate
degree of
efflorescence
8.0 REINFORCEMENT STEEL
8.1 Tensile Every 20T or every Measu Universal IS: 1599 Manufactur Manufacturer test
Strength consignment purchased rement Testing er/ certificate must be
by Package Contractor Machine Package submitted
Contractor
8.2 Bend Strength -do- -do- -do- -do- -do-

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test

Page 48 of 378

8.3 Surface Random Visual Visual

cracks, Rusts
etc.
9.0 TIMBER
9.1 Moisture Every 1M3 or part thereof Measu Moisture Package Mandatory Test
Content rement meter Contractor
10.0 FLUSH DOOR SHUTTER
10.1 End N = Total No of Shutters Destru At IS: 2202 Package Mandatory Test
Immersion 1 Shutter for N<=65 ctive approved Contractor
10.2 Knife Test 2 Shutters for Test test house
10.3 Adhesion Test 65<N<=180
3 Shutters for
180<N<=300
4 Shutters for 300<
N<=500
5 Shutters for N>=501
11.0 ALUMINIUM DOORS/ WINDOW FITTINGS
11.1 Thickness of Cost of fittings of every Measu At IS: 5523 Package Mandatory Test
Anodic Coating Rs.20,000/- or part rement approved Contractor
thereof test house

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test

Page 49 of 378

12.0 MARBLE
12.1 Moisture For value of every Measu IS: 1124 Package Mandatory Test
absorption Rs.10,000/- or part rement Contractor
thereof
12.2 Mhose Scale Optional Test
hardness
13.0 TERRAZO TILES
13.1 Transverse Every 2000 tiles or part Site IS: 1237 Package MandatoryTest
Strength thereof Measu Contractor
rement
13.2 Water -do- Site -do- -do- -do-
absorption Measu
rement
13.3 Abrasion Test -do- Labora -do- -do- -do-
tory
Test
14.0 WHITE GLAZED TILES
14.1 Water Every 3000 tiles or part Measu IS: 777 Package Mandatory Test
absorption thereof rement Contractor
14.2 Crazing Test -do- -do- -do- -do- -do- -do- -do- -do-

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

Page 50 of 378

Description ment
of test
14.2 Impact Test -do- -do- -do- -do- -do- -do- -do- Optional Test
15.0 MORTICE LOCK
15.1 Testing of Every 100 locks or part Measu Approved Package Mandatory Test
springs thereof rement Test House Contractor
16.0 BITUMEN
IS: 73
17.0 STORAGE OF MATERIALS

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

Page 51 of 378

Description ment
of test
17.1 Cement 100% Visual IS: 4082 Covered

storage.
・ Clear gap of
min. 15cm
from the
floor.
・ Space of
min. 45cm
around the
exterior
wall.
・ Stacking not
more than
15 bags
high
arranged
alternately
lengthwise
and
crosswise.

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

Page 52 of 378

Description ment
of test
・
Width of the
stack shall not
be more than 3
meters
17.2 Reinforcement 100% Visual IS: 4082 Open storage.
・ Bars of
different
classification
, sizes and
length will
be stacked
separately.

Page 53 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test
17.3 Brick 100% Visual IS: 4082 Open storage.

・ Bricks shall
be stacked
on dry firm
ground.
・ Stacks shall
be 50 bricks
long and 10
bricks high.
・ Bricks shall
be placed on
edge.
・ Width of
each stack
shall be two
bricks.

Page 54 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test
17.4 Aggregates 100% Visual IS: 4082 ・ Shall be

stored at
site on a dry
ground/
platform of
planks/ old
corrugated
iron sheets/
floor of
bricks/ thin
layer of lean
concrete.
・ Stacks of
fine
aggregate
and coarse
aggregate
shall kept in
separate
stockpiles.

Page 55 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test
17.5 Other Bought 100% Visual IS: 4082 Covered

Out Items storage.
Materials shall
be stored as per
manufacturer's
specification.
18.0 PILING
18.1 PLANT & MACHINERY

Page 56 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test
・ Concrete Visual/
mixer Physical
・ Vibrators
of
adequate
capacity
・ Power
driven rigs
of
adequate
capacity
・ Weigh
Batchers
・ Lighting
・ Mobile
Cranes
19.0 CONSTRUCTION OF PILE
19.1 SPT values 100%
during boring
operation

Page 57 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test
19.2 Tolerances in 100% Measu Measuring IS: 2911 Piles <600mm: Piling
position rement Tape (Part I/ 75mm or D/4 Contractor
Sec2) whichever is
less.
Piles >600mm:
75mm or D/10
whichever is
more.
For single pile:
<600mm:
50mm or D/4
whichever is
less.
>600mm:
100mm.
19.3 Control of 100% Measu Measuring IS: 2911 Vertical pile:
alignment rement Tape (Part I/ 1.5 % deviation
Sec2) maximum.
Raker pile: 4%

Page 58 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test
19.4 Chipping of 100% Manual

pile top chipping after 3
days of casting.
Pneumatic tools
after 7 days of
casting.
20.0 BENTONITE SUSPENSION:
20.1 Liquid limit Measu >300% Piling
rement <400% Contractor
20.2 Sand content -do- Not more than -do-
of Bentonite 7%
powder
20.3 Density of -do- Hydrometer IS:9556 Between 1.034 -do- Shall be recorded for
freshly and 1.10gm/ initial 10 piles and
prepared ml. subsequently at every
Bentonite 10th pile.
suspension
20.4 Marsh -do- Marsh cone Between 30 -do-
viscosity and 60 sec

Page 59 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test
20.5 PH value of -do- PH Between 9 and -do-

Bentonite indicator 11.5
suspension paper strip
20.6 Density after -do- Hydrometer Maximum. -do- Shall be recorded for
mixing with 1.25gm/ ml. initial 10 piles and
deleterious subsequently at every
material 10th pile.
21.0 PILE TESTING

Page 60 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test
21.1 Vertical Load Test pile. No of pile to be Testin Dial Gauge IS:2911, Safe load shall Piling
Test ( for tested shall be minimum g (Sensitivity Part-IV be minimum of contractor
both test & job one. of dial the following:
piles ) gauge : (a)2/3rd of final
0.01 mm ) load against
total
displacement of
12 mm. (b)
50% of final
load against
total
displacement of
10% of pile
diameter.

Page 61 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test
Working pile. No of piles -do- -do- -do- Maximum -do-

to be tested shall be settlement shall
minimum 1/2 % of total not exceed 12
no of piles. mm against
test load 150%
of working
load.

Page 62 of 378

21.2 Lateral load Optional Testin -do- IS:2911, Safe load shall -do-
Test g Part-IV be minimum of
the following:
(a) 50% of the
final load
against total
displacement of
12 mm. (b)
Final load
against total
displacement of
5 mm

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
Description ment
of test

Page 63 of 378

21.3 Pull out Test Optional Testin -do- IS:2911, Safe load shall -do- Initial test shall be
g Part-IV be least of the carried out up to twice
following: the estimated safe load.
(a) 2/3rd of
total load Routine test shall be
against carried out to 150% of
displacement of the estimated safe load
12mm. or 12mm total
(b) Half of the displacement.
load at which
load
displacement
curve breaks

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
ANNEXURE - 2 TESTING EQIPMENT FOR SITES
SL BROAD CLASS NOMENCLATURE UTILITY TEST PROCEDURE REFERENCE TO BE AVAILABLE
NO DESCRIPTION DOCUMENT AT SITE
1.0 ROUTINE TEST 1.1 Vicat Apparatus Cement consistency & Penetration of Std. Needle IS : 5513 Yes
Penetration

Page 64 of 378

LAB. EQUIPMENT 1.2 Lechatelier’s test Cement shrinkage Size variation after curing IS : 5514 Yes
Apparatus of sample
1.3 Mould ( Cement) Cement cubes Cubes made of 1:3 cement IS : 10086 Yes
(70.7x70.7x70.7 mm) : Sand
1.4 Cement Mortar Mould Cube compaction Vibration for fixed IS : 10078 Yes
Vibrator duration
1.5 Concrete Cube mould ( Concrete Cubes - IS : 10086 Yes
150x150x150) mm
1.6 Compressive strength Concrete Cube Test Crushing strength of cube IS : 2505 Yes
Testing machine
1.7 Concrete slump cone Workability Check Drop in cone height of IS : 7320 Yes
concrete
1.8 Coarse aggregate sieves Sieve analysis Sieving IS : 383 Yes
1.9 (a) Soil Core cutter To test compaction of soil Core cut out of soil and IS : 2720 Yes
(b) Proctor Compaction density measured
1.10 Fine aggregate sieves Sieve analysis Sieving IS : 383 Yes
1.11 Sieve shaker Mechanical sieving - - Yes
1.12 Aggregate impact Test Impact value of aggregate - IS : 9377 Yes
Machine
2.0 DIMENSIONAL & 2.1 Theodolite & levelling Levelling and centre line Measurement and - Yes
ALLIED staff marking and verticality recording
MEASURING measurement
EQUIPMENT 2.2 Measuring Tape Dimension - - Yes
J PRABHAKAR AGM (Civil) P.Sivanandam DGM (Civil) K.N.Raju DGM I/c (Civil) MEC/05/11/QA&QC/SQP -02 - R0

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
ANNEXURE - 2 TESTING EQIPMENT FOR SITES
SL BROAD CLASS NOMENCLATURE UTILITY TEST PROCEDURE REFERENCE TO BE AVAILABLE

NO DESCRIPTION DOCUMENT AT SITE

Page 65 of 378

2.3 Laser Beam apparatus Verticality of structures Centre line alignment - Yes
3.0 PROCESS 3.1 Oven Material Drying for moisture Material to be kept for - Yes
CONTROL control specific duration
ACCESSORIES 3.2 Physical balance Weighing - - Yes
3.3 Air entrainment meter To determine % of air in fresh Samples of fresh concrete IS : 1199 Yes
concrete mix to be taken and tested in
the equipment
4.0 SPECIAL TEST NDT Strength test of concrete Rebound of the ball is - Yes
EQUIPMENT 4.1 Rebound hammer proportional to the strength
of concrete
4.2 Ultrasonic test for concrete Test for porosity for concrete Speed of the ray - Yes
transmitted through the
concrete indicates the
extend of porosity
4.3 Profometer/Micro Location & diameter of Variation in density used to - Yes
covermeter reinforcement detect steel location
D.T. Strength of In-situ concrete Core cut out of concrete - Yes
4.4 Portable electrically tested for strength
operated concrete core
cutter

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
ANNEXURE - 3 WORKMANSHIP CHECKS FOR DIFFERENT SITE ACTIVITIES
SL. Description of Workmanship Checks to be undertaken Remarks

No Site Activity

Page 66 of 378

1 Earth work (a) Classification of Soil, for payments, if required.

(b) Line & level.
(c) Disposal lead.
(d) Levelling at Disposal Yard.
(e) Initial & Final level in Level Book.
(f) Rolling/Tamping/Compaction of Fills, as per IS : 2720
(g) Arrangement for de-watering.
(h) Shoring & Strutting.
(i) Safety (side slopes, ramps, working space around foundation, dumping
at safe distance beyond top edge).
(j) Excess excavation depth properly filled for foundation works.
(k) Foundation bed level, bearing capacity conformance.
Date of Issue 13-08.2015

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

Page 67 of 378


No Site Activity
2 Piling Work a) Diameter of Pile.

b) Depth Driver.
c) Sequence of driving in a pile group.
d) Set for last 10 blows or as specified.
e) Type and size of hammer and its stroke, in case of double acting
hammer, No. of blows per minute & stroke.
f) Type and condition of packing on the pile head and or dolly in the
hammer.
g) Driving resistance record through variable strata in case of driven cast-
in-situ pile.
h) Bore log in case of Bored pile.
i) Density of slurry in case of Bentonite slurry pile.
j) Date & time of driving.
k) Date of concreting & time gap between end of driving & concreting.

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

Page 68 of 378


No Site Activity
l) Standing ground water level.

m) Ground level at the commencement.
n) Length of Pile.
o) Length of Permanent casing.
p) Set at intervals during last 3 Metres.
q) Concrete Mix.
r) Details of Reinforcement.
s) Volume of Concrete supplied to pile against theoretical volume.
t) Water tightness of pile before concreting.
u) Eccentricity
v) Deviation for Verticality.
w) Condition of pile head at cut-off.
x) Routine load test results.
y) Initial load test results.
z) Integrity test results of each pile.

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

Page 69 of 378


No Site Activity
3 Concreting (a) Check quality and size of coarse aggregate with special reference to
Works undersize/oversize materials, disintegrated/self materials, earth and
other foreign materials beyond limit, organic impurities.
(b) Fineness modulus of sand, silt content, bulkage, foreign materials in
sand.
(c) Check formwork.
(d) Line, level of concrete.
(e) Honeycombed surface in concrete.
(f) Strength of Concrete.
(g) Check Mix Boxes.
(h) Mixing of concrete by hand/machine.
(i) Use of Vibrator.
(j) Slump of concrete.

Page 70 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

No Site Activity
4 Formwork a) Line, level and dimensions as per drawing.

b) Cross bracing of supporting framework.
c) Diagonal bracings.
d) Ground support rigidity to avoid settlement.
e) Plumbness of shores.
f) Wedge tightening of shores.
g) Thickness of shutter to withstand pressure of wet concrete.
h) Leakproofness of shutter ( IS : 457 )
i) Demoulding agent/Oiling of shutter.
j) Facility for removal of formwork in proper sequence.
k) Avoid premature removal.

Page 71 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

No Site Activity
5 Reinforced a) Sieve analysis of coarse aggregate to check oversize, undersize,

Concrete improperly graded aggregate.
Works b) Check presence of disintegrated/soft or foreign materials in aggregates.
c) Quality of sand, Silt content, Bulkage test.
d) Quality of Cement and age of Cement ( 1st in 1st OUT system )
e) Quality of water for mixing and curing.
f) Slump test.
g) Cube Tests.
h) Cover Block thickness and integrity (cover not reduced more than 2mm
or increased by more than 10mm).
i) Whether reinforcement exposed on removal of forms.
j) Tensile testing of steel reinforcement, as required.
k) Gauge of binding wire and its use at all joints.
l) Reinforcement placement as per drawing and top reinforcement to be
supported by chairs etc.

Page 72 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

No Site Activity
m) Spacing of laps and staggering and length of lap.

n) Mix design record/requirements.
o) Rigidity and evenness of centring & shuttering.
p) Finish requirement of surface.
q) Throating and moulding requirements as per drawings.
r) Line and level requirements as per drawing.
s) Expansion joint contraction, joint provisions.
t) Fixing of inserts, conduits, bolts to proper alignment.
u) Hacking of green concrete for future plastering.
v) Adequate curing.
w) Corrosion protection requirements of reinforcement.
x) Drainage provisions on roof surface ( slope & spout )
y) Gangway placement for concreting to be independent of
reinforcement.
z) Rigidity of reinforcement cage to avoid distortion during concreting

Page 73 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

No Site Activity

Page 74 of 378

aa) Compaction requirements of concrete by needle vibrators/Form

vibrator etc.
bb) Provisions at construction joint - Waterbar - Nozzles etc.
cc) Provision of dowel bars 12mm  300 long ( 400mm either side ) at 250
C/C on construction joint surface.

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

No Site Activity

Page 75 of 378

6 Brickwork (a) Quality of bricks for strength, dimensional accuracy, efflorescence

water absorption and evenness of backing.
(b) Sand quality for fineness modulus and Silt content.
(c) Cement quality.
(d) Mixing of Mortar to structural space.
(e) Thickness of joint not exceeding 10mm.
(f) Raking of joints in green stage by raking tool ( 15mm deep )
(g) Filling of vertical joints properly.
(h) Soaking of bricks.
(i) Line and level of brickwork.
(j) Plumbness.
(k) Brick corners are provided with proper brick closer not by brick bat.
(l) Top coarse in plinth, windowsill, below RC slab and parapets are with
brick on edge.

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

Page 76 of 378


No Site Activity
(m) Type of scaffolding.

(n) Filling of scaffolding potholes.
(o) Brick coarses are in level.
(p) Proper bonding of main wall with cross wall ( No toothing joints )
(q) Brickwork taken-up in layers not exceeding 1 Metre.
(r) Proper provision of reinforcement in brick-wall.
(s) Lateral bonding of brick-wall to steel/concrete columns.
(t) Filling-up voids between brick -wall and door/windows shutter.
(u) Adequate curing of brickwork.

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

Page 77 of 378


No Site Activity
7 Stone (a) Quality of stone.

Masonary (b) Strength of Mortar.
Work
(c) Mix of Mortar.
(d) Quality of Sand - Silt content & fineness modulus.
(e) Whether joints fully filled with Mortar.
(f) Whether required number of bond stones provided (Marking of bond
stone during construction needed for easy identification ).
(g) Extent of spalls in hearting.
(h) Line, Level, Thickness.
(i) Joint thickness ( whether excessive thick )
J PRABHAKAR AGM (Civil) P.Sivanandam DGM (Civil) K.N.Raju, DGM I/c (Civil) MEC/05/11/QA&QC/SQP -03 - R0

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

Page 78 of 378


No Site Activity
8 Flooring Work
8.1 Cement (a) Aggregates, Sand - refer PCC Works.
Concrete Floor (b) Strength.
(c) Thickness.
(d) Hardener type and mix.
(e) Panel size.
(f) Curing arrangement.
(g) Polishing requirement.

Page 79 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

No Site Activity
8.2 Cast in situ a) Aggregates, Sand - refer PCC Works.

Mosaic Floor b) Strength.
c) Thickness.
d) Hardener type and mix.
e) Panel size.
f) Curing arrangement.
g) Polishing requirement.

Page 80 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

No Site Activity
8.3 Terrazzo Tile (a) Quality of Lime.

Floor (b) Strength test of tile.
(c) Abrasion test of tile.
(d) Thickness of Joint & Colour matching.
(e) Polishing by 80, 120, 320 Grade Carborandum.
(f) Any hollow sound when tapped.
(g) Curing arrangement.
8.4 Glazed Tile (a) Size of Tile

Floor (b) Thickness of Tile ( ・ 0.5 mm )
(c) No glazed surface at edges.
(d) Free from crazing.

Page 81 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

No Site Activity
9 Woodwork a) Specified timber is used.

b) Grade of Wood.
c) Free from cracks, dead knots etc. as per grade specification.
d) Seasoning done or not.
e) Moisture content by moisture meter.
f) Lines, level and smoothness of finish & planning.
g) Glue utilised in joints or not and whether bamboo pin (min. 10mm dia.)
used in joint.
h) Tolerance of finished size.
i) Use of preservative against masonry surface.
j) Size of Holdfasts as per Specification.
k) Thickness and dimension of shutter in door panels.
l) Thickness of glass panels and quality of glass.
m) Whether Putty provided between glass-pane and sash bar & glass pane
and beading (No rattling sound when tapped).

Page 82 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

No Site Activity
n) Whether healing in flush door is of specified type solid core, hollow,

particle board etc.
o) Quality of Ply and Glue in flush door (Not Urea formaldehyde).
p) Destruction test of flush door (End emersion, Knife test etc.)
q) Fitting quality and number as per Specification.
r) Surfacing of steel fittings as per specification (bright, black Japan, black
enamelled, oxidised) and plate thickness.
s) Anodising thickness of aluminium fittings.
t) Type of brass fittings (Extruded/Cast) with plate thickness.
u) Check whether top & bottom surface of shutter properly painted or
note.
v) Painting of shutter to be done after checking of Knots etc.
w) Provision of Chits and Sand blocks.
x) Quality of Mesh in meshed shutter (No. of mesh/Sq.inch. ) and folding
of mesh at the edges before fixing.
J PRABHAKAR AGM (Civil) P.Sivanandam DGM (Civil) K.N.Raju, DGM I/c (Civil) MEC/05/11/QA&QC/SQP -03 R0

Page 83 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

No Site Activity
10. Steel doors
/Windows a) Size of frame and corner welding of frames ( Flush butt welded as per
/grills
specification )
b) Proper fixing of Hinge.
c) Primer Coating.
d) Provision of Tie Rod at bottom of Door frame for proper size
maintenance during fixing.
e) Line, Level & Plumb.
f) Quality of friction hinges.
g) Quantity of Putty ( ・185 Gm. Per Meter length ) and painting of Putty
within 2 weeks.
h) Number of glazing Clips ( 4 to 6 ).
i) Provision of metal beadings as per specification.
j) Material of striking plate in windows (brass or not as per specification )
k) Welding of grill before fixing glazing without deformation of frame.
l) Length of screws for fixing grills to windows frames.

Page 84 of 378

Prepared by Checked by Approved by QUALITY ASSURANCE PLAN NO.

J.PRABHAKAR,AGM(Civil) P.Sivanandam (Civil) K.N.Raju, DGM I/c(Civil) MEC/05/11/QA&QC/SOP-03-R0
Date of issue:13.08.2015

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

No Site Activity
11. Painting work
(a) Name of Manufacturer, Specification, Batch Number, Colour, Date of
Manufacture, ISI Marking on Paint Contai
(b) Cracks, voids, pores on masonry surface properly filled.
(c) Nail-holes, cracks on wood surface properly filled.
(d) Steel surface preparation, sand blasting, derusting etc. as per
Specification.
(e) Soundness and adherence of Old Paint.
(f) Paint quality ( No. adulteration by thinner ) and quality of Primer.
(g) Application of each coat of Paint for uniformity, paint drop, dabs,
brush-marks, waves and variation of colour.
(h) Difficult to reach areas like edges, corners, nuts, bolts etc. are
properly painted.
(i) Spilled Paints on floors & walls properly cleaned.
(j) Painting of fan hooks and exposed surfaces of inserts as per
Specification.

Page 85 of 378

Prepared by Checked by Approved by QUALITY ASSURANCE PLAN NO.

J.PRABHAKAR,AGM(Civil) P.Sivanandam (Civil) K.N.Raju, DGM I/c(Civil) MEC/05/11/QA&QC/SOP-03-R0
Date of issue:13.08.2015

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
No Site Activity
12 Roofing Works (a) Slope of roof.
(b) Quality of Lime, Waterproofing materials etc. as per Specification.
(c) Size & quality of brick ballast.
(d) Weight & quality of bitumen felt.
(e) Over-lapping of bitumen felts.
(f) Test by ponding with water.
(g) Formation of ridges & valleys.
(h) Drip course provision.
(i) Embedding of felt at vertical wall.
(j) Hollering at the vertical turning point below felt.
(k) Grouting of rainwater pipe.
(l) Proper termination of Tarfelt near RWP.

Page 86 of 378


MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

No Site Activity

Page 87 of 378

13 Water Supply (a) Quality of G.I. Pipe with original colour paint for class of pipe and IS Mark on
& Sanitary surface of pipe.
works
(b) Joining of pipe with white lead and jute yarn on threads.
(c) Pipes are approachable for future maintenance.
(d) Provision of union at each Stop Cock.
(e) Supporting pipes with clamps suitably embedded & jammed in wall
(f) Quality/Weight of water-tap, Stop Cocks, Ball Valves and Water Supply fittings
as per Specification and ISI Mark.
(g) Provision of Vent. Pipe above Overhead Tank to avoid Airlock.

(h) Leading over-flow pipe from Tank upto roof drain spout.
(i) Mosquitoproof cemplings at over flow pipe of Tank & Cisterns.
(j) Quantity of lead provided at Spigot & Socket joints of pipes.
(k) Internal surface of HCI Pipes to have painting with Dr. Angus Smith Solution.
(l) Hydraulic testing of Water Supply system.
J PRABHAKAR AGM (Civil)) P.Sivanandam DGM (Civil) K.N.Raju, DGM I/c (Civil) MEC/05/11/QA&QC/SQP -03 - R0

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)

No Site Activity

Page 88 of 378

(m) Proper quality HCI Pipes used (Dimension, Weight, Finish, ISI Marks etc.) in
Sewage System ( C.I. Rain-water pipes ) are not used in Sewage System.
(n) Flushing test of flushing Cistern.

(o) Hume Pipe Class, makes, dimension and test certificate.
(p) Stone ware pipe make, dimension, finish, glazing and conforming to Class
AA/Class A as per Specification.
(q) Quality of Line and level of system.

(r) Floor tap water-seal to be minimum as per Specification.
(s) Manhole covers, road gully groutings weight, sizes, make & finish.
(t) Commercial quality ceramic fittings are not used.
(u) Brand name, quality, dimension, colour, ISI marking for sanitary fixtures as
per Specification.
(v) Static head water test for HCI Pipe in section ( 4.5 Metres )
(w) Test Performance for Water closets ( six pieces of toilet papers 150 x
115mm flushed completely 3 times out of 4 trials )
Water supply network tested to a pressure of 10 Kg/Cm2 before taking over
the system.

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
ANNEXURE - 4 FORMATS FOR SITE RECORDS
FORMAT NO.L -01
DETERMINING THE GRADING OF SAND (FINAL AGGREGATE)

Page 89 of 378

Date of Testing: Type of aggregate PERCENTAGE REMARKS

Wt. Of samples: gms. PASSING (GRADING ZONE)
SI.NO. RETAINED ON WT.RETAINED PERCENTAGE WT. CUMULATIVE

IS SEIVE NO. . RETAINED %WT. RETAINED
1 10 mm
2 4.74 mm
3 2.36 mm
4 1.18 mm
5 600 microns
6 300 microns
7 150 microns
8 75 microns
REFERENCE GRADING ZONES OF FINAL AGGREGATE (IS 383)

IS SEIVE DESIGNATION GRADING ZONE I GRADING ZONE II GRADING ZONE III GRADING ZONE IV
10mm 100 100 100 100
4.75 mm 90-100 90-100 90-100 95-100
2.36 mm 60-95 75-100 85-100 95-100
1.18 mm 30-70 55-90 75-100 90-100
600 microns 15-34 35-59 60-79 80-100
300 microns 5-20 8-30 12-40 15-50
150 microns 0-10 0-10 0-10 0-15
J PRABHAKAR AGM (Civil) P.Sivanandam DGM (Civil) K.N.Raju, DGM I/c (Civil) MEC/05/11/QA&QC/SQP -04 -
R0

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
FORMAT NO.L-02

Page 90 of 378

METHODS OF DETERMINING THE GRADE OF COARSE AGGREGATE
Date of Testing: Type of aggregate PERCENTAGE REMARKS

Wt. Of samples: gms. PASSING (GRADING ZONE)
SI.NO. RETAINED ON WT.RETAINED PERCENTAGE WT. CUMULATIVE

IS SEIVE NO. . RETAINED %WT. RETAINED
1 40 mm
2 20 mm
3 16 mm
4 12.5 mm
5 10 mm
6 4.75 mm
7 2.36 mm
GRADING ZONES OF COARSE AGGREGATE (IS 383)

IS SEIVE DESIGNATION 40 mm 20 mm 16 mm 12.5 mm
40 mm 95-100 100 - -
20 mm 30-70 95-100 100 100
16 mm - - 90-100 -
12.5 mm - - - 90-100
10 mm 10-35 25-55 30-70 40-85
4.75 mm 0-5 0-10 0-10 0-10
2.36 mm - - - -
J PRABHAKAR AGM (Civil) P.Sivanandam DGM (Civil) K.N.Raju, DGM I/c (Civil) MEC/05/11/QA&QC/SQP -04 -
R0

MECON LIMITED
& QUALITY CONTROL
(SITE QUALITY PLAN)
FORMAT NO.L-03

Page 91 of 378

DATE :
COMPRESSIVE STRENGTH OF CEMENT CONCRETE
AGENCY :
LOCATIONS :
CUBE SIZE :
DATE OF CAST :
TYPE OF CEMENT :
GRADE OF CONCRETE :
WATER/ CEMENT RATIO :
ADDITION OF PLASTICISER :
WEIGHT OF CUBE :
CUBE TEST 7 DAYS STRENGTH
28 DAYS STRENGTH
SL. NO MARK DATE SLUMP FAILURE STRENGTH FAILURE STRENGTH
LOAD (KN) (Kg/Cm2) LOAD (KN) (Kg/Cm2)
1
2
3
4
5
6
PERIOD SPECIFICATION ACTUAL (AVERAGE)
7 DAYS Kg/Cm2 Kg/Cm2
28 DAYS Kg/Cm2 Kg/Cm2

Page 92 of 378

GAIL GAS LIMITED
COMPOSITE WORKS FOR CONSTRUCTION OF CNG
COCO STATIONS & CNG STATIONS IN OMC/ROS

TECHNICAL SPECIFICATION FOR
STEEL STRUCTURAL WORKS
FOR
SPECIFICATION
FOR FABRICATION, ERECTION AND PAINTING
OF
STEEL STRUCTURES
NO-MEC/23QQ/01/12/S2/CN/ST/0301/R00
MECON LIMITED
BANGALORE
Contents

GENERAL ....................................................................................................................................

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GAIL GAS LIMITED

SECTION-1 FABRICATION OF STEEL STRUCTURES .....................................................

SECTION 2 ERECTION OF STEEL STRUCTURE .................................................................
SECTION-3 PAINTING OF STEEL STRUCTURES .............................................................
ANNEXURE-A ............................................................................................................................
ANNEXURE –B ...........................................................................................................................
ANNEXURE – C ..........................................................................................................................
ANNEXURE – D..........................................................................................................................
ANNEXURE – E ..........................................................................................................................
ANNEXURE - F ...........................................................................................................................

1.0 GENERAL
1.1 This specification shall apply to steelwork in Canopy Structures and general structural
works for the following Units :
Sl.no. Part of the Scope of work

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GAIL GAS LIMITED

CNG station
1. Part A i. CNG COCO station at KIADB land, Software park.
ii. 3(THREE) nos of CNG COCO stations at other locations

& CCTV system for 1 no. of existing CNG station.
iii. 2(TWO) nos. of CNG stations in OMC/DODO ROs.
2. Part B i. 3(THREE) nos of CNG COCO stations & CCTV system

for 1 no. of existing CNG station.
ii. 9(NINE) nos. of CNG stations in OMC ROs
3. Part C i. 3(THREE) nos of CNG COCO stations & CCTV system

for 1 no. of existing CNG station.
ii. 9 (NINE) nos. of CNG stations in OMC/DODO ROs

The locations will be intimated to the successful bidder after award of contract.
SECTION‐1 FABRICATION OF STEEL STRUCTURES

2.0 SCOPE OF WORK
2.1 The scope of work under fabrication includes, but not limited to, the following:

Page 95 of 378

GAIL GAS LIMITED

a) Preparation and submission of material indents, bolt lists and bought-out items list.
b) Procurement and Supply of Colour coated sheets for structures including packing,
loading, transportation, unloading, stacking & storing on skids or supports at site.
d) Procurement and supply of all consumables like bolts nuts, hooks, Polycoated hook
bolts, washers, electrodes, paints, shims, packs, etc., taking into consideration
allowance for spares and wastage.
e) Preparation and submission of fabrication drawings ( based on MECON Design

drawings ) assembly drawings for sheeting, modification / rectification sketches,
erection drawings, as-built drawings, bill of materials, bolts lists and shipping
documents for approval of purchaser.
f) Submission of design calculation for non-standard connections, temporary bracings

etc. for approval of purchaser.
g) Cold straightening of section and plates, whenever they are bent and kinked.
h) Fabrication of all steel structural components covered under design drawings

including M S, G I Gratings are generally described under the scope of the project.
i) Making arrangements for and conducting tests, such as chemical analysis, physical
and mechanical tests on raw materials where specified/as directed by the
Purchaser/Consultant. The scope of testing includes conducting tests at shop as
well as at site in line with the instruction of Purchaser/Consultant.
j) Making arrangements for providing all facilities for conducting ultrasonic, X-ray or
gamma ray tests of welds, getting the tests conducted by reputed testing
laboratories making available test films / graphs, reports and interpretation. The
scope of testing includes conducting tests at shop as well as at site in line with the
instruction of Purchaser/Consultant.
k) Controlled Assembly of steel structural components at shop, wherever required.
l) Preparation of steel structural surfaces for painting as provided in the specifications

/ drawings.
m) Application for one primer coat of painting at shop, as specified in the design
drawing/specifications.
n) Loading, transportation from fabrication workshop to site of erection and unloading

of all steel structural components / units / assemblies, Colour coated sheets, FRP
sheets and their erection complete with all fittings and fixtures.

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GAIL GAS LIMITED

o) Receipt of free issue items if any from Purchaser’s place, handling and unloading at
site and fabrication/erection.
p) Dismantling wherever required and disposal of debris at a place designated by

Purchaser or re-erection of the same as instructed by Purchaser.
q) Rectification of damaged structures including fixing, aligning, levelling, bolting and

welding etc.
r) Preparation of "As-built" drawings.
3.0 PREPARATION OF FABRICATION AND ERECTION DRAWINGS
3.1 Fabrication drawings shall be prepared based on MECON design drawings of steel
structures.
3.2 Drawing shall be prepared in metric system as per IS:696-1972 and IS:813-1986.
The fabrication drawings shall specify the following details:-
(a) Type, size and length of welds in case of welded connections,(specifying clearly
shop or site weld). Length of weld specified shall be effective length (excluding
end crates).
(b) In case of bolted joints, arrangement of bolts and specification of bolts, nuts
etc.(specifying clearly shop and site bolts).
(c) Specification of electrode/wire flux.
(d) If required special provision to be mentioned in the drawings for handling of

structures during and after fabrication.
(e) Specification of paint and corresponding surface preparation for painting.
(f) General arrangement/marking plan.
(g) Reference to design drawings.
(h) Material list indicating mark number-wise material requirement giving size, weight,
material specification, identification number of each items, number of pieces
required etc.
(i) Layout with all connecting members with blown up joint details wherever required,
in order to specify clearly various fabrication and erection requirements as per
design drawings.

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GAIL GAS LIMITED

(j) Specification of preparation of mating surfaces in case of connection by HSFG

bolts.
(k) Appropriate edge preparation in case of butt/groove welds in accordance with

IS:9595-1996, for all plates and sections having thickness greater than 8 mm.
(l) Erection clearances in order to facilitate smooth erection at site (ref clause
no.17.2.2.of IS: 800- 2007).
(m) Each erection piece shall be clearly identified by an erection mark in these
drawings. All loose members shall be given part mark, which shall be 'wired on' the
main erection piece for despatch.
3.3 Fabrication drawings shall be prepared in such a manner that structures can be
dispatched from fabrication shop to erection site with maximum economic
transportable size, so as to reduce work involved at site to a minimum.
3.4 Bracings shall be connected for 50% of the capacity of the member or the force
specified in the design drawing, whichever is more.(for single angle bracing
member, consider full area as effective for this purpose).
3.5 Standard simple beam connections, unless otherwise stated in the drawings, shall
be designed and detailed for 60% beam shear / moment carrying capacity.
3.6 Wherever there is risk of nuts becoming loose due to vibration, lock nuts shall be
provided, or nuts shall be welded after alignment and tightening.
3.7 For all connections by permanent bolts, two nos. of washers shall be used. One
washer bearing against the head and the other bearing against the nut.
3.8 Detailing of structural steel members subject to dynamic loading shall be such as to
ensure smooth transition of load, as well as best behaviour under stress due to
fatigue. Welding across tension flange of crane girders is not permitted.
3.9 For detailing connection, the allowable stress for materials, welds, bolts etc, shall
be as per IS:800- 2007 and IS:816-2007, or as specified in the drawing.
3.10 The contractor shall be responsible for design and detailing all connections. The
design of connection shall provide adequate strength for transfer of force in the
structural elements, as indicated on design drawings. Detailing shall be such that
erection shall be convenient and free from all interfaces, drilling and cutting at site.
4.0 MATERIALS
4.1 Structural Steel

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GAIL GAS LIMITED

Structural steel and other related materials for construction shall conform to
ANNEXURE-F.
4.1.2 Due to non-availability of specified materials, suitable substitutions may be provided

with the consent of the purchaser. Such substitution shall be incorporated in the
"As-built" drawings.
4.1.3 All the items are to be cut as per requirements of the drawing. If joints are to be
provided in any item, in order to meet requirements of size and shape, cutting plan
showing locations of joints shall be prepared for consideration of purchaser. Joints
provided shall be incorporated in "As-built" drawings.
4.1.4 Rolling and cutting tolerances shall be as per IS: 1852:1985.
4.1.5 Only tested materials shall be used unless use of untested materials for certain
secondary structural members is permitted by purchaser. If test certificate for the
material is not available from the main producer, the following tests shall be carried
out at the discretion of the purchaser.
(a) Chemical Composition

(b) Mechanical Properties
(c) Weld ability test
4.1.6 Where steel castings are to be used the same shall conform to IS: 1030:1998
4.2 Bolts and Nuts
4.2.1 Black hexagonal bolts, nuts and lock-nuts shall conform to IS:1363(Part1to3):2002
4.2.2 Precision and semi-precision hexagonal bolts, screws, nuts and lock-nuts shall
conform to IS:1364(Part 1 to 6):2002.
4.2.3 High tensile friction grip bolts shall conform to IS:3757:1985 and high strength
structural nuts shall conform to IS:6623:2004, and hardened steel washers to IS:
6649:1985.
4.3 Electrodes
4.3.1 Mild steel electrodes and high tensile steel electrodes shall conform to IS:814:2004.
Electrode to be used for submerged are welding shall conform to specification
IS:7280:1974.
5.0 STORING OF MATERIALS

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5.1 Materials shall be stored and stacked properly ensuring that place is properly
drained and is free from dirt. It shall be ensured that no damage is caused due to
improper stacking.
6.0 MATERIAL PREPARATION
6.1 Cut edges shall be finished smooth by grinding or machining wherever necessary.
Sufficient allowance (3 mm to 5 mm ) should be kept in the items in case machining
is necessary.
6.2 Cutting may be effected by gas cutting, shearing, cropping or sawing. In gas cutting
of high tensile steel, special care is to be taken to leave sufficient metal to be
removed by machining so that all metal that has been hardened by flame is
removed.
6.3 Sufficient shrinkage allowance (@ 1mm/M) shall be kept wherever heavy welding
is involved.
6.4 Straightening and bending shall be done in cold condition as far as practicable.
6.5 If required, straightening and bending may be done by application of heat between
900C and 1100C. Cooling down of the heated item shall be done slowly.
7.0 DRILLING AND PUNCHING OF HOLES
7.1 Drilling and punching of holes for bolts shall be done as per IS:800:2007, unless
otherwise specified by the purchaser.
7.2 Drifting of holes for bolts during assembly shall not cause enlargement of holes
beyond permissible limit or damage the metal.
7.3 Holes for bolted connection should match well to permit easy entry of bolts. Gross
mismatch of holes shall be avoided.
7.4 Permissible deviation in holes for mild steel bolts of normal accuracy and high
strength bolts are given in the ANNEXURE-A.
8.0 ASSEMBLY FOR FABRICATION
8.1 Fabrication of all structural steelwork shall be in accordance with IS:800-2007 and
in conformity with various clauses of this specification, unless otherwise specified in
the drawings.
8.2 Fabrication of structures shall preferably be taken up as per the sequence of

erection.

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8.3 All erection units shall bear erection mark no. and reference drg no. at a prominent
location on the structures for easy identification at site.
8.4 Fabricated structures shall conform to tolerance as specified in this standard and in
IS:7215-1974. In case of contradiction, tolerances specified in this standard shall
prevail.
8.5 All the components of structures shall be free from twist, bend, damage etc,
8.6 Assembly of structures shall be carried out by using suitable jigs and fixtures in
order to obviate distortion during welding.
8.7 Cutting of items specially for truss, bracing, bunker, hopper, galleries surge girder,
portal etc, shall be done only after checking of sizes as per Layout.
8.8 Surface, wherever machining is specified , shall be either planed or milled or

ground to ensure maximum contact.
8.9 If end-milling or machining is planned after the assembly is over, sufficient

allowance (5 mm to 15 mm) shall be kept in the items where milling/machining is to
be done.
8.10 If pre-bending of the plate is required to avoid welding distortion, it shall be done
in cold condition.
8.11 If extra joints are required to be provided in column, crane girder etc, approval
should be obtained from the purchaser. However, as general guidance following is
suggested. Splice joints of column and crane girder shall of full strength butt weld
and wherever possible shall be located at zones of minimum or substantially lesser
stress.
8.12 Splice joints of flange and web should be staggered.
8.13 Sufficient trial assembly of fabricated components (despatch elements) shall be

carried out in the fabrication works to control the accuracy of workmanship.
8.14 Where necessary, washers shall be tapered or otherwise suitably shaped to give
the heads of nuts and bolts satisfactory bearing.
8.15 The threaded portion of each bolt shall project through the nut at least by two
thread.
8.16 Tolerance of assembled components of structures is given in ANNEXURE-B.

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8.17 Permissible deviations from designed (true) geometrical form of the despatch
elements shall be in accordance with IS: 7215-1974.
9.0 WELDING
9.1 The Contractor shall work out welding procedure for Purchaser's approval,
considering the following factors :-
(i) Specification and thickness of steel.
(ii) Specification of electrode or/and base wire.
(iii) Welding process (manual arc welding, submerged arc welding).
(iv) Type of structures to be welded (thickness of components meeting at a

joint).
(v) Pre and post heating requirement.
(vi) Preparation of fusion faces.
(vii) Sequence of welding.
(viii) Weather condition.
(ix) Use of jigs and fixtures etc.
(x) Type of non-destructive testing to be carried out.
(xi) Inspection procedure to be followed
(xii) Design requirements of the joints.
9.2 Welding of any load bearing structure shall be carried out only by the person who
has passed welder's qualification as per IS:7318 (Part-I)-1974.
9.3 All metal arc welding shall be carried out as per IS:9595-1996.
9.4 Submerged arc welding of mild steel and low alloy steel shall be as per
IS:4353-1995.
9.5 Electrode shall conform to IS 814: 2004
9.6 Electrodes shall be stored in a dry place. Electrodes whose coatings are damaged
due to absorption of moisture or due any other reason shall not be used.

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9.7 Low Hydrogen electrodes and flux for submerged welding shall be dried as per
manufacturer’s recommendation at 250-300 C for one hour in drying oven before
use.
9.8 For suitability of wire flux combination, procedure test shall be carried out as per
IS:3613-1974 if so required.
9.9 Welding shall be done by electric arc process. Generally submerged arc, automatic
& Semi-automatic welding shall be employed. Only where it is not practicable,
manual arc welding may be resorted to. In case of manual arc welding,
recommendations of electrode manufacturer is to be strictly followed.
9.10 Welding surface shall be smooth, uniform, free from fins, tears notches or any
other defect which may adversely affect welding.
9.11 For multi-run weld deposit , the next run should be done only after thorough
removal of slag and proper cleaning of surface.
9.12 Fillet weld shall have the correct profile with smooth transition into parent metal.
Dressing of welds, if specified, shall be done by such method which does not
cause grooving and other surface defects on the weld or on the parent metal.
9.13 All butt welds shall start and end with run-on and runoff plates. All such plates
shall be carefully trimmed off by gas cutting after welding is over.
9.14 Fillet welds shall not be stopped at corners but shall be returned round them.
9.15 If butt weld is to be ground flush with the surface of the member as per drawing.
adequate reinforcement shall be built up and then the same shall be chipped off
and ground flush. The grinding is to done in the direction of stress flow till the
transverse marks are eliminated.
9.16 Welding shall not be done under such weather conditions which might adversely
affect the efficiency of the welding.
9.17 Manipulators shall be used wherever necessary and shall be designed to facilitate
welding and ensure that all welds are easily accessible to the operators.
9.18 Stress relieving after welding shall be done if especially called for in the drawing or
specification. Ends of structural members and portions of gussets receiving welding
at site shall be left unpainted.
9.19 Permissible deviation in assembly of weld joints shall be in accordance with

ANNEXURE - C.

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10.0 INSPECTION & TESTING
10.1 The purchaser/Inspector shall have free access at all times to those parts of
Contractor's or his Sub- Contractor's works which are concerned with the
fabrication of steel works and shall be afforded all reasonable facilities at all stages
of preparation, fabrication and trial assemblies for satisfying himself that the
fabrication is being undertaken in accordance with the provisions of relevant
specification.
10.2 All gauges and templates, tools, apparatus, labour and assistance for checking
shall be supplied by the contractor free of charge. The purchaser /Inspector may at
his discretion, check the test results obtained at the Contractor's works, by
independent test at the Government Test House or elsewhere, and should the
material so tested be found to be unsatisfactory, the cost of such test shall be borne
by the Contractor.
10.3 Contractor shall make all necessary arrangements for stage inspection by
purchaser/Inspector during the fabrication at shop and incorporate all on-the-spot
instructions / changes conveyed in writing to the Contractor.
10.4 Material improperly detailed or wrongly fabricated shall be reported to the

Purchaser/Inspector and shall be made good as directed. Minor misfits which can
be remedied by moderate use of drift pins, and moderate amount of reaming and
slight chipping may be corrected in that manner, if in the opinion of the
Purchaser/Inspector the strength or appearance of the structure will not be
adversely affected. In the event the Purchaser/Inspector directs otherwise, the
items will be rejected and a completely new piece shall be fabricated. The cost of
correcting errors shall be to the account of the Contractor.
10.5 i) The Purchaser/Engineer shall have the power:
a) To certify, before any structure is submitted for inspection, that the same
is not in accordance with the contract, owing to the adoption of any
unsatisfactory method of fabrication.
b) To reject any structure as not being in accordance with specifications &

drawings.
c) To insist that no structure or parts of the structure once rejected is

resubmitted for inspection/test, except in cases where the Purchaser /
Inspector authorised representative considers the defects as rectifiable.

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ii) If, on rejection of structure by the Purchaser/Inspector the Contractor fails to

make satisfactory progress within the stipulated period, the Purchaser/Inspector
shall be at liberty to cancel the contract and fabricate or authorize the
fabrication of the structures at any other place he chooses, at the risk and cost
of the Contractor, without prejudice to any action being taken in addition to
terms of General Conditions of Contract.
iii) The Purchaser / Inspector's decision regarding rejection shall be final and
binding on the Contractor.
iv) The specifications prescribe various tests at specified intervals for ascertaining
the quality of the work done. If the tests prove unsatisfactory,
Purchaser/Inspector shall have liberty to order the Contractor to re-do the work,
done in that period and/ or to order such alterations and strengthening that may
be necessary at the cost of the Contractor and the contractor shall be bound to
carry out such orders failing which the rectification/redoing will be done by the
Purchaser through other agencies and the cost recovered from the Contractor.
v) Notwithstanding any inspection at the workshop the Purchaser/Inspector shall

have the liberty to reject, without being liable for compensation any fabricated
members or materials brought to site that do not conform to specifications /
drawings.
vi) All rejected materials shall be removed from the site of fabrication by the
Contractor at his own cost and within the time stipulated by the
Purchaser/Inspector.
11.0 CONTROL IN WELDING
Before inspection, the surface of weld metal shall be cleaned of all slag, spatter
matter, scales etc. by using wire brush or chisel.
b) Dye Penetration Test (DPT)
This shall be carried out for all important fillet welds and groove welds as desired by
purchaser for both statically and dynamically loaded structures to check the
following :
i) Surface cracks
ii) Surface porosities

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Dye Penetration Test shall be carried out in accordance with American National
Standard ASTM E165.
c) Ultrasonic testing
Ultrasonic test shall be conducted for all butt/groove welds and heat affected zone
in dynamically loaded structures and for other important load bearing butt welds in
statically loaded structures as desired by purchaser, to detect the following :
i) Cracks
ii) Lack of fusion
iii) Slag inclusions
iv) Gas porosity
Ultrasonic testing shall be carried out in accordance with American National

Standard ANSI/AWS D1.1.
Before ultrasonic test is carried out, any surface irregularity like undercuts, sharp
ridges etc. shall be rectified. Material surface to be used for scanning by probes
must allow free movement of probes. For this purpose, surface shall be prepared to
make it suitable for carrying out ultrasonic examination.
d) Radiographic Testing
(X-ray and Gamma-Ray Examination) :- This test shall be limited to 2% of length of

butt/groove welds for welds made by manual or semi- automatic welding and 1 %
of length of weld if made by automatic welding machines . The location and extent
of weld to be tested by this method shall be decided by purchaser to detect the
following defects: -
11.1 The extent of quality control in respect of welds for structural elements for both
statically and dynamically loaded structures shall be as follows and shall be
conducted by the contractor at his own cost:-
a) Visual Examination - All welds shall be 100% visually inspected to check the
following:
i) Presence of undercuts
ii) Visually identifiable surface cracks in both welds and base metals.
iii) Unfilled craters

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iv) Improper weld profile and size
v) Excessive reinforcement in weld
vi) Surface porosity
Before inspection, the surface of weld metal shall be cleaned of all slag, spatter
matter, scales etc. by using wire brush or chisel.
b) Dye Penetration Test (DPT)
This shall be carried out for all important fillet welds and groove welds as desired by
purchaser for both statically and dynamically loaded structures to check the
following :
i) Surface cracks
ii) Surface porosities
Dye Penetration Test shall be carried out in accordance with American National
Standard ASTM E165.
c) Ultrasonic testing
Ultrasonic test shall be conducted for all butt/groove welds and heat affected zone in
dynamically loaded structures and for other important load bearing butt welds in
statically loaded structures as desired by purchaser, to detect the following :
i) Cracks
ii) Lack of fusion
iii) Slag inclusions
iv) Gas porosity
Ultrasonic testing shall be carried out in accordance with American National Standard
ANSI/AWS D1.1.
Before ultrasonic test is carried out, any surface irregularity like undercuts, sharp ridges
etc. shall be rectified. Material surface to be used for scanning by probes must allow
free movement of probes. For this purpose, surface shall be prepared to make it
suitable for carrying out ultrasonic examination.
d) Radiographic Testing

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(X-ray and Gamma-Ray Examination) :- This test shall be limited to 2% of length of

butt/groove welds for welds made by manual or semi- automatic welding and 1 % of
length of weld if made by automatic welding machines . The location and extent of
weld to be tested by this method shall be decided by purchaser to detect the following
defects: -
i) Gas porosity
ii) Slag inclusions
iii) Lack of penetration
iv) Lack of fusion
v) Cracks
Radiographic testing shall be conducted in accordance with American National

Standard ANSI/AWS D1.1
Any surface irregularity like undercuts, craters, pits etc. shall be removed before
conducting radiographic test. The width of the radiographic film shall be width of the
welded joint plus 20 mm on either side of the weld.
12.0 ACCEPTABLE LIMITS OF DEFECTS IN WELD
12.1 Limits of Acceptability of welding defects shall be as follows: -
a) Visual inspection & Dye Penetration Test - The limits of acceptability of

defects detected during visual inspection and Dye Penetration Test shall
be in accordance with American National Standard ANSI/AWS D1.1 for
statically as well as dynamically loaded structures.
b) Ultrasonic Testing - The limits of acceptability of defects detected during

ultrasonic testing shall be in accordance with American National Standard
ANSI/AWS D1.1 for statically and dynamically loaded structures.
c) Radiographic testing - The limits of acceptability of defects detected during

Radiographic testing shall be in accordance with American National
Standard ANSI/AWS D1.1 for statically and dynamically loaded structures
13.0 RECTIFICATION OF DEFECTS IN WELDS
13.1 In case of detection of defects in welds, the rectification of the same shall be done
as follows :
i) Al2l craters in the weld and breaks in the weld run shall be thoroughly filled
with weld.

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ii) Undercuts, beyond acceptable limits, shall be repaired with dressing so as

to provide smooth transition of weld to parent metal.
iii) Welds with cracks and also welds with incomplete penetration, porosity,
slag inclusion etc. exceeding permissible limts shall be rectified by removing
the length of weld at the location of such defects plus 10 mm from both
ends of defective weld, and shall be re-welded. Defective weld shall be
removed by chipping hammer, gouging torch or grinding wheel. Care shall
be taken not to damage the adjacent material.
14 .0 COMPLETION DOCUMENTS
14.1 On completion of work, the Contractor shall submit to the Purchaser the following
documents: -
a) The technical documents according to which the work was carried out.
b) Copies of the "As built" drawings showing thereon all additions and
alterations made during the fabrication.
c) Manufacturers test certificates
d) Certificates/documents on control checking
e) Test of welds
f) Inspection Certificates issued by Purchaser/Consultant for the

material/structures.
15.0 In addition to provision of erection and transport equipments, the scope of work
includes supply of tools and tackles, consumables, materials, labour and
supervision and shall cover the following:
a) Storing and stacking of all fabricated structural components/units/assemblies at

site storage yards till the time of erection.
b) Transportation of structures from storage yard to site of erection, including

multiple handling, if required.
c) All minor rectification / modifications such as :-
i) Removal of bends, kinks, twists etc. for parts damaged during

transportation and handling.

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ii) Reaming of holes which do not register or which are damaged, for use
of next higher size bolt.
iii) Plug-welding and re-drilling of holes which do not register and which
cannot be reamed for use of next higher size bolt.
Drilling of holes which are either not drilled at all or are drilled in incorrect position
during fabrication.
d) Fabrication of minor missing items as directed by the purchaser.
e) Verification of the position of embedded anchor bolts and inserts w.r.t. line find
levels, installed by others based on Geodetic Scheme / Bench mark /
Reference co -ordinates to be furnished by the Purchaser.
f) Assembly at site of steel Structural components wherever required, including

temporary supports and staging.
g) Marking arrangements for providing all facilities for
i) Conducting ultrasonic x-ray or gamma ray tests by reputed testing

laboratories
ii) Making available test films / graphs, with reports / interpretation.
h) Site Rectification of damaged portions of shop primer by cleaning and

application touch-up paint.
i) Erection of structures including making connections by bolts / High strength

Friction Grip bolts/welding as per drawing.
j) Alignment of all structures true to line, level plumbs and dimensions within specified
limits of tolerance.
k) Application at site after erection, required number of coats of primer and

finishing paint as per specification and drawing.
l) Rectification of structures as per Preliminary acceptance report and Final

acceptance report.
SECTION 2 ERECTION OF STEEL STRUCTURE

16.0 ERECTION

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16.1 General
16.1.1 Erection shall be carried out in accordance with IS:800:2007 and other relevant
standards referred to therein.
16.1.2 For safe and accurate erection of structural steelwork, staging, temporary support,
false-work etc. shall be erected as required.
16.1.3 The fabricated materials received at erection site shall be verified with respect of
marking on the key plan/marking plan or shipping list.
16.1.4 Any material found damaged or defective shall be stacked separately and the
damaged or defective portions shall be painted in distinct colour for identification
and the same shall be brought to the notice of the Purchaser.
16.2 Erection of Structures
16.2.1 Erection work shall be taken up after receipt of clearance from the purchaser.
16.2.2 For safety requirements during erection, provisions in IS:7205:1974, IS:7969:1975

and other relevant Indian standards shall be followed.
16.2.3 Erection shall be carried out with the help of maximum mechanization possible.
16.2.4 Prior to commencement of erection, all the erection equipment ,tools, tackles, ropes
etc. shall be tested for their load carrying capacity. Such tests may be repeated at
intermediate stages also if considered necessary and frequent visual inspection
shall be done of all vulnerable areas and components to detect damages or
distress in the erection equipment, if any.
16.2.5 Following shall be taken care of during erection, whenever necessary:-
16.2.5.1 Temporary bracing, whenever required, shall be provided to sustain forces due to
erection loads and equipment etc. Erected parts of the structures shall remain
stable during all stages of erection when subjected to the action of wind, dead
weight and erection forces etc. Specified sequence of erection of vertical and
horizontal structural members shall be followed.
16.2.5.2 Erected members shall be held securely in place by bolts to take care of dead load,
wind load and erection load.
16.2.5.3 All connections shall achieve free expansion and contraction of structures
wherever provided.

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16.2.5.4 No final bolting or welding of joints shall be done until the structure has been
properly aligned.
16.2.5.5 For positioning beams, columns and other steel members, the use of steel sledges
is not permitted.
16.2.5.6 Instrumental checking of correctness of initial setting out of structures and

adjustment of alignment shall be carried out in sequence and at different stages as
required. The final leveling and alignment shall be carried out immediately after
completion of each section of a building .
16.2.5.7 All structural members shall be erected with erection marks in the same relative
position as shown in the appropriate erection and shop drawings.
16.2.5.8 The contractor shall design, manufacture, erect and provide false-work, staging
temporary support etc. required for safe and accurate erection of structural
steelwork and shall be fully responsible for the adequacy of the same.
16.2.5.9 The Contractor shall also provide facilities such as adequate temporary access
ladders, gangways, tools & tackles, instruments etc.to purchaser for his inspection
at any stage during erection.
17.0 ROOF AND SIDE CLADDING WITH PRE-COLOUR COATED GALVALUME

TROUGHED STEEL SHEETS
17.1.1 The scope of work shall cover:
a) Preparation of drawings showing layout and size of sheets used details

of connections and flashings, bill of materials.
b) Roof & Side Pre- color coated galvalume troughed steel sheets
,flashings and like corner pieces, apron pieces, ridges etc, loading,
transportation and supply at site, unloading, stacking & storing on
skids, cutting and bending of sheets wherever required; drilling of holes
all as per specification and drawings.
c) Supply , Loading, transportation, unloading and delivery of sheeting

material to erection site.
d) Provision of all tools, tackles, equipment, labour supervision and

services required for the satisfactory completion of the work specified
herein and on the drawings.

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f) Erection in position sheets for roofing, sides, erection of all flashings,

fittings like ridges, valleys, gutters, corners, apron etc. at all locations
all work as per drawings and specifications.
g) Gutters with Down comers work shall be carried out in line with the
drawings.
17.1.2 The roof sheet shall be of Galvalume/zincalume BHP steel sheet made of cold
rolled steel of 550 MPA minimum yield strength conforming to ASTM A366 or
AS 1595. Base metal thickness shall be 0.5mm and total thickness of colour
coated profiled sheet shall be 0.58mm.
17.1.3 Linear Metal False Ceiling :
a) Providing, cutting, fabrication and installation of canopy false ceiling with

TRAC 150 F of Interarch (or equivalent) coil coated (Pre-painted) steel false
ceiling system comprising of 150 mm wide x 17 mm deep roll formed out of
0.50 mm thick polyester coated galvanized steel panels, fixed on steel
runner of 34.5 mm width x 48 mm deep manufactured out of 0.60 mm
thick
precoated galvanized steel with rigid suspension of 20x20x0.5
mm fixed with steel brackets/clips etc. The suspension system should be
meant of exterior use. The carrier shall be suspended at 1mtr c/c supported
from purlin and suspension angle at 500 mm c/c. panel shall be factory cut
to provide minimum joints. The longitudinal joints shall have additional
special G.I. Splice in between two panels. The carrier joint shall have a
carrier splice
maintaining a module of 150 mm. The ceiling shall be clipped on to the
suspended carriers after they are aligned and leveled. Cutting for fixing of
light fittings shall be done as per the cutout required to fit the fixture. The
work shall be carried out under a specialized and experienced supervisor.
shall be humidity resistance, Fireproof, Moisture-Proof, Mould-Proof,
Smoke-Proof, Sound-Absorbing product Metal ceiling panels shall be coil
coated steel or Aluminum alloy of thickness 0.5 to 0.7MM
b) Providing cut out in the false ceiling for the under lights as required. The
under lights and wiring for the canopy, sinages shall be payable as per
electrical SOR and Technical specifications.
Technical details
Size –150F
Thickness: 0.5 to 0.9MM
Sound Absorption (NRC): 0.60-0.70
Sound attenuation (dB): 28-34

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Humidity Resistance (%RH): 100

Fire Reaction: Class A (ASTM E84)
Fire proof
Light Reflectance (%): 83-85
Panels are coil coated steel or Aluminum alloy
18.0 RULES & REGULATIONS OF SAFETY, ELECTRICITY BOARDS, FACTORY ETC.
18.1 The Contractor shall at all times comply with all relevant factory acts, electricity rules,
safety regulations etc. as per statutory regulations of Central / State Government.
19.0 DEVIATIONS
19.1 Should the Contractor wish to deviate from any specification or details shown on the
purchaser's approved drawings and / or Technical Specifications, he shall obtain the
purchaser's written authority before proceeding with the deviations.
20.0 MEASUREMENTS
20.1 Structural Steel
Structural steelwork will be measured by the metric tonne and as per IS: 1200
(part-8) - 1993 and IS: 1200 (part-9) -1973 subject to provisions outlined below:-
a) The calculation of quantities shall be based on unit weights for structural

sections as given in IS: 808-1989 . The payments will be made on the basis
of weights of members given in the approved fabrication drawings.
However, any changes on the above weights during fabrication erection,
payment shall be based on sketches Approved by the purchaser.
b) In the event the I.S. does not specify any mode of measurement for a
particular item of work, the same shall be measured as per any other
relevant international standard or as directed by the Purchaser.
c) The weight of all plates and sections shall be calculated from the approved
drawing using the minimum overall square or rectangular dimensions and
theoretical weight, no deduction being made for skew cuts, holes etc. In the
case of plates, other than gussets, the actual dimensions shown on
approved drawings will apply unless approved otherwise by the purchaser
based on cutting diagram of mother plates.

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d) The weight of all welding runs, bolt, stanchion base packing, cuttings to
waste and rolling margins, and coatings of paint, will be excluded from the
measured weight and shall be deemed to have been allowed for in the
rates for structural steelworks quoted by the Contractor.
e) Temporary works and all other materials not included in the permanent
works shall be excluded from any measurement for payment.
21.0 SIGNAGE WORKS
21.1 Monolith tower(or Pylon)
21.1.1 4mm thick ACM (Aluminium Composite Material) panel router cut cladding on
M.S.framework (hollow steel sections as per design requirement) with Product
Panels of Retro Reflective Sheeting Type XI DG3 Microprismetice as per ASTM D
4956-09 in required colour & Size on both sides. Retro Reflective shall be of
appropriate approved colour and cutouts for product names, logos, etc. duly CNC
Plotted. The body of the monolith shall be in ACM having Total Thickness of 4mm :
Top Coil 0.5mm ( 3003/3105 Grade as per IS - 737 1986 with minimum 25 microns
PVdF Coating on top coil and Polyester / Epoxy coating on Back Coil ( 4 -7 microns
PVDF ACM in colour and shape as per approved design.
The company logo should be prepared in polycarbonate sheets (GE/ LEXAN

make)
in corporate colours and thermoformed to form the design which shall be in turn
fixed in cutouts made in monolith body of ACM. The portions of the monolith to be
backlit to make the acrylic/ polycarbonate portions/ logos visible at night. Special
spot lights (2 nos.- 400 watts with metal halide lights of Philips make) to be
incorporated in design to light up the entire tower with throw from base. The backlit
portion of the monolith to be lit with sufficient numbers T5 (28 W) tube lights
(Philips make) with electronic choke, mounted on MS tube frames with plastic
holders. Multi-strand copper conductors with PVC insulation to be used. Steel
structural frame to be installed on RCC foundations. Top and exposed sides of the
foundation to be cladded in 18 mm thick black polished granite. All work to be done
in line, level and plumb, all complete with by works, as approved.
21.2 Canopy Fascia (1000mm wide) on canopy vertical faces
21.2.1 4mm thick ACM (of approved make) cladding in a combination of corporate colours
with the use of Retro Reflective Sheeting Type XI DG3 Microprismetice duly pasted
on ACM in required size & shape (colour scheme and design to be approved) on
mild steel framework with part backlit for company logo and name. The letters shall
be in 30 mm thick Acrylic/ PC duly CNC Routed in require shape & Size as per

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direction of concerned engineer. Structural frame to be welded rigidly/ Bolted to the

structural member of existing canopy structures. Canopy fascia to be made in 12
m. (min.) long straight panels factory plan/processed at converters factory and
assembled/installed at site. Corner piece (1 metre both sides) on both sides (as
required), also to be factory plan/processed/assembled and installed at site. Only
bottom trim and top flashing is to be Plan/processed and installed at site. All work
to be done in line, level and plumb.
M.S. frame shall be made minimum size of 50 x 30 x 2.5mm (RHS) rectangular
steel hollow section (2.92 kg/m) for main horizontal support and vertical M.S.
section shall be minimum size of 40 x 25 x 2.5mm (RHS) rectangular steel hollow
section (2.23 kg/m) at c/c 500mm.
Backlit section of the fascia shall be of 4 meters length and one/ two logos
(depending on design) and shall have sufficient number of LED/T5 (28 W) tube
light with electronic chokes mounted with plastic holders to structural frame. The
top of the fascia shall have 4 mm thick ACM with hinged GI service door in backlit
part. The back of the fascia to have 18 gauge GI sheets. Multi-strand copper
conductors with PVC insulation to be used. The bottom and top of the fascia shall
have a white ACM trim to cover the gap between the canopy and fascia. The
backside will be non-lit. the contractor should make suitable fixing arrangement,
which should be duly vetted by a certified structural engineer as per the actual
dimensions of the canopy structure.
The canopy fascia shall have a combination of approximately 200 wide ACM on
the
top and 700 wide below in proper approved design and colour scheme, complete
with all by works
21.3 Building Fascia, 700mm wide on top of building faces I n elevation
21.3.1 4mm thick ACM (of approved make) cladding in a combination of corporate colours
with the use of Retro Reflective Sheeting Type XI DG3 Microprismetice as per
ASTM D 4956-09 duly pasted on ACM in required size & shape (colour scheme to
be approved) on mild steel framework. Structural frame to be fasteners/ Nut Bolted
to the building walls with dash fasteners and leveling 'arrangement. Building fascia
to be made in maximum length of straight panels (with minimum no. of joints)
straight panels factory plan/processed at converters factory and
assembled/installed at site.
Corner piece (1 metre both sides) on both sides, also to be factory
plan/processed/assembled and installed at site. Only bottom trim and top flashing
is
to be Plan/processed and installed at site. All work to be done in line, level and
plumb, all complete with by works, as approved. M.S. frame shall be made
minimum size of 50 x 30 x 2.5mm (RHS) rectangular steel hollow section (2.92
kg/m) for main horizontal support and vertical M.S. section shall be minimum size
of 40 x 25 x 2.5mm (RHS) rectangular steel hollow section (2.23 kg/m) at c/c
500mm.

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21.4 Spreader, 1200X450X150mm
21.4.1 4mm thick ACM (Aluminium Composite Material) cladding with the use of Retro
Reflective Sheeting Type XI DG3 Microprismetice as per ASTM D 4956-09 duly
pasted on ACM in required size & shape on structural framework with back-lit
panels in 10 mm thick Acrylic/ PC duly CNC Routed in require shape & Size as per
direction of concerned engineer. Front face of panels to have appropriate colour
with cutout for text as indicated in drawings as approved and the sides to be white.
Spreader frame to be fixed securely to canopy columns with box & cap
arrangement. The spreader to be made in two sections as per design with 'L' lock.
The smaller section to be mounted on sliding channel with sufficient no. of LED/
CFL lights and electronic chokes fixed with plastic holders. Multi-strand copper
conductors with PVC insulation to be used. AII work to be done in line, level and
plumb, all complete with by works, as approved.
21.5 Mandatory sign, 300X750mm(on column), 300X450(on toilets)&300X600
(in compressor & LCV area)
21.5.1 4mm thick. ACM (Aluminum Composite Material) sheets cladded on

structural framework. Matter/Logo in Retro Reflective Sheeting Type XI DG3
Microprismetice as per ASTM D 4956-09 duly pasted on ACM in required size &
shape, all complete with by works, as approved.
300mm X 750mm
300mm X 450mm
300mm X 600mm
21.6 Direction sign
21.6.1 4mm thick. ACM (Aluminum Composite Material) cladding on steel framework with
the use of 3M (or approved equivalent make) Retro Reflective Sheeting Type XI
DG3 Microprismetice as per ASTM D 4956-09 duly pasted on ACM in require size
& shap & back-lit panels in 10 mm thick Acrylic/ PC duly CNC Routed in require
shape & Size as per direction of concerned engineer or 3 mm thick, thermoformed
PET-G (Spectra Copolymer/ Relstar) on both sides. Front face of PET-G panels to
have acrylic of appropriate colour with cutout for arrow sign as indicated in
drawings and the sides to be white. The sign frame to be fixed securely to CC
foundation as shown in drawings. The CC foundation shall have 8mm thick
polished black granite tiles cladding on top and all exposed side surfaces.

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Sufficient no. of LED/ T5 (14 W) tube lights with electronic chokes fixed with plastic
holders and electric coneections. Multi-strand copper conductors with PVC
insulation to be used. All work to be done in line, level and plumb, all complete with
by works, as approved.
21.7 Canopy column cladding
21.7.1 Cladding in white 4mm thick ACM (Aluminum Composite Material) on structural
with suspension pin, fixed securely to existing canopy column by welding at site.
ACM panel fixing to ensure consistent joint gaps and panel size. All grooves shall
be sealed with sealant material of approved colour, all complete with by works, as
approved.
250mm X 500 mm
200mm X 400mm
M.S. frame shall be made minimum size of 50 x 30 x 2.5mm (RHS) rectangular

steel hollow section (2.92 kg/m) for main horizontal support and vertical M.S.
section shall be minimum size of 40 x 25 x 2.5mm (RHS) rectangular steel hollow
section (2.23 kg/m) at c/c 500mm.
a) Hoarding
Printed Flex sheet (make LG or 3M) with approved Art work (suitable for
front lit) to be Fitted to the steel sheet of existing Hoarding structure in
aluminium frame using Klick Rail System & as per direction of concerned
Engineer/ client.
b) Spot halogen lights
Supplying and fixing Spot halogen lights (150 watts of Philips make) at an
interval of 2 m center to center on top of existing hoarding including supply
with steel bracket and laying of cable upto electrical panel of Electrical
room (in Utility building) complete in all respect.

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SECTION‐3 PAINTING OF STEEL STRUCTURES

22.0 SURFACE PREPARATION FOR PAINTING
22.1 General
The steel surface which is to be prepared shall be cleaned of dirt and grease and
the heavier layers of rust by grinding prior to actual surface preparation to a
specified grade.
22.2 Mechanical Cleaning
22.2.1 Manual/power tool cleaning.
Manual/power tool cleaning shall be done as per grade St-2 or St-3,of Swedish
Standard Institution SIS 055900.

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i) Grade St-2: Thorough scraping and wire brushing, machine brushing,

grinding etc. This grade of preparation shall remove loose mill scale, rust
and foreign matter. Finally the surface is to be cleaned with a vacuum
cleaner or with clean compressed air or with clean brush. After preparation,
the surface should have a faint metallic sheen. The appearance shall
correspond to the prints designated St-2.
ii) Grade St-3: very thorough scraping and wire brushing, machine brushing,
grinding etc. The surface preparation is same as for grade St-2 but to be
done much more thoroughly. After preparing the surface, it should have a
pronounced metallic sheen and correspond to the prints designated St-3.
23.0 PAINTS AND PAINTING
23.1 For use of specific painting system, the paint manufacturer's specification shall
prevail.
23.2 General compatibility between primer and finishing paints shall be established
through the paint manufacturer supplying the paints.
23.3 Before buying the paint in bulk, it is recommended to obtain sample of paint and
establish "Control Area of Painting". On control area surface preparation and
painting shall be carried out in the presence of manufacturer of paint.
23.4 In order to ensure that the supplied paint meets the stipulation in design drawing/
specification, if required, samples of paint shall be tested in laboratories to
establish quality of paint with respect to (i) Viscosity (ii) adhesion/ bond of paint in
steel surfaces (iii) adhesion/simulated salt spray test (iv) chemical analysis
(percentage of solids by weight) (v) normal wear resistance as encountered during
handling & erection (vi) resistance against exposure to acid fumes etc.
23.5 Whole quantity of paint for a particular system of paint shall be obtained from the
same manufacturer.
23.6 Thinners, wherever used, shall be as per recommendation of the paint

manufacturer.
23.7 Areas which become inaccessible after assembly of structures shall be painted
before assembly, after cleaning the surfaces as specified.
23.8 Wherever shop primer painting is scratched, abraded or damaged, the surfaces
shall be thoroughly cleaned using emery paper and power driven wire brush
wherever warranted, and touched up with corresponding primer. Touching up paint
shall be matched and blended to eliminate conspicuous marks.

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23.9 If more than 50% of the painted surface of an item requires repair, the entire item
shall be mechanically cleaned and new primer coats shall be applied followed by
finishing coats as per painting specification.
All field welded areas on shop painted item shall be mechanically cleaned
(including the weld area proper, adjacent areas contaminated by weld spatter or
fumes and areas where existing primer. intermediate / finishing paint is burnt).
Subsequently, new primer and finishing coats of paint shall be applied as per
painting specification.
23.10 Application of paint shall be by spraying or brushing as per IS:487-1985 and in

uniform layers of 50% overlapping strokes. Painting shall not be done when the
temperature is less than 5C or relative humidity more than 85%, unless
manufacturer's recommendations permit. Also painting shall not be done in frosty
or foggy weather. During application, paint agitation must be provided wherever
such agitation is recommended by the manufacturer.
23.11 Paint shall be applied at manufacturer's recommended rates. The number of coats
shall be such that the minimum dry film thickness (DFT) specified is achieved. The
dry film thickness of painted surfaces shall be checked with ELCOMETER or
measuring gauges to ensure application of specified DFT.
23.12 All structures shall receive appropriate number of primer and finishing coats in
order to achieve overall DFT as per design drawings/ specifications. First coat of
primer paint shall be applied not later than 2-3 hours after preparation of surface,
unless specified otherwise.
23.13 The finishing paint as specified shall be of approved colour and quality. The under
coat shall have different tint to distinguish the same from the finishing coat.
23.14 Edges, corners, crevices, depressions, joints and welds shall receive special
attention to ensure that they receive painting coats of the required thickness.
23.15 Machine-finished surface shall be coated with white lead and tallow before
shipment or before being put into the open air.
23.16 Parts of surfaces embedded in concrete shall be thoroughly cleaned of grease,
rust, mill scale etc. and shall be given a protective coat of portland cement slurry
immediately after fabrication. No paint shall be applied on this part.
23.17 Zinc-rich primer paints, which have been exposed several months before finishing
coat is applied, shall be washed down thoroughly to remove soluble zinc salt
deposits. In similar circumstances, the surfaces of paint based on epoxy resin
should be abraded or lightly blast cleaned to ensure adhesion of next coat.

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23.18 Surfaces which cannot be painted but require protection shall be given a coat of
rust inhibitive grease according to IS:958-2000 or equivalent international standard.
24.0 PAINTING SYSTEM
The recommended painting system for general service requirement of steel

structures Refer ANNEXURE-E.
ANNEXURE‐A
Permissible deviations in pitch and gauge of holes for bolts of normal accuracy (high
strength bolts included)
Description Hole diameter Permissible Permissible deviations in each
(mm) Deviations in group of holes
Spacing (mm)
Carbon Low
Steel
1 2 3 Alloyed Steel
4
5
a) Deviation in the Upto 17.0 +1

No limits
hole diameter. +1.5
Above 17.0
b) Ovality
(difference between Upto 17.0; +1 No limits
the biggest and the Above 17.0; +1.5
smallest diameter)
c) Curves, exceeding Not

1mm and cracks _ _
onthe hole edges Permissible
d)
(i)Non-coincidence of _ _ Upto 50% Upto 50%

holes in separate
details of the
assembled unit, upto

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1mm
(ii) Above 1 mm upto _ _ Upto 10% Upto 10%

1.5 mm
Upto 30% of the

e) Slope of axis _ No limits No limits
thickness of unit
ANNEXURE –B
TOLERANCE OF ASSEMBLED COMPONENTS OF STRUCTURES
Description of Deviation (±) in mm for the Elements of Structures Components of Length in
Metres
Structures Up 1 5 10 15 20 Over
to to to to to to 25
1 5 10 15 20 25
1 2 3 4 5 6 7 8
I.i) Deviations from the dimensions assembled.

Length & width of the Details Cut :
a) Manual gas Cutting as per marking 3 3.5 4 4.5 5 - -
b) With shears or with a saw as per marking 2 2.5 3 3.5 4 - -

c) With shears or with a saw with a stop 1.5 2 2.5 3 3.5 - -
d) Machine Gas Cutting 2 2.5 3 3.5 4 - -
ii)Length and width of planed ends processed on 1 1.5 2 2.5 3 - -
Edge Planing Machine
II i) Distance between the Centres of the End holes.
a) Drilled according to marking 2 2.5 3 3.5 4 - -
b) Drilled according to a gauge with bushing 1 1.5 2 2.5 3 - -
ii)Distance between the centres of adjacent holes
a) Drilled according to marking or to a gauge 1.5 - - - - - -
b) Drilled according to a gauge with bushings 0.5 - - - - - -

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III. Deviation in the dimensions of despatch

elements after completion of fabrication,
Assembled in positioners or in other Devices with
clamps in fixed positioners and also
a) According to guide blocks with pins. 2 3 5 7 8 9 10
b) Assembled with bolts 3 5 8 11 12 14 15
c) Size (length & width) between Milled surface 1 1.5 2 2.5 3 3.5 4
(for all cases of assembly)
d) The same made in separate details during 2 3 5 7 8 9 10
machining & fixed during the assembling work with
clamps
e) The same drilled according to positioners in 1 1.5 2 2.5 3 3.5 4
finished structures
ANNEXURE – C
PERMISSIBLE DEVIATION IN ASSEMBLY OF WELDED JOINTS:
Permissible
Sketch
Description deviation
A. Square-butt
Joints:
a) Gap between the ± 1 mm

ends of plates (d)
b) Stepping of one 1 mm
plate over the
other (s)
B. Single Vee-
groove Joints
(without backing
strip)
a) Bevel angle (Aº) ± 5º
b) Gap between two ± 1 mm

Plates (d)

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c) Stepping of one 2 mm
plate over the
other (s)
d) Root thickness (t 1 mm
C. Double V-groove
Joint
Stepping of one
a) plate over the 2 mm
others (s)
b) Deviation in the 1 mm
value of Root
thickness (t)
c) Deviation in Bevel ± 5º
angle (Aº)
d) Deviation in value ± 1 mm
of Gap (d)
D. Lap Joints:
a) Overlap (B) 5 mm
b) Gap between the 1 mm

surfaces (e)

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E. Tee fillet Joints:
a) gap between
the edge of the
web and the
surface of the
flange(e)
ANNEXURE – D
TOLERANCES IN ERECTED STEEL STRUCTURES
Sl Description Tolerance (mm)

No.
A. COLUMNS
1. Deviation of column axes at foundation top level with

respect to true axes.
i) In Longitudinal direction ±5
ii) In Lateral direction ±5
2. Deviation in the level of bearing surface of columns at ± 5

foundation top with respect to true level
3. Out of plumbness (verticality) of column axis from true

vertical axis and measured at column top :
a) For columns without any special requirements :
i) Upto and including 30m

±H/1000 or ± 25mm height
whichever is less
ii) Over 30 m height ± H/1200 Or ± 35mm maximum

b) For column with special requirements like cranes or
such similar requirements :
i) Upto and including 30m ±H/1000 or ± 20mm height

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whichever is less
ii) Over 30 m height ± H/1500 or ± 25mm
maximum
Deviation in straightness in longitudinal & transverse ± H/1000or ± 10mm whichever
4. planes of columns, at any point along the height is less.
Difference in the erected position of adjacent pairs of

5. columns along length or across width of building, prior ± 5
to connecting trusses / beams, with respect to true
distance.
Deviation in any bearing or seating level with respect to

6. ±5
true level.
Difference in bearing levels of a member on adjacent

7. pair of columns both across and along the building, from ± 5
the true difference.
NOTE :i) Tolerance specified under 3(a) and 3(b) should be read in conjunction with 4 and 5.
ii) "H" above is the column height in mm
B. TRUSSES
Shift, at the centre of top chord member of truss with ± 1/250 of height span in mm or
1. respect to the centre of span or vertical plane passing
through the centre of bottom chord. ± 15 mm whichever is less
Lateral shift of top chord at the centre of of truss span

± 1/1500 of span of truss in mm
2. from the vertical plane passing through the centre of
or ± 10 mm whichever is less
supports of the truss.
Lateral shift in location of truss from its true vertical

3. ± 10
position.
4. Lateral shift in location of purlins from true position. ±5
Deviation in difference of bearing levels of trusses or L/1200 or 20 mm whichever is

5. beam from the true less
(L =span) difference.

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Relative shift in the track location of crane stops (end 1/1000 of gauge S in mm
6. buffers) along the crane tracks, along track
subject to maximum of 20 mm
gauge.
ANNEXURE – E
PAINTING SYSTEM
Enamel System :
i) Primer Paint : Two coats of Zinc Phosphate in phenolic alkyd medium

(DFT=40 microns/coat)
ii) Intermediate Paint : One coat of Synthetic MIO( ie: micaceous iron oxide)
(DFT=75 microns/coat)
iii) Finishing paint : Two coats of Synthetic enamel (DFT=25

microns/coat) conforming to IS: 2932-2003
ANNEXURE ‐ F
MATERIAL OF CONSTRUCTION (AS APPLICABLE)
1. Unless otherwise specified in the drawing:
a) All rolled sections and plates shall conform to Grade‐A as per IS:2062‐1999.
b) Plated structures subjected to dynamic loading shall conform to Grade-B as
per IS: 2062-1999.
2. Steel sheets shall conform to IS:1079-1994.

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3. Steel tubes for structural purposes shall conform to IS:1161 1998(Grade YST-240).
4. Collectors and down comers shall conform to IS:3589-2001.
5. All black hexagonal bolts, nuts and locknuts shall conform to IS:1363(Part 1 to 3
-2002 and IS:1364(Part 1 to 6)-2002(for precision and semi- precision hexagonal
bolts). Washers shall conform to IS:5369-1975.
6. All HSFG bolts shall conform to IS:3757-1985.
7 Covered electrodes for arc welding shall conform to IS:814- 1991. Coding of
electrodes shall be as follows :-
a) ER 421 'C' x for mild steel of Grade A and Grade-B as per IS:2062-1999.
b) EB 542 'C' x H3X
for
i) Mild Steel of Grade B as per IS:2062-1999 for dynamically loaded structures
(arising out of crane, vibratory screen, equipment etc.)
ii) For SAIL-MA micro alloyed steel 350 HYA/HYB.
iii) When combined thickness (CT) for steel conforming to IS:2062-1999
exceeds 40mm as per Fig.1
"C" is the value of current as recommended by the electrode manufacturer.

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COCO STATIONS & CNG STATIONS IN OMC/ROSE-
Tender no. -------
Bid Document No.: ----------------------------
STRUCTURAL AND CIVIL

DRAWINGS
LIST OF STANDARD DRAWINGS (CIVIL AND

STRUICTURAL)
Sl No. Description Document No./ Drawing Rev.

No. No.
1 TYPICAL DETAILS OF SS TUBE MEC/GGL/G1/01/TD/1051 Rev. 0
TRENCH
2 TYPICAL DETAILS OF SOAK PIT & MEC/GGL/G1/01/TD/1052 Rev. 0
SEPTIC TANK
3 DETAILS OF DISPENSER ISLAND MEC/GGL/G1/01/TD/1053 Rev. 0
4 ELEVATION OF CHAINLINK FENCING MEC/GGL/G1/01/TD/1057 Rev. 0
5 PART PLAN OF BOUNDARY WALL, MEC/GGL/G1/01/TD/1056 Rev. 0

COLUMN AND INSERT PLATE SHEET 1 OF 3

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COCO STATIONS & CNG STATIONS IN OMC/ROSE-
Tender no. -------
Bid Document No.: ----------------------------
6 ELEVATION OF BOUNDARY WALL , MEC/GGL/G1/01/TD/1056 Rev. 0

DETAILS OF PRE CAST SLAB SHEET 2 OF 3
7 SECTION A-A, SECTION B-A AND MEC/GGL/G1/01/TD/1056 Rev. 0
DETAILS A & B SHEET 3 OF 3
8 TYPICAL DETAILS OF CANOPY –A (TWO MEC/23QQ/01/12/D2/CN/ST/0301Rev. 0
LEGGED)
9 TYPICAL DETAILS OF CANOPY –A MEC/23QQ/01/12/D2/CN/ST/0302 Rev. 0
(FOUR LEGGED) 3

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ELECTRICAL WORKS

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ELECTRICAL WORKS

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ELECTRICAL WORKS

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ELECTRICAL WORKS

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ELECTRICAL WORKS

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ELECTRICAL WORKS
PART-II
ELECTRICAL & ILLUMINATION WORKS
PART – A – GENERAL ISTRUCTIONS
1.01 Introduction

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ELECTRICAL WORKS
The intent of this specification is to define t requirements for the supply of equipment and materials
(as required), erection, testing and commissioning of the electrics and illumination power distribution
system.
The work shall be carried out in the best workmanship - like manner, in conformity with these
specifications, approved drawings and the instructions of the Engineer-in-charge from time to time.
The contract shall include clearing of temporary construction, waste materials and loose earth,
which might get collected in and nearby the work site consequent of the execution of work under
this contract.
1.02 Standards
The equipment to be supplied as well as the work being executed shall conform to applicable Indian
Standards ( BIS)/ recognized International Standards viz IEC/IEEE/VDE where corresponding
Indian Standards do not exist , code of practices of the Bureau of India Standards, technical
specifications and installation standards enclosed herewith In case of any conflict, the most
stringent specification shall govern.
In addition, the work shall also conform to the requirements of the following:
The Indian Electricity Act, and the Rules framed there under
The fire Insurance Regulations
The regulations laid down by the Chief Electrical Inspector of the state government / Central
Electricity Authority (CEA).
The regulations laid down by the Factory Inspector.
The regulations laid down by the Chief Inspector of Explosives.
Any other regulations laid down by the Central, State or Local Authorities from time to time during
the pendency of this contract.
1.03 Site Condition
The equipment offered and the installation shall be suitable for continuous operation
under the following site conditions.

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ELECTRICAL WORKS
Max. / Min temperature : 400C/50C
Max. relative humidity : 90 %
Altitude : Less than 1000 m above MSL
1.04 Power Supply Parameters
NORMAL POWER 415V AC, 3 Phase & Neutral

LIGHTING DISTRIBUTION (Normal) 230 V AC, 1 Phase
INSTRUMENTATION(UPS) 230 V AC, 1 Phase
1.05 SCOPE OF WORK

Scope of work shall cover procurement, supply, loading, transportation, delivery, transit
insurance, unloading, storage and handling at site, erection, insurance during erection till
handing over, testing and commissioning of various equipment/systems/sub-systems of
11/0.433kV Distribution transformer, 11KV Load break switch, DP/ spun pole structure, Power
distribution board, Lighting distribution board, FRLS,1.1kV Grade Copper LT Power cables, FLP
Outdoor Illumination consisting of Street light poles, light fixtures, switches/sockets, FLP type
Isolating switch , Earthing& lightning protection system including civil and structural works,
conducting site Tests and trial runs of the above System, Watch and ward of the site till handing
over to Owner, preliminary acceptance test (PAT), final acceptance test (FAT) and handing over
the system in ‘Ready to switch on’ condition to the Owner, as described in the specification .The
package shall be executed on ITEM RATE BASIS as per enclosed BOQ.
All equipments / materials supplied by the contractor shall be as per the list of approved makes
enclosed with this document subject to submission of Certification and approvals.
Special Instructions to the Tenderer :
1. The scope of work shall include minor civil works related to the placement of panels/equipment
being supplied by tenderer in electrical premises viz, chipping, grouting, making/closing,
providing chequered plates for unused openings etc.
2. Tenderer shall coordinate and co-operate with Owner/ Owner’s Consultant, other agencies
engaged by the Owner for any data/information exchange, installation / erection, testing and
commissioning of plant . The scope includes attending various co-ordination meetings/ progress
review meetings, design review meetings etc.
3. The successful tenderer shall carefully go through the clause of Invitation to Tender,
specification, Bill of Quantities and drawings and shall include in his rates any sum he may
consider necessary to cover fulfillment of the various clauses contained therein. Unit prices
stated in the Bill of Quantities against the item of work shall be inclusive of all installation
accessories and consumables necessary to complete the said work within the contemplation of
the contract. Beyond the unit prices no extra amount will be paid for incidental contingent work
or materials.

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ELECTRICAL WORKS
4. For installation work at site, the successful tenderer shall be fully responsible for arranging the
required handling equipment, winches, pulley, drilling machines, tools and tackles, welding sets,
pipe bending machine, cable crimping tools, gauges, scaffoldings, ladders, temporary water and
power connections, testing instruments etc as required for smooth execution of work.
5. On completion of the installation but before energisation of the system, all installations shall be
physically checked and properly tested. These checks and tests shall be conducted by the
tenderer under the supervision of Owner/Consultant .The tenderer shall furnish the final status
and test results. Any defect observed during such check and tests shall be rectified by the
tenderer free of cost within contract completion period.
6. The wastage limits for cables shall not be more than 2.5 % of total quantity of cables. Before
cutting of cables from drums, the tenderer shall carry out measurement of cable required to be
laid and the cable shall be cut from the drum as per drum cutting schedule to be prepared by
him so that wastage is minimized.
7. The quantities given in Schedule of Quantities are probable quantities of work involved. These
are furnished for the tenderer’s conveniences and it must be clearly understood that the
contract is not a lump sum contract, that the probable quantities and the aggregate value of the
entire tender are only indicative and the OWNER does not in any way assure the tenderer or
guarantee that the actual quantity of work would correspond to the probable quantities in the
tender.
8. Cables shall be supplied in wooden cable drums and the minimum cable length in a drum shall
generally not be less than 1000M. Tenderer shall note that variation of cable length in each
cable drum shall not be more than + / - 5 % of total cable length for the cable drum. However,
there shall not be any “negative” (-ve) tolerance in the quantity of cables for each size of cable.
9. Tender shall note that the cable jointing shall be avoided as far as possible, however if the
requirement of cable joints is inevitable the same shall be done only after the approval from
Owner / consultant at site.
10. The installation price for equipment and fittings shall include supply, fabrication and erection of
painted supporting brackets made of steel angles, flats etc including bolts, nuts, washers etc.,
minor civil work and all consumable materials required for the installation. Suitable identification
tags shall be provided without any extra cost to the OWNER.
11. Generally all floor mounted panels shall be tack welded to embedded channels and inserts
provided in the floor. Where foundation pockets are not provided, and are required for fixing of
equipment the tenderer shall provide adequate size of expansion type fasteners which shall be
installed in the floor slab or brick wall by drilling as recommended. No additional rates shall be
admissible on this account, whatsoever.
12. The tenderer shall include in his quoted installation price the supply of all necessary
miscellaneous erection materials such as cable clamps, bolts, nuts, washers, shims, tapes etc
as required to complete the installation of individual equipment and cables in all respect.

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13. Installation price of cables/wires shall include supply and installation of all accessories like
glands, lock nuts, cable lugs and ferrules, bolts, nuts, screws, washers, identification tags etc
and all other consumable materials as required. Also cost for transporting of cable drums, laying
of cable, cutting of cables as per required length, returning surplus/cut length, sealing of pipes
and holes including spare ones are included. Installation price of cables shall include laying of
cables through pipes and pipe sleeves wherever required. Installation price for laying of cables
in air shall include required consumables, clamps, providing aluminium cable tags at both ends
at specified lengths including supply and punching of tags.
14. Installation price of pipes to be laid in ground required for cable laying, road / rail crossings
shall include necessary cutting of road, excavation of required depth as per the drawings, Back
filling, Laying, concrete embedment and subsequent repair and finishing the road as before.
15. Installation price of cables/wires shall include all the labour along with the rate for the services
of jointer and labour, supervision, testing and cost of installation material such as identification
tags, consumable material etc as required for completing the termination work in all respects.
The rate for pulling of cables through conduits / pipes, laying inside covered cable trenches,
laying on walls on saddles / Clamps, measurement at site prior to cutting of cable, cable ties,
cable clamps, dressing of cables, providing cable tags at intervals and at exit / entry points of
buildings, sealing of the conduit/pipes with cable putty, Cable markers shall be provided at
every 10 meters for cable directly buried in ground. shall be included in the rates quoted for
installation of cables. Installation price for cable trays shall also include the rates for coupler
plates, Zinc passivated fasteners, clamps for fixing on cable tray supports etc in the rate quoted
for the supply and installation of cable trays.
16. Installation price of directly buried underground cables shall include excavation of cable trench
to a depth of 1000mm from finished ground level, providing at least 75mm sand cushion in the
trench, laying of cable over the sand cushion, again providing 75mm sand cushion on the cable
laid, placing burnt red bricks suitably over top layer of sand cushion and back filling of
excavated trench with good soil. The installation charges of underground cabling shall include
labour, supply & installation of above said materials viz., sand, burnt red bricks, good earth for
back filling, cable route markers, joint markers etc.
17. The installation price of equipment like LDB, MCBDBs, MCB box, earthing, cables, wiring,
lighting etc covered in the scope shall include floor openings/drilling/cuttings, provision of
sleeves / inserts/ mounting channels wherever required, foundation bolts along with all civil
materials for completion of installation in all respects for smooth and reliable operation. The
installation rates shall also include supply and fabrication of steel materials including all
miscellaneous accessories. Tenderer shall include the rates for minor civil works such as
chipping/grouting, providing shim plates, tack welding to floor / wall embedded inserts, providing
bolts/nuts for fastening to embedded bolts, welding of supports to column etc., in cost for the
installation of switchboards along with the cost for embedment in concrete / supply of fabricated
supports.
18. Installation prices of fan/exhaust fans, PVC conduits etc shall include supply and erection of
supporting brackets, clamps, saddles, brackets, hooks, cleats including bolts, nuts, washers

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identification tags etc and other consumables as well as minor civil work involved for the
installation.
19. Installation price of light fittings viz.,FLP light fixtures, well glass/Road light fittings / low bay
fluorescent / CFL / HPSV/LED light fittings shall include mounting of lighting fittings on
structure/wall including mounting of control gear box by means of conduits of required length,
MS angle / pipe, brackets, suspension hooks, straps, clamps, ball and socket, nuts, bolts and
terminal boxes wherever required, cutting and making of required threads and supply steel
materials, fabrication of brackets, interconnection between control gear box, bushing, locknuts
etc. as required. Flexible cables as required for tapping to individual lighting fittings as well as
14 SWG GS wire for earthing and flexible conduits shall be included in the prices quoted for
installation of lighting fittings. Supply of all materials and accessories shall be included in the
installation price, Installation rates for road lighting fittings shall also include supply of steel
materials, fabrication of brackets, interconnection between Control Gear box and fittings with
supply of suitable clamps, lugs etc. Flexible conduits wherever required same shall be included
in the installation rate of light fittings.
20. Installation price of point wiring includes cabling /wiring, installation of switchboards, modular
type switches & universal socket outlet, junction boxes, ceiling roses along with 19mm dia Rigid
PVC conduits. The point wiring shall also includes circular/rectangular thermoplastic material
junction boxes, bends, tees, sockets, adopters, reducers etc and accessories such as saddles,
distance pieces etc as per requirement for installation on walls / structure / ceiling.
21. Installation prices of earthing conductors along floor, wall, structures, etc shall include clamps,
cleats and other fixing devices, jointing as well as termination including chipping of floors where
required and making good the same after erection. The installation price of earthing strips laid
buried in ground shall include excavation upto 800mm depth, laying, backfilling including
clamps, cleats and other fixing devices , jointing as well as termination, bitumen paint at the
joints of the earth strip . Also the installation price of earth station shall include excavation,
dewatering, laying of pipes, providing supports, drilling, welding, hot boring, jointing with jointing
materials, , fabrication, fixing of all fittings and accessories, wrapping and coating, construction
of concrete enclosure with top cover and filling with salt and good earth complete with testing,
painting the tested value together with station No. on aluminium marker plates and
commissioning to ensure satisfactory earth resistance results.
22. The rates for fixing of supports by means of tack welding, grouting, anchor bolts etc as required
as per site conditions shall be included in the rates quoted for installation of prefabricated
galvanized cable tray support structures.
23. Submission of manufacturer’s test reports of all equipment is in the scope of work of the
tenderer.
24. Submission of documentation on safety and statutory measures.
25. Any rework required to be done due to inadequacies in the work of tenderer and any reasons
not attributable to Owner shall be done by the tenderer at no extra cost.

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26. During site installation, testing and commissioning if any damages are caused by incorrect
procedures of the successful tenderer such items to be repaired / replaced by tenderer free of
cost within the time schedule for completion of work at no extra cost.
1.06 DRAWINGS, STANDARD SPECIFICATIONS AND INSTALLATION STANDARDS
1) The drawings accompanying the tender documents when read with specification shall depict
the electrical system of the Terminal. These are indicative of the nature of work and issued
for tendering purposes only. Purpose of these drawings is to enable the tenderer to make
an offer in line with the requirements of the Owner. Construction shall be as per drawings /
specifications issued / approved by the Engineer-in-charge during the course of execution of
work.
2) Conduit layout drawing in ceiling, wherever required, to be prepared by the contractor and
shall be submitted for approval.
3) After the job completion, contractor shall submit catalogues/manuals (O&M) of major
brought out items. Final certified as built drawings, documents and manuals etc shall be
submitted by the contractor to Owner in bound volume with one set in soft copy (CD) plus
five sets of prints.
PART – B - EQUIPMENT SPECIFICATIONS (To be read always in conjunction with Design

Basis as stated in Part – A above)
1. TRANSFORMERS
1.1. General
1.1.1. The distribution transformer will be connected to supply system to step down the supply
voltage
to feed 415V substations.
1.2. Transformer rating and over loading
Transformers shall be capable of delivering the rated current at a voltage equal to 112.5
percent of the rated voltage without exceeding the temperature limits specified for liquid,
winding and hot spot.
Transformers shall operate satisfactorily without injurious heating at rated kVA, at any
voltage within  12.5% of the rated voltage of the particular tap.

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Transformers shall be designed for 50Hz +2 % & -5%, unless specified otherwise in design
criteria.
Transformers for two or more limits of voltage or frequency or both shall operate
satisfactorily at its rated kVA without injurious heating under all the rated conditions of
voltage or frequency or both: provided increase in voltage is not accompanied by decrease
in frequency.
Transformers shall be suitable for over loading as per IS 6600, unless specified otherwise.
Off circuit tap switch, terminal bushings, other auxiliary components/ equipment shall be
designed for maximum permissible over loading. Short time over loading to the extent of
50% shall be considered for this purpose unless specified otherwise.
1.3. Short circuit withstand capability
Transformers shall be capable of withstanding thermal and mechanical stresses during 3

phase, line to line, double line to earth and line to ground dead short circuits at the
transformer terminals, for 2 sec, without any injury. Temperature of the winding prior to the
short circuit to be considered for this shall be that corresponding to the maximum
permissible value applicable to the overloading cycle specified.
`
For this purpose, fault and type of system earthing shall be considered as indicated in
Design Criteria.
1.4. Vibration and noise level

Design and manufacture of transformer shall be such as to reduce noise and vibration level.
The noise level shall be as per NEMA TR-1.
1.5. Harmonics
The transformer shall be designed with particular attention to the suppression of harmonics,
especially the third and fifth.
1.6. Flux density
The rated flux density in any part of the core and yoke at rated voltage and frequency shall
be such that the flux density shall be 1.7 Tesla.
The maximum flux density in any part of the core and yoke at rated voltage and frequency
shall be such that the flux density with + 12.5 percent combined voltage and frequency
variation from rated voltage and frequency shall not exceed 1.9 Tesla.
1.7. CONSTRUCTIONAL FEATURES:
Magnetic Circuit
1.7.1. Transformers shall be of core type construction. The cores shall be constructed from high

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grade, low loss, high permeability cold rolled non-aging grain oriented silicon steel
laminations of grade M4 or superior.
Thickness of laminations shall not be more than 0.3 mm. Surface insulation of laminations
shall be rust resistant and have high inter laminar resistance. Insulation shall withstand
annealing temperature as high as 850 deg.C. The insulation shall be resistant to the action
of hot cooling medium.
The insulation structure for the core to bolts and core to clamp plates shall be such as to
withstand a voltage of 2000V AC for one minute.
M.S Channel of size indicated in design criteria shall be used for clamping the core and the
same shall be painted by Varnish and corrosion oil resistant paint before use.
Wherever the CRGO sheets are punched or sheared into laminations, laminations shall be
annealed in a non-oxidizing atmosphere to relieve stresses and restore the original magnetic
properties of CRGO sheets. The laminations shall be free of all burrs and sharp projections.
The design of magnetic circuit shall be such as to avoid static discharges, development of
short circuit paths within itself or to the earthed clamping structure and production of flux
components at right angles to the plane of the laminations which may cause local heating.
All steel sections used for supporting the core shall be shot or sand blasted after fabrication.
The finally assembled core and coil assembly shall be rigidly fixed to the tank to avoid
shifting during transport, handling and short circuits. Adequate provision shall be made for
lifting the complete core and coil assembly.
The supporting frame work of the cores shall be so designed as to avoid the presence of
pockets which would prevent complete emptying of the tank through the drain valve, or
cause trapping of air during filling.
1.8. Windings
Transformers shall be suitable for earthing system as specified in Design Criteria. The
windings shall be fully insulated.
Temperature of winding shall be limited to Maximum 90°C for transformers rated upto
200kVA and shall be 95°C for transformers rated above 200kVA when measured by
resistance method.
Hot spot temperature shall be as per IS 2026.
The coil clamping arrangement shall be such as to not impede the free circulation of cooling
media.

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The windings/ and connection of transformer shall be braced to withstand shocks which may
occur during transport or due to short circuits, repeated peak loads and other transient
conditions during service.
Windings shall be subjected to a shrinkage treatment before final assembly, so that no
further shrinkage occurs during service. Adjustable device shall be provided for taking up
any possible shrinkage of coils in service if required.
The conductors shall be transposed at sufficient intervals in order to minimize eddy currents
and equalize the distribution of currents and temperature along the windings.
Coil clamping rings shall be of steel or of a suitable insulating material. Axially laminated
material other than bakelised paper shall not be used.
Completed core and winding assembly shall be dried in full vacuum to eliminate presence of
moisture. After drying process, the full assembly shall be impregnated immediately.
No strip conductors wound on edge shall have a width exceeding six times its thickness.
The winding material shall be aluminium.
All insulating materials used shall be compatible with cooling medium and other materials
that come into contact with the insulation system, under all operating conditions.
Windings shall not have sharp bends which might damage insulation and/ or produce high
dielectric stresses.
Coils shall be supported using dried and high pressure compressed wedge type insulation
spacers at frequent intervals.
All threaded connections shall be locked. Leads from the winding to the terminal board and
bushings shall be rigidly supported to prevent injury during short circuits / vibration.
Permanent current carrying joints in the windings and leads shall be welded or brazed.
Clamping bolts for current carrying parts inside the transformer shall be compatible with
liquid under all service conditions.
1.9. Taps
No taps are required for transformers rated up to 100kVA.
Taps shall be provided on the higher voltage winding of the transformer and shall be
arranged so as to maintain as far as possible the electromagnetic balance of the windings.
It shall be possible to vary the voltage in 4 positions by 3 equal steps of 2.5% each for a
variation of +2.5% to -5 % for transformers rated above 100kVA upto 200kVA.
It shall be possible to vary the voltage in 6 positions by 5 equal steps of 2.5% each for a
variation of +5% to -10 % for transformers rated above 200kVA upto 500kVA.
1.10. Off-circuit tap switch
Tap-changing shall be carried out with the transformer off-circuit by means of links or by
means of an externally-operated switch with mechanical locking device and a position
indicator. Arrangement for pad-locking shall be provided.

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1.11. Transformer Liquid

Naptha based mineral oil shall be used as transformer liquid and shall conform to IS – 335.
All transformers shall be supplied along with first filling of liquid with top up oil being
supplied loose in drums. When the oil is topped up, the oil level as seen at the
conservator shall be at “Maximum” level. All components, insulating materials used in
the transformer construction shall be compatible with the liquid under all operating
conditions.
Temperature rise of top oil shall be limited to 35°C for transformers rated upto 100kVA and
40 °C for transformers rated above 100kVA up to 500kVA when measured by thermometer
method.
1.12. Transformer Cooling

The transformer shall be Oil Natural Air Natural ( ONAN ) cooled type.
1.13. Radiators
Radiators shall have fixed connection to tank.
1.14. Tank
Tank shall be made from high quality low carbon steel and shall have oil tight welded
construction. The transformer tank covers shall be bolted/clamped alternatively welded with
tank rim so as to make a leak proof joint. The curb design in case of welded construction
shall be such that it is possible to remove the weld and reweld the tank at least two times.
The tanks of all transformers shall be complete with all accessories and shall be designed so
as to allow the complete transformer filled with liquid to be lifted by cranes or jacks,
transported by road, rail or water without over straining any joints and without causing
subsequent leakage of liquid.
In case of transformers up to 200 kVA, plain tank shall be capable of withstanding a
pressure of 80 kPa and a vacuum of 250 mm of mercury. Limiting values of the deflections
are specified in Cl. 21.7.1 of IS 1180.
For transformers above 200 kVA and up to 2500 kVA, plain tank shall be capable of
withstanding a pressure of 80 kPa and a vacuum of 500 mm of mercury. Limiting values of
the deflections are specified in Cl. 21.7.2 of IS 1180.
For three phase transformers up to 2500 kVA, transformer tanks with corrugations shall be
designed for a pressure of 15 kPa measured at the top of the tank with no leakage.
The base of each tank shall be so designed that it shall be possible to move the complete
transformer unit by skidding in any direction without injury when using plates or rails.
Tank cover shall be of adequate strength and shall not distort when lifted.
Tank covers shall have pockets for bulbs of liquid temperature indicators. Thermometer
pockets shall have captive screwed top to prevent ingress of water. The pockets shall be
located in the position of maximum liquid temperature and it shall be possible to remove the
instrument bulbs without lowering the liquid in the tank.
1.15. Lifting and Pulling Lugs

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Lifting Lug -Minimum 4 nos. of welded heavy duty lifting lugs of M/S Plate 8mm thick suitable
reinforced by vertical supporting flat welded edgewise below the lug on the side wall shall be
provided.Lifting lugs shall be suitable for lifting the transformer with liquid.
Pulling Lug – 4 Nos. of welded heavy duty pulling lugs of M/S plate 8 mm thick shall be
provided to pull the transformer horizontally.
1.16. Top Cover Fixing Bolts
GI bolts and nuts of size 12mm x 40mm with one plan and one spring washer suitably apart
(100mm ) shall be used to press the cover.
1.17. HV/LV Terminations

Bare Bushing shall be considered for terminations on both HV and LV side. Further, the HV
and LV terminations shall be oriented at 1800.
1.18. Bushings
The transformers shall be fitted on high voltage and low voltage sides with outdoor
typebushings of appropriate voltage and current ratings. The high voltage bushings (3
Nos.) shall conform to IS 2099. The low voltage bushings (4 Nos.) shall conform to IS
7421.Alternatively, the low voltage side may be made suitable for adoption of PVC / XLPE
cables of suitable size.
Minimum rated current of the line end bushing shall be 1.5 times the rated current of the
corresponding winding ; where repeated peak loads are specified, bushing rating shall be
selected accordingly. Rating of LV Neutral bushing shall be same as that of LV line side
bushing. Porcelain bushings shall be provided for HV and LV terminations; however for LV
terminations epoxy bushings are also acceptable.
Bushings shall be suitable for atmosphere present in the place of installation. Total
creepage distance shall not be less than 25 mm/kV of highest system voltage.
The bushing shall be made in two parts. The outer bushing shall be of porcelain. The
dimensions of the outer bushing shall conform to relevant part /Section No. of IS 3347
depending on the Voltage Class. The internal bushing shall be of either porcelain or tough
insulating material, like epoxy and shall have embedded stem. Metal portion of the internal
HV and LV bushing inside the tank shall remain dipped in oil in all operating conditions.
Short time rating and insulation level of bushing shall be same as that for transformer.
The minimum phase to phase and phase to earth external clearances for HV & LV
bushings shall be as follows:-
Minimum Clearances
Phase to Phase Phase to Earth (in

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(in mm) mm)
HV Bushing 255 140
LV Bushing 75 40
1.19. Conservator
Conservator shall be located in such a position as not to obstruct the electrical connections
to the transformer. The conservator volume shall be sufficient to maintain the oil seal from
ambient temperature to maximum oil temperature allowed specified elsewhere in the
specification, with oil level varying within minimum and maximum levels.
The conservator shall be provided with dial type magnetic oil level gauge with pointer and
potential free contacts for alarm/trip. In addition , prismatic type oil level gauge with
minimum and maximum levels marked shall also be provided. Taps or valves shall not be
fitted to the oil gauge.
Drain plug shall drain the conservator oil completely. One end of conservator shall be
bolted into position so that it can be removed for cleaning purposes. If the sump is formed
by extending the feed pipe into the conservator vessel, the extension shall be for at least 20
mm.The minimum oil level (corresponding to - 5°C) should be above sump level. Oil filling
hole(1 ¼ nominal size thread) with cap shall be provided.
A silica gel breather with inspection window and oil seal shall be mounted at 1.4m above
transformer base and connected to the conservator.
1.20. Breathers
Breather joints shall be of bolted type.It shall have die cast Aluminium body and inside
container for Silica gel shall be of tin.
1.21. Losses and Impedance
The losses and impedance for various ratings of transformers of 11kV class shall be within
the permissible limits. These losses are the maximum permissible.
Rating Max. Max. Impedance %

(kVA) Losses Losses at (subject to
at 50 % 100 % tolerance as per
loading loading IS : 2026)
(Watts) (Watts)

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63 380 1250 4.5
100 520 1800 4.5
160 770 2200 4.5
200 890 2700 4.5
250 1050 3150 4.5
500 1600 4750 4.5
No positive tolerance shall be allowed on the maximum losses displayed on the label for
both 50 % and 100 % loading values.
1.22. Valves and connections
All valves shall be of gun metal/ cast steel, full way type with internal screwed ends and will
be opened by turning counter clockwise when facing the hand wheel. There will be no oil
leakage when the valves are in closed position. All valves opening to atmosphere shall be
fitted with blank flanges. Means shall be provided for padlocking the bottom valves in
open and closed position. All valves shall be provided with an indicator to show clearly the
position of the valve. Means shall be provided for top and bottom oil sampling. All
transformers shall have residual drain plug, bottom drain valve, top and bottom filter valves
suitable for connecting to oil filtration unit. The filter valves shall be arranged on opposite
sides of the transformer.
1.23. Joints and gaskets
All gaskets used for making oil tight joints shall be of proven material such as granulated
cork-bonded with synthetic rubber ( SRBC ) or synthetic rubber ( nitrile ) gaskets for oil filled
transformers confirming to IS 11149/Type C as per IS – 4253 Part- II .
1.24. Explosion vent/ pressure relief device
Means provided for release of excess pressure generated inside the tank shall be either
double diaphragm type explosion vent or pressure relief device. In case pressure relief
device is provided, same shall be of sufficient size for rapid release of any pressure that may
be generated within the tank and which might result in damage to the equipment. The device
shall operate at static pressure of less than the hydraulic test pressure for transformer tank.
Means shall be provided to prevent the ingress of rain water. The device shall be provided
with potential free contact wired up to Marshalling Box.
The PRD shall be mounted on the main tank and if on the cover, shall be fitted with skirt
projecting 25 mm inside the tank and of such a design toprevent gas accumulation.
If diaphragm type explosion vent is used, the diaphragm shall be of suitable design and
material and situated above maximum oil level. An equalizer pipe connecting the explosion
vent and conservator shall be provided for relieving or equalizing the pressure in the device
depending upon design consideration.

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1.25. Internal earthing arrangements

All metal parts of the transformer with the exception of individual core laminations, core bolts
and associated individual clamping plates shall be maintained at fixed potential by earthing.
1.26. Core clamping structure earthing
The top main core clamping structure shall be connected to the tank body by a copper strip
of adequate cross section. The bottom clamp structure shall also be connected to the tank
by one or more of the following methods.
By connection through vertical tie rods of the top structure.
a. By direct metal to metal contact with tank base maintained by the weight of the core
and winding.
b. By connection to the top structure on the same side of the core as the main earth
connection to the tank.
1.27. Earthing of coil clamping rings
Where coil clamping rings are metal, at earth potential, each ring shall be connected to the
adjacent core clamping structure on the same side of the transformer as main earth
connections.
1.28. Earthing of magnetic circuit
Magnetic circuit shall be earthed to the clamping structure at one point only.
1.29. Size of earth connection
All earth connections, except those from the individual coil clamping rings shall be done by
copper conductor with min. cross section of 80 mm2. Copper connections inserted between
laminations of different sections of core shall not be less than 20 mm2.
1.30. Fitting and accessories
Transformer shall be provided with fittings and accessories as specified in Annexure-II
ANNEXURE- I

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DESIGN CRITERIA
1 Rating of transformer 63kVA, 250kVA & 500 kVA
Percentage impedance of
2 4.5% up to 500kVA
transformer
3 Phase power supply system in

3
which transformer is to be used
a) Primary side (HV) max. voltage 12 kV
System Earthing
Effectively grounded
Primary side(HV)
Secondary side (LV)

Effectively grounded
Max. 3 phase fault levels
4 Primary side (HV) 40 kA
Secondary side (LV) 25 kA
5 Insulation level
a) PF withstand in kV (RMS)
HV winding 28 kV
LV winding 3 kV
b) Impulse withstand KVP
HV winding 75 kV
LV winding NA
6 Core
a) ISMC 125 X 65 mm for 500kVA

i) Core Clamping b) ISMC 100 X 50 mm for 250kVA
c) ISMC 75 X 40 mm for <= 100kVA
a) 20 mm High Tensile bolt for 500kVA
ii) Core fixing bolt – 2Nos.
b) 16 mm High Tensile bolt for 250kVA

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c) 12 mm High Tensile bolt for <= 100kVA

iii) Tie rod insulating Kraft paper tube of thickness 1.5 mm
medium
Annexure-II
Fitting and accessories
1. 1 No. of Rating and Terminal marking Plate.
2. 2 Nos. of Earthing terminals minimum M12 with nuts should be provided on the tank.
3. 4 Nos. of Lifting lugs for the complete transformer as well as for core & winding assembly.
4. 1 no. of Cap for oil filling (on conservator).
5. Drain cum Sampling valve (3/4 ̎ normal thread size) with cover preferably steel with plug.
6. 1 No. of Conservator with drain plug .
7. 1 No. Thermometer pocket.
8. Air Release plug on main tank.
9. Platform mounting channels.
10. Uni directional Flat rollers.
11. Inspection hole.
12. Pressure relief device or Explosion vent.
13. Dehydrating breather :Silicagel breather of 500 gms capacity.
14. Oil Level guage shall be provided indicating 3 position of oil marked as below:
Minimum (-) – 5 degree C
Maximum (+)- 30 degree C to 90 degree C.
15. Off circuit tap switch handle shall be provided with locking arrangement.
16. HT & LT bushings- 3Nos. of HT bushings and 4 Nos. of LT bushings shall be provided with
terminal connectors .Each bushing of HV and LV shall be provided with 3 Nos. of brass nuts
and 2 Nos. plain brass washers for connecting terminal.LT terminal connectors for 250kVA
transformers shall be supplied in separate packing.

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17. Radiators: Elliptical/fin/tubular type radiators shall be provided as per design.
18. Arching horns for HT hushing with adjustable type on the ground side.
19. Filter Valve – 20mm dia. shall be provided on the upper side of the tank.
2. HT LOAD BREAK SWITCH CUM METERING CUBICAL

2.1 DESIGNB CRETERIA:
1. Type of load break switch (fixed Triple pole, air break, manually operated,
/draw out) quick break and make, Load break type in a
Fixed design.
2. Service Outdoor
3. Applicable standard IS 12729
4. Rated voltage 11 kV ±10%
5. Rated frequency 50Hz ±5%
Maximum continuous voltage up 12 kV
6. to which load break switch can be
used
7. Short circuit withstand capacity 40kA for 3 sec.
Rated current inside cubicle 400 A or 1250A as per Schedule of
8. based on specified ambient Quantities.
temperature
9. Operating mechanism
a) Type of arc quenching Air break
b) Contact material Silver plated copper
c) Provision of stored energy Yes
spring charged mechanism
d) Mechanical trip push button To be provided
10. Switching rating at rated voltage

a) Breaking capacity 400 Amps and 1250A at 0.7 pf
b) Breaking capacity of 5 Amps
magnetising current of
transformer
1.2 / 50 microseconds lightning

11. impulse withstand voltage / one
minute PF withstand voltage)
a) Across the isolating distance 85kV peak / 32 kV RMS
b) To earth, between poles and 75 kV peak / 28 kV RMS
across open switching device

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12. Minimum clearances in air in mm

a) Between phases 130 mm
b) To earth & between poles 130 mm
13. Earth switch

a) Type of operating mechanism Quick make / Quick break
b) Interlocks between load break
switch and earth switch
c) Mechanical interlocks Yes
14. Cubicle
a) Enclosure as per IS 3427 IP 52 or better
b) Compartmentalization Yes, I/C , O/G and LV partitioned with FRP
shrouds
c) Applicable standard IS 3427, 1997
d) Maximum continuous voltage 12 kV
15. Insulation level

I) Lightning Impulse withstand 75kV
voltage, kV peak
ii) One minute PF withstand 28kV
voltage, KV (RMS)
16. Minimum clearances in air in mm

i) Between phases 130 mm
ii) Between live part and earth 130 mm
17. Material of bus bars Aluminium

18. Temperature rise As per IEC
Type of bus bar support insulators Epoxy resin cast
19.
20. Creepage distance 31 mm / kV of highest system voltage
21. Extensibility of cubicle on both No
sides
22. Space heater Required
23. Termination
i) Cable entry Incoming /outgoing Bottom
ii) Number & Size of cables 3 runs of (3Cx300) sq.mm, XLPE armoured
cables (Max)
24. Auxiliary contacts 4No + 4NC

25. Control Supply Voltage 240V, AC
26. Accessories Mechanical ON/OFF indicator
27. Door interlock To be provided with isolator

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2.2 TECHNICAL SPECIFICATION – 11 kV Load Break Switch
2.2.1 General
HT load break switch is intended to connect/disconnect distribution transformer or any other

equipment as specified in the design criteria.
2.2.2 Rating
The load break switch shall be fault make, load break type. The load break switch shall have
specified rated current, fault making capacity, short time thermal rating, dynamic through fault
withstand capability without HRC fuses in the circuit.
Earth switch, where specified, shall be provided for earthing of outgoing equipment and it shall have
same fault making ratings as applicable to load break switch. Earth switch shall have interlock with
the main switch i.e. the earth switch cannot be closed unless the main switch is OFF
2.2.3 Type
Load break switch shall be air break, in fixed design
2.2.4 Operating Mechanism
The load break switch shall have quick make, quick break independent manual operating
mechanism and mechanical trip device. Earth switch, shall also have manual independent operating
mechanism.
Both main switch and earth switch shall be provided with quick make, quick break mechanism.
2.2.5 Interlocks
Where fixed type load break switch is specified, panel door shall be mechanically interlocked so that
isolator cannot be closed on open position of door and door cannot be opened on close position of
isolator.
Mechanical interlocks between load break switch and earthing switch shall be provided such that it
shall not be possible to close the earthing switch with load break switch in ON position and vice
versa.
2.2.6 Cubicle

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Load break switch cubicle shall be floor mounting, outdoor, self-standing, sheet steel enclosed,
dead front conforming to IP-55 or better enclosure as per IS 3427.
The cubicle shall have segregated compartments for isolator, cable termination, load break switch,
low voltage chamber as per design criteria.
The cubicle shall have hinged doors with locking device on the front. If cable chamber is provided
on the backside, provision of hinged door on the backside shall be made. Wire mesh with suitable
fixing arrangement shall be provided to prevent accidental contact with live parts, when doors are
opened. Bus bar chamber shall have bolted covers. Caution inscriptions painted in red shall be
provided for each cubicle.
2.2.7 Auxiliary Contacts
4 NO + 4 NC auxiliary contacts shall be wired to terminal block.
2.2.8 Indications
Mechanical ON/OFF indications shall be provided on the front of the panel for load break switch and
earth switch. These shall be visible from outside
2.2.9 Control Circuit Protection
All incoming control circuits shall be fed through MCBs.
2.2.10 Terminations
The cubicle shall be suitable for Bottom cable entry for incoming and outgoing HT power cables and
control cables. Removable GI gland plate shall be provided.
2.2.11 Space Heater
Space heater with isolating MCB suitable for 240V along with thermostat shall be provided. Power
cable shall be terminated in the terminal block.
2.2.12 Earthing& Mounting
Aluminium earth bus of adequate cross section shall be provided and shall be terminated on earth
terminals provided, external to the cubicle for cubicle earthing. Necessary termination facility shall
be provided for terminating armour of HT cables on to the earth bus.

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Each unit shall be constructed to ensure satisfactory electrical continuity between all metal parts not
intended to be alive and the earth terminals of the unit. Further the necessary base frames shall be
provided for grouting the panel / welding to the plate insert provided in the foundation.
2.2.13 Tests
All Routine tests shall be carried out as per IS and approved QAP.
Type Tests
Test reports carried out on identical units shall be furnished when called for. If the Type Test reports
of equipment of the same design are not available, the tests shall be carried out on equipment at no
extra cost.
Routine Tests
Load Break switch shall be subjected to the routine tests in accordance with applicable standard
and are subject to witness by external agency.
3. 415V Switchboard
3.1. General

i) The 415V Switchboard Panelshall be designed to carry continuously without overheating, the
rated current specified in the schedule of quantities.
ii) The busbars shall be rated to limit the temperature rise within 40 deg.c over the specified
ambient temperature of 45 deg.c (total temperature: 85 deg.c)
iii) The 415V Switchboard Panelshall comply with IS 8623 Part I&II,IEC 439 and other relevant
Indian/International Standards.
iv) The ratings of incomer and feeders shall be as indicated in schedule of items/ single line
diagrams enclosed.
3.2. Construction
i) The 415V Switchboard Panelshall have sheet steel enclosure cubicle type and shall be

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a) Floor mounted, self standing/supporting type
b) Totally enclosed, dust, damp and vermin proof
c) Single front and preferably without rear access.
d) With IP 42 enclosure as per IS 2147
e) Fully compartmentalized, fixed type, in tier formation with Aluminium busbars
f) Easily extensible on both sides at site
The 415V Switchboard Panel shall have MCCB acting as incomer while the outgoing feeders
shall be with MCCBs as indicated in the enclosed single line diagram.
ii) The 415V Switchboard Panelshall be of indoor, factory assembled, continuous boards suitable
for cable entry from bottom.
iii) The boards shall be provided with lifting eye bolts for each shipping section.
iv) The cubicles shall be manufactured using high quality CRCA sheet steel of at least 2 mm
thick.
v) Suitable neoprene gaskets shall be adequately provided on all doors and covers for making
the boards dust proof.
vi) All operating handles shall be accessible from the front side of the cubicle. The operating
handles shall be suitably interlocked mechanically with the door such that the door can be
opened or closed only with the switch in OFF position. Provision for defeating the door
interlock also shall be provided.
vii) The number of accepted tier formation shall be subject to the condition that the operating
handles shall be above 400 mm from floor level and shall not exceed 1800 mm from floor level
for convenience of the operating personnel.
viii) Each unit compartment shall have full metal barrier on all sides except front, which shall be a
hinged door. All hinges shall be concealed.
ix) Each vertical section shall have a busbar alley on one side for tap off to feeders and cable
alley on the other side and shall be provided with door/removable covers at the front.
x) The clearances required at the back and front side, shall be indicated.
xi) There shall not be more than 6 compartments in a vertical section.
xii) A base channel/frame of minimum 50 mm height and 2.5 mm thickness shall be provided.

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xiii) All inscriptions shall be on traffolite/anodised aluminium sheets with white letters on black
background.
Feeder details

i) 415V Switchboard Panelshall have MCCBs as incomer and outgoing feeders conforming to
the detailed specifications given below :
ii) All incomer feeders shall have 3 indicating lamps, red, yellow, blue in colour, to announce
power supply 'ON'.
iii) All incomer feeders shall have voltmeters and ammeters with selector switches with off
position. All outgoing feeders shall be provided with ammeters with selector switches.
iv) Incomers of 415V Switchboard Panelshall have specially designed termination arrangements
to accommodate multiple cables (as indicated in schedule of items).
v) Number and ratings/details of feeders are given in schedule of items/SLD
3.3. Busbars, busbar supports, connections
i) 415V Switchboard Panelshall have metal enclosed chamber for main busbars at the top
running throughout the length of the board. The busbar chamber shall have removable covers
for easy maintenance.
ii) Outgoing feeders shall be connected to the main busbars through vertical busbars provided in
the busbar alley. Vertical bus bars shall be easily accessible for maintenance. Vertical bus
bars for TP&N shall be arranged to run full height of the vertical section irrespective of whether
the bottom most section is used or left as empty feeder.
iii) Busbars (triple pole and neutral) shall be
a) Aluminium conductor
b) Uniform in cross section throughout the length of the bus and identified by
colour code throughout.
c) Selected giving due consideration to proximity effect.
iv) All the busbars shall have dynamic stability for the peak current and thermal stability for the
specified symmetrical short circuit current for 1 second without any deformation, deterioration
or damage.

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v) Busbars shall be provided with heat shrunk insulation.
vi) An earth bar of adequate cross section for terminating fourth core of outgoing cable shall be
provided running throughout the length of the power distribution board at the bottom with
provision to connect to shop earth grid at either end of the board. Size of earth bar shall
however be not less than neutral bus size. Removable bus link shall be provided between
neutral and earth bus bars.
vii) Bus bar support shall
a) Have high dielectric strength and high impact strength capable of withstanding dynamic
stability currents.
b) Be of non-hygroscopic type
c) be with antitracking barriers
d) beself extinguishing and fire retardant insulators with ribbed construction to prevent
tracking due to dust accumulation and to have larger creepage distance.
viii) Size of the neutral bus shall not be less than half of the size of main busbar.
ix) The busbars shall be rated to limit the temperature rise within 40 deg. C over the specified
ambient temperature as indicated in the design criteria.
x) Allowance shall be made for reduction in section by boltholes.
xi) Busbar, connecting fishplates, zinc bichromated bolts, nuts and washers shall be provided at
each end of a shipping section to facilitate connection at site.
xii) The clearance between bare phase power busbars and between phase and earth in air shall
not be less than 25 mm and 19 mm respectively.
xiii) All busbar joints shall be of bolted type. Belleville/ spring washers shall be used for joints to
prevent loosening.
xiv) Busbars shall be phase identified by colour code.
3.4. Cable alley

i) Each vertical section shall have a cable alley along side
ii) Cable alley shall have adequate space for terminating copper power cables.
iii) Barriers running complete height of the board shall effectively isolate the cable alley from
horizontal and vertical busbars.

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iv) Bottom cable chamber shall be left free completely for accommodating power cables and
shall be completely isolated from vertical busbars.
v) Removable, undrilled gland plates shall be provided for each cubicle/vertical.
vi) There shall be no horizontal cross bracings within 250 mm of gland plates where the cables
enter.
vii) All power outgoing terminals shall be brought out to a separate terminal block/strip through
solid links with bellows and located in the cable alley.
3.5. Interchangeability
i) All identical equipment and corresponding parts, accessories shall be fully interchangeable
without any modification.
ii) Components and equipment that are not fully interchangeable are liable for rejection and the
supplier shall replace all such items by fully interchangeable ones free of cost.
3.6. Make up of Modules
i) Incoming feeder:
- Shall be ACB/MCCB unit of adequate rating in fixed module. ACB/ MCCB shall be with
microprocessor based direct acting self-powered adjustable O/C, E/F, S/C release.
- Provided with voltmeter and ammeter with selector switches. Multifunction meter & energy
meter shall be provided at the incomer .Meters to have accuracy class 1.0 and size 144 x
144 sq. mm.
- Provided with microprocessor based metering system, MFM with RS 485 communication
port and pulse energy output.
- Provided with R, Y, B phase indication lamps and ON,OFF & TRIP lamps
- MCCB shall have 1 NO + 1 NC contacts rated for 6A, AC 11 duty. ACB shall have minimum
4 NO = 4 NC auxiliary contacts rated for 6A, AC 11 duty.
ii) Outgoing MCCB feeders:
- With microprocessor based adjustable, self powered release for O/C, S/C and E/F. In case,
E/F release is not possible then ELR with CBCT shall be provided.
- With 1 NO + 1 NC auxiliary contacts rated for 6A at AC11 duty.

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- Provided with ON, OFF and Trip lamps, ammeter for all feeders rated 100 A and above
Moulded Case Circuit Breakers (MCCBs):
MCCBs shall be of triple pole construction suitable for panel mounting, Operating mechanism shall
be trip free, quick make, quick break type.
The MCCBs shall be provided with front operating handles and mechanical ON/OFF indicators. In
case of trip, the handles shall rest in an intermediate position.
MCCBs shall be provided with microprocessor-based release for O/C, S/C, and E/F, which
shall be fully adjustable.
Where MCCBs are used in the motor starter modules in conjunction with contactor and
thermal overload relay, type 2 coordination shall be provided.
MCCBs shall have following accessories and features:
a) Shunt trip release
b) Auxiliary contact set of 1 NO + 1 NC contacts
c) Fault signaling contact set of 1 NO + 1 NC contacts
d) Insulation shields to isolate the connections between each pole
e) Finger protection plate to prevent accidental contact
The compartment door shall be interlocked with the handle of the MCCB
3.7. Indicating instruments and current transformers
i) All indicating instruments (voltmeters and ammeters) shall conform to IS 1248.
ii) All indicating instruments shall be of taut band flush mounting type size 96 mm x 96 mm and
shall conform to 1.5 accuracy class.
iii) All instruments shall be provided with zero adjusting device for external operation.
iv) Ammeters shall be suitable for operation on CT and scaled to read actual currents flowing in
the circuits.

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v) All measuring current transformers shall conform to IS 2705. The current transformers shall be
of cast resin/bakelite housing type, with bar primary, 5A secondary current and class 1
accuracy. The burden of CTs shall be as required by the associated measuring instruments
and connecting leads.
3.8. Indicating lamps
All indicating lamps shall be of low wattage cluster LED type. Red, Yellow and Blue colour lenses
shall be provided for the lamps of the incomer.
3.9. Wiring and terminations
i) The Emergency Panel shall be completely factory assembled and wired.
ii) Power connections shall be done by 1100 V grade single core pvc insulated copper conductor
or by aluminium strips of sizes adequate for the respective ratings. Control / Aux. wiring shall
be by 650 V/1100V grade PVC single core copper conductor of min. cross-section 2.5sq.mm.
iii) Each wire shall be identified by ferrules at each end in accordance with schematics.
iv) Wiring to the door shall be done by flexible cable and the cables shall be bunched, sleeved
and cleared so that no mechanical damage can occur to the cables during door movements.
All terminations shall be of adequate current rating and size to suit individual feeder rating.
v) Outgoing power terminals shall be designed for connecting PVC Aluminium/copper cables of
sizes indicated in schedule of items/SLDs.
vi) Not more than 2 wires shall be connected at one control terminal.
vii) Required number of heavy duty double compression type brass cable glands suitable for the
outgoing cables, projected nipple type complete with two locknuts and earthing washer
(provided with earth studs) shall be supplied.
viii) Edge of cable glands shall have threaded projection to enable the locknut to fit from inside of
the equipment.
ix) Terminals, crimping type cable lugs and glands shall be suitable for the cable sizes to be
indicated by the Owner during the execution of order.
4. Lighting distribution board (LDB)

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A. General :-
1.0 Type - Metal clad

- Shall be suitable for 415/240V, 3 phase and
neutral.
2.0 Construction - Totally enclosed.
- Dust & vermin proof.
- Welded back and sides .
3.0 Enclosure class IP54 .
IP 55 (with canopy) for outdoor installation .
4.0 Type of execution Single front.
5.0 Mounting Wall mounting .
6.0 Installation Indoor / Outdoor (with canopy).
B. Constructional Features :-
1.0 Sheet steel CRCA
Thickness 2 mm .
2.0 Cable entry - Incomer :- Bottom cable entry.

- Outgoing :- Top / Bottom cable entry.
3.0 Design - One Incomer and outgoings .
- All the components shall be accessible from front
- Access to the operating handle of the incoming

isolating switch shall be from the front of the
cubicle without opening the front door.
- Operating knobs of outgoing MCBs shall be
accessible from outside without opening the
door. The ougoing MCB shall be provided
with a glass door.
- Protective insulated cover plate (3 mm thick
Bakelite sheet ) shall be provided inside the

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cubicle to shroud all the live parts .

4.0 Gland plate Undrilled detachable gland plates (3 mm thick) shall
be provided at the top and bottom with suitable
gaskets for cable entry.
5.0 Miscellaneous - Neosprene rubber gasket shall be provided

for all the doors , removable covers &
between adjacent covers .
- Suitable locking devices.
- Doors shall have concealed hinges .
6.0 Labelling Clear legible identification labels (anodized
aluminium with white letters engraved on black
background ) with letter sizes of :-
- 5 mm for components and module name plates.

- Danger board on front and rear sides in English ,
Hindi and local language .
7.0 Earthing Two separate earthing terminals shall be provided.
8.0 Limiting dimensions - Width of SLDB :- 800 mm

- Depth of SLDB :- 300 mm
- Height of SLDB :- 400 mm (min)
C. Busbars
1.0 Arrangement Three phase & neutral.
2.0 Material High conductivity electrolytic aluminium alloy

confirming to grade E91E as per IS-5082 –1981.
3.0 Phase Busbar Rating - Shall be able to carry continuously the connected
load (considering all derating factors) plus a 25%
margin .
- Max. current density shall be
- 1.0 A/sq.mm for Aluminium
- 1.5 A/sq.mm for Copper .
4.0 Neutral Busbar Rating 50 % of phase busbar rating

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5.0 Short circuit rating 25 kA for 1 sec (or higher as per system
requirement).
6.0 Busbar configuration Red-yellow-blue , black for neutral .
7.0 Busbar insulation Heat shrinkable PVC
- R,Y,B coloured sleeves for phases

- Black for neutral.
8.0 Busbar supporting - Non-hygroscopic
insulators - Flame retarded
- Track resistant
- High strength
- Sheet moulded compound or equivalent polyster
fibre glass moulded type .
9.0 Air clearance for bare Phase to phase :- 25.4 mm (minimum)
busbar
Phase to earth :- 19.0 mm (minimum)
D. Feeder arrangement
Incomers
1.0 Isolating Equipment 4 pole ELCB/RCCB with MCCB .

ELCB/RCCB shall be of AC 23 duty category conforming
to IS: 13947-1993 having fully shrouded contacts.
2.0 Quantity One
3.0 Indication Lamps LED type indicating lamps for :-
- Power ON R / Y / B .
Outgoing feeder arrangements
1.0 Circuit breaker DP MCB
E. Panel wiring

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1.0 Power / current 1.1Kv grade single core , black colour PVC
transformer circuit insulated , stranded copper conductor of minimum
size 2.5 sq.mm.
2.0 Ferrules - Numbered plastic/ceramic ferrules.

- Self locking type.
3.0 Marking - Wiring shall be properly marked as per relevant
IS.
4.0 Terminals - Power & control terminals shall be segregated
by insulating material like hylam / bakelite sheet.
- Terminals shall be ELMEX type suitable for
connecting two cores of 2.5 sq.mm wires.
- Minimum 20 % spare terminals shall be
provided.
- The minimum rating of control terminal shall be
10 Amps.
5.0 Cable glands Double compression cable glands for receiving
cables .
5. SPECIFICATIONS OF MAJOR COMPONENTS

Specification of major components are listed as below and shall be followed unless specified
specifically in equipment specification. In case of contradiction between parameter of a specific
component in equipment specification and here below then parameters indicated in equipment
specification shall prevail.
5.1. MOULDED CASE CIRCUIT BREAKER (MCCB)
1.0 Reference standard IS : 13947 (Part-2) : 1993
2.0 Rated Current Minimum 100A (frame rating). I rated shall be as per
load current with 150% margin with adjustable setting.
3.0 Type Complete with continuous electronic / microprocessor

based adjustable releases.
5.0 Short circuit rating 10 kA (Minimum) (Ics =Icu).

(Ics) = Service Short circuit breaking capacity

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(Icu) =Rated ultimate short circuit breaking capacity.
6.0 Operating handle Yes
7.0 Safety Door interlock Door interlock, Padlocking in ON/OFF position
8.0 Withstand capability Rated short time with-stand current (Icw) shall be 12
times maximum rated operational current for 1 sec.
9.0 Utilisation category AC23B
10.0 Electrical features - S/C , O/C, E/F protection for power supply feeders
MCCB’s.
- Features to minimise the let-through energy (I2t) in
the event of short circuit on load side.
11.0 Auxiliary contacts 1 NO + 1 NC, Alarm contacts.
12.0 Miscellaneous Can be used in load side or line side vice versa.
Shunt trip coil .
5.2. AC CONTACTORS
1.0 Service Indoor within steel cubicle for maximum system

voltage, starting of motors and miscellaneous loads
2.0 Standard Shall conform to IS / IPSS
3.0 No. poles 3 pole air break .
4.0 Operating type Magnetic coil operated at 240 V AC.

No economy resistors.
Insulation for coils shall be class 'E' or better
5.0 Rating 25A (Minimum) , Rated generally for 150% of full load
motor rated current. However, contactor ratings with
respect to motor ratings are standardized and shall be

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followed as per Table-1A.
6.0 Interrupting capacity Ten times the rated current for rated size upto 100A
and eight times the rated current for larger sizes.
7.0 Duty According to IEC 158-1

- AC 1 duty :- Non inductive or slightly inductive loads
- AC 3 duty :- Squirrel cage motors : starting ,
switching off motors during running
8.0 Utilisation category AC23A for unidirectional motors
9.0 Aux. contact - Minimum 4 NO +4 NC contacts with minimum rating

requirement of
- 10A , 415 V for rated duty AC-11.
- 2A , 220 V for rated duty DC-11.
- Shall have the facility of adding add-on contact
blocks.
10.0 Closing (pick-up) 85% to 110%
11.0 Dropout 65% to 45%
5.3. CURRENT TRANSFORMERS:
1.0 Type Bar type primaries and 5A (max) secondary with

thermal and dynamic ratings corresponding to the units
with which they are used.
2.0 Accuracy class - Measuring CT accuracy class 1.0.

- Protective CT accuracy class 5 P 10.
5.4. CONTROL TRANSFORMERS

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1.0 Type Dry type , cast resin
2.0 Voltage 415V/240V
3.0 Primary taps +2.5 %, +5 %
5.5. INDICATING INSTRUMENTS
1.0 Basic details - Shall not damage by passage of fault current or existence
of over voltage for the maximum permitted duration of fault
conditions.
- Voltmeters protected by fuses placed as close to the
busbar as possible.
2.0 Mounting Flush mounting, square dial with zero adjusting device for
external operation .
3.0 Accuracy class 1.5
4.0 Size - Size of voltmeter and ammeter for incomer 144 x 144 mm
for incoming feeders.
- Size of ammeter for motor feeders 96 x 96 mm.
5.6. THERMAL OVERLOAD RELAYS
1.0 Standard IEC:292-1
2.0 Basic details - Triple pole

- Ambient temperature compensated .
- Inverse time lag.
- Hand reset type.
- Bimetallic with adjustable setting and builtin single phase
protection .
- Reset PB shall be operable from outside .
- Shall be able to withstand prospective short circuit current
without damage or injurious heating till the motor protection
MCCB clears the fault .
- Auto tripping shall be indicated on MCC .

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3.0 Contacts 1 NO + 1 NC contacts with minimum rating of

- 10A , 415 V for rated duty AC-11.
- 2A , 220 V for rated duty DC-11.
5.7. PUSH BUTTONS
1.0 Basic details - All push button switches including illuminated push
buttons shall be of sturdy design
- Shrouded actuator for "START" application, and
"STOP" application shall be provided.
- Mushroom Head actuator for “EMERGENCY STOP”
shall be latched type with turn to release.
- Press to latch in operated position and turn-to-
release in unactuated position.
- Double break parallel contact design or other suitable
design feature enhancing contact reliability required
in circuits with electronic interfaces involving low
voltages and small currents shall be adopted.
2.0 Size - 22.4 mm diameter
3.0 Contact rating - Minimum 2 NO + 2NC contacts (or 4 NC for Em Stop

PB) with following current ratings .
 Continuous - 10 A
 AC 11 - 1.5 amps at 240V
 DC 11 - 0.5 amps at 110 V DC, L / R -
40 ms
- All contact faces of contacts shall be of silver or
silver alloy.
- Facility of adding addon contact blocks to be
provided
4.0 Colour  Accept - Blue

 Test - Yellow
 Reset - Black
5.8. INDICATING LAMPS

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1.0 Type - LED Cluster type
2.0 Basic details - Sufficient number of lamp grips shall be provided for
easy replacement of lamps.
2.0 Size - 22.4 mm diameter
3.0 Colour - For motor ÒN’, valve/damper/gate

‘OPEN’, supply ÒN’, breaker `CLOSE’ : Red
- For motor ÒFF’, valve/damper/gate
‘CLOSE’, supply ÒFF’, breaker ÒPEN’ : Green
- Fault indication, over load, alarm : Amber
condition, ‘SERVICE & TEST POSITION’
indication.
- General purpose indication, : White
motor ÀUTO TRIP’.
Other colours may be adopted depending upon
particular application as approved by the Owner.
4.0 Layout of indication Indicating lamps shall be located just above the
lamps on boards / associated push-button / control switches.
panels
Red lamps shall invariably be located to the right of
green lamps.
In case a white lamp is also provided, it shall be placed
between red and green lamps along the centre line of
control switch/ push button pair.
Blue and Amber should normally be located above the
Red and Green lamps.
When associated with push buttons, red lamps shall be
directly above the green push button and green lamp
shall be directly above the red push button.
5.9. MINIATURE CIRCUIT BREAKERS (MCB)

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1.0 Type Heat resistant plastic moulded type,
2.0 Number of Poles Double Pole (DP)
3.0 Ref . Standard IS: 8828 –1978
4.0 Protections MCBs shall be provided with quick break trip-free mechanism
and direct acting thermal overload and short circuit trip
elements.
5.0 Short circuit capacity Not less than 9kA at 0.8pf
6.0 Mounting DIN Channel mounting .

Single phase MCBs mounted adjacent to each other and
connected to different phases shall be provided with
adequate insulated phase barriers.
7 Current Rating The MCBs shall be selected from standard current

ratings.(As per SLD)
MCB characteristics curve shall be as per application .
5.10. SELECTOR SWITCHES
1.0 Basic details - Shall have modular construction with number of switching
contacts for each position operated by a single shaft.
- Inscription for each position shall be provided.
- Stay-put or spring return arrangement shall be provided
as per the circuit and control/operational requirement.
- The contacts shall be designed for higher contact
reliability and electronics compatibility involving low
voltage and small value of currents.
- The operating handle shall be robust and strong.
- One number of potential free switching contact for each
position shall be provided as spare.
- Control switches for circuit breaker ON/OFF control 3
position spring return to neutral with lost motion device
and pistol grip handle.
- Other control and selector switches - stay put type with

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wing type knobs.
2.0 Contacts 2 NO + 2 NC contacts with minimum rating of

- All the selector switches shall be of 10 A rating
- 25A for sturdy applications.
- 1 NO & 1 NC contact / poles shall be potential free for
PLC inputs.
6. SPUN POLE AND DOUBLE POLE STRUCTURES (11 kV)
6.1.1 GENERAL
Spun pole and Double pole structures with bracings and cross arms for supporting / installing the
pin and / or strain insulators shall be designed in line with BESCOM standard and as per the
following specification and drawings. Make of all components shall be as per BESCOM approved
make.
Any other items not specifically mentioned but which are essentially required forsatisfactory
performance & completeness of work shall deemed to be included in the scope of specifications and
works and the same shall be executed / carried out by the contractor at no extra cost to the owner.
6.1.2 RCC Pole
9.0 Mtr long RCC poles of 145 Kg working load shall be provided for DP structure and 13 Mtr long
pre-stressed RCC pole of 500 kG working load shall be provided for spun pole structure with factor
of safety 2.5. The general recommended profile of the DP structure/Spun pole with cross arm(s),
bracings, placement of ACSR conductors and earth wire shall be as per IS and BESCOM standard.
RCC Pole are generally as per drawing enclosed with the specification and are intended to be used
on 11 kV overhead electric distribution lines. The materialsmanufactured shall conform strictly to the
requirement of relevant INDIAN STANDARDS and latest addition of IS using the best quality of
materials and workmanship.
The Double Pole / Spun pole structures shall be designed suitable for mounting one lightning
arrestor, Dropout fuse per phase and Air break switch. Further this DP structure shall be provided
with extra cross arm(s) arrangement to erect / install HT XLPE Aluminium cables with outdoor
termination. It shall facilitate termination of each core of the HT cable directly without any further
links. The arrangement of all the components on this DPS/SPS shall be furnished along-with the
offer.
Earth shall be excavated to make pits size 1Mx1Mx2.5M (depth) for each pole of the DP structure.
The rail pole shall be placed over a small (50—100 mm thick) padding of concrete in perfectly
vertical position and then the entire pit shall be concreted & compacted using a concrete mix of “1
cement: 3 coarse sand: 6 graded stone aggregate” including curing thereafter. Compacting the soil
around, using boulders / earth shall be carried out if required at no extra cost.

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Each pole of the Double pole/Spun pole structures shall be provided with anti-climbing devices.
Danger boards (Normal) indicating the voltage and in three languages (English, Hindi & local) shall
be provided for each DP structure.
Each DP structure/Spun pole structure shall be earthed as per the rules of IE/BESCOM.
6.1.3 Stays
Stays shall be provided for the DP/Spun structure wherever strain (tension) insulators are
envisaged and at other places as necessitated by the various forces acting on the line.
No. of stays shall be designed as per the layout, site conditions and static & dynamic forces that
arise due to severe stormy / cyclonic conditions. Where required 6 nos. of stays per DP structure
and 2 nos of stays per spun pole shall be supplied / provided.
Each stay set shall be galvanized complete with 25 mm dia x 1.85 mtr long stay rod, anchor plate of
size 300x300x10 mm thimble, stay clamps, bow tightner, 7 x 4.0 mm dia GI wire, strain insulators
etc. If required, size of gay wire & accessories shall be increased.
The stay wire shall usually make an angle of 30 deg to 45 deg with the vertical depending up to the
alignment of the line.
Pits of size 1M x 1Mx 2.5M (depth) shall be excavated for placement of anchor plate of stay set and
the pit shall be concreted & compacted using a concrete mix of “1 cement 3 coarse and 6 graded
stone aggregate”, including curing thereafter. Compacting the soil around using boulders / earth
shall be carried out if required at no extra cost.
GI stranded wires shall comply with the specific requirements of IS 2141—1979, IS 4826—1979 &
IS 6594— 1974.
6.1.4 HORIZONTAL CROSS ARMS
This Specification provides for the manufacture of Horizontal straight cross arms and Horizontal
special 3 pin cross arm for the use in 11 KV distribution lines. The structural steel for the
manufacture of cross arm shall be commercial grade angles 50 x 50 x 6 mm and conform to IS:1977
/ ST-42 /ST –32..The cross arms should be painted with two coats of ACB paints after red-oxide
primer coat. The cross arm should have voltage grade (11 KV) marked on it. The contractor shall
submit a sample and get the approval of the Engineer before taking up the works. The cross arms
shall be securely packed to avoid damages during transport. Each horizontal cross arm shall be 980
mm length and weight approx 4.86 Kg / Piece, and Horizontal Special 3 pin cross arm shall be 1980
mm length and weight approx 11.484 kg/piece as mentioned in the drawings.
6.1.5` CLAMPS
The specification of RCC clamp provides for the manufacture and supply of clamps for theRCC
Poles, for use in distribution lines, fabricated out of 50 x 6mm M.S flat, conforming to commercial
quality IS-1977 / SP-42 / ST-32. The clamps shall be painted with two coats of ACB paint after
primer. The clamps shall be marked with suitable identification marks on each type of clamps for
easy identification. The clamps shall be securely packed so as to avoid damage in transit. The

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length and weight of clamps is to be as mentioned in the drawings: RCC Pole clamps: ‘A’ Type…
428 mm …. 1.027 Kg.
6.1.6 45KN DEAD END DISC INSULATORS 11KV CLASS
This specification covers details of 11KV Class 45KN Disc Insulators for use in 11KV overhead lines
in the distribution system.
APPLICABLE STANDARDS:
IS 2099:198 : Bushing for all voltage above 1000V.
IS 2486:1986 : Insulator fitting for OH.
Part1, 2, 3&4 : power lines for nominal voltage greater than 1000V.
IS 731:1971 : Porcelain insulators for overhead power lines.
The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed.
Unless otherwise specified, the glaze shall be brown in colour. The glaze shall cover all the
porcelain parts of insulators except those areas which serve as supports during firing or are left
unglazed for the purpose of assembly.
The design of insulators shall be shall be such that stresses due to expansion and contractors in
any part 6 of the insulator shall not lead to deterioration. The porcelains shall not engage directly
with hard metal.
.
TECHNICAL PARTICULARS:
a) DESCRIPTION:
1 Product Identification 45 KN DEAD END

2 Product Code IP-03D
3 Type of Insulator (Pin & Cap)
4 Porcelain Disc Diameter mm 255 ±11
5 Unit Spacing mm 235 ± 10
6 Coupling DEAD END
7 Creepage Distance (Total) mm 292
Protected Mm 165
8 Electro-mechanical Strength KN 45
b) ELECTRICAL CHARACTERISTICS :
1 Power frequency Dry flashover voltage --KV 78

2 Power frequency dry withstand voltage- KV 70
3 Power Frequency wet flashover voltage -KV 45
4 Power frequency wet withstand voltage -KV 40

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5 Impulse flashover voltage- KV (Peak) 120

6 Impulse withstand voltage -KV (Peak) 110
7 Power frequency puncture voltage -KV 120
8 Visible discharge voltage -KV 18
9 RIV at 10 KV- KV 50
10 Power frequency Dry flashover voltage -KV 78
Markings on porcelain shall be printed and shall be applied before firing.
All insulators (without fitting) shall be packed in wooden crates suitable for easy but rough handling
and acceptable for road/rail transport, where more than one insulator is packed in crate, wooden
separators shall be fixed between the insulators to keep individual insulators in position without
movement within the crate.
6.1.7 11 KV PIN INSULATORS (SHELL)
This specification covers details Porcelain insulators for use on 11KV overhead power lines in the
distribution system. Except when in conflicts with the specific requirements of this specification, the
insulators shall comply with IS.731 and SI.3188 as amended from time to time.
The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed. Unless
otherwise specified, the glaze shall be brown in colour. The glaze shall cover all the porcelain parts
of insulators except those areas which serve as support during firing or are left unglazed for the
purpose of assembly. The design of insulators shall be such that stresses due to expansion and
contractors in any part of the insulator shall not lead to deterioration. The porcelains shall not
engage directly with hard metal.
TEST VOLTAGES:
1) Highest System Voltage – 12 kV (rms)
2) Mechanical Strength of the insulator (minimum failing load) 5 KN (509.660 Kgf.)
3) Wet Power Frequency Voltage withstand Test 35 KV (rms)
4) Power Frequency Puncture Voltage withstand test 105kV (rms)
5) Visible discharge test – 9 KV (rms)
6) Impulse Voltage withstand test – 75 KV (Peak)
7) Total creep age distance – 230 mm. for moderately polluted atmosphere
The insulators shall comply with the tests as per IS: 831. Each insulator shall be legibly and
indelibly marked to show the following:
a. Name or trade mark of manufacturer.

b. Month and year of manufacture.
c. Minimum failing load in KN.
d. ISI Certificate mark, if any

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6.1.8 ACSR Conductor & Earth wire:

Aluminium conductors (Rabbit) shall be Galvanized / Aluminized steel reinforced confirming to IS
398 (Pt—II)-l976 and IS 398 (Pt—III)-l976 or the latest versions thereof.
The specification covers manufacture, testing and supply of ACSR conductors.
The conductor shall comply in all respects with the latest edition of ISS-298 (PartII) 1976 with its
latest amendment. The Aluminum wires used in the manufacture of the conductor shall be of the
highest electrical quality and free from scratches, die marks and other surface imperfections. They
shall be reinforced with a central core of galvanized high tensile steel wire having negligible sulphur
and phosphorous contents. The steel wire shall not be subject to any heat treatment after being
galvanized. The zinc coating of steel wires shall be smooth and of uniform thickness. There shall be
no bare spots owing to adherence of scales or other causes.
Joints in the individual Aluminium, wires are permitted but no two such joints shall be within 15
meters apart in the complete stranded conductors. There should be no joints in the galvanized steel
wire except those made in the base rod or wire before final drawing forming the core of steel
reinforced Aluminium.
The resistance of the individual Aluminium wire shall be determined separately before stranding by
means of standard tests on sample wires. The Aluminium wire and galvanized steel wire for the
standard construction of conductors have diameter specified as per Tables 1&2 Section of IS 398
(Part-II).
Any mid-span jointing of ACSR conductor is not acceptable.
6.1.9 METAL OXIDE SURGE ARRESTERS (GAPLESS TYPE) FOR 11KV SYSTEMS
The Surge Arresters shall conform to the latest edition and amendments if any to the standards
listed hereunder.
(a) IEC 99.4 - Specification for Surge Arresters.

(b) IS 5561 - Electric Power Connectors.
(c) IS 3070 Part II - Specifications for Surge Arresters for AC System.
(d) No. 55/1987 - REC Spec. for Metal Oxide Lightning Arrestors.
Principal Parameters:
1) Normal System Voltage 11KV
2) No. of Phases 3
General Requirements:
a) The materials and components not specifically stated in this specification but which are
necessary for satisfactory operation of the equipment are deemed to be included in the scope of
supply unless specifically excluded.

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b) Each individual unit of Surge Arrester shall be hermetically sealed and fully protected against
ingress of moisture. The hermetic seal shall be effective for the entire inhume of the Arrestor and
under the service conditions as specified. The supplier shall furnished sectional view of the Arrestor,
showing details of sealing employed.
Construction:
a) All the units of Arresters of the same rating shall be interchangeable without adversely affecting
the performance.
b) Single Arresters shall be suitable for outdoor mounting.
Porcelain Housing:
a) All porcelain housings shall be free from lamination cavities or other flaws affecting the maximum
level of mechanical and electrical strengths.
b) The porcelain shall be well verified and non-porous.
c) The creepage distance of the arrester housing shall be as per clause 4.01.
d) The porcelain petticoat shall be preferably of self-cleaning type (Aerofoil design).
Other Details:
i. All ferrous parts exposed to atmosphere shall be hot dip galvanized as per IS:2629.
ii. Terminal connector to suit ACSR Rabbit of dia 10.05mm rating 200 Amps is in scope of supply.
Current Impulse with stand levels
The 9KV Arresters shall withstand 18 impulses of long duration current with a peak level 75 amps
and duration 1000 micro seconds.
Protective levels
a) Maximum residual voltage at nominal discharge current 11KV Peak – 32KV.

b) Maximum steep current impulse residual voltage at nominal discharge Current KV(Peak) – 38KV.
Tests:
i. Type test reports as per relevant standards shall be furnished along with the tender.
ii. Acceptance and routine tests as stipulated in relevant standards shall be carried out
in presence of the buyer representative.
Guarantee Technical Particulars:
1 Rated Arrester Voltage (KV 9KV

rms)
2 MCOV (Maximum continuous 7.5

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operating voltage)
3 Installation Outdoor
4 Class Distribution Class
5 Nominal discharge current 5KA
corresponding to 8/20 micro
sec
wave shape (KA rms)
6 Type of mounting Outdoor
7 Long duration discharge Phase to earth
class
connection
8 Terminal Connector Single Rabbit
a) Suitable for ACSR
Conductor of Size Vertical of Horizontal
b) Take off
9 Minimum creepage distance 300
of Arrester housing (mm)
6.1.10 Wire mesh

A suitable GI wire mesh (guard) shall be provided under the HT line wherever it is crossing the
roads, P&T lines, other power lines and at places to be specified by the Owner/ Engineer while
approving the line alignment drawings. The minimum clearance under maximum sag conditions of
ACSR conductor shall be 1.25 mtrs between the conductor and the mesh.
6.1.11 Earthing
Earthing shall be provided in accordance with the “Code of practice for Earthing” — IS 3043 and
Indian Electricity Rules 1956 as amended from time to time and the relevant regulations of CSEB,
central electricity authority and shall meet the approval of DGMS (E).
A continuous earth wire of size 7 x 16 SWG galvanized iron shall be laid all along the HT line
preferably located above the power conductors, and connected to earth pits provided for the
purpose. Minimum current carrying capacity shall be as per IS governing mines.
Earth pits shall be provided at either end of each line as well as at each cut point and at each 3rd
pole along the HT line and connected to both the poles of DPS & earth wire running at the top
separately.
Separate earth pits shall be provided for lightning arrestors and connected to the same directly.
Each stay wire shall be permanently and efficiently earthed and a stay insulator has been fixed at a
height not less than 3 Mtrs from the ground.

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Each earth pit shall comprise of pipe electrode of size 100 mm dia, 3 mtrs length GI pipe with all
accessories required such as charcoal, salt, clamps / clips bolts / nuts / washers, funnel and also
the masonry work of the pits including supply of bricks cement and excavations of earth for pit.
6.1.12 Tests & Inspection
Routine tests shall be carried out on all equipment at manufacture’s works as per appropriate IS
regulations. The Tenderer shall arrange all necessary facilities, free of cost for inspection and
testing of the equipment by the purchaser no equipment shall be dispatched to site without a
provisional certificate of acceptance issued by the Purchaser /consultant.
Inspection and test shall be carried out at the place of manufacture as well as on receipt of the
equipment at site. Inspection and tests do not relieve the Tenderer of his contractual obligation
regarding performance of equipment at site / in actual use. Type test certificates of all equipment,
under Tenderer's scope shall be submitted.
7. CABLES
7.1. HT XLPE CABLES 11 kV / 6.6 kV (E)
Sl.No. Parameter Description
1.0 Voltage Grade 11 kV (E)/ 6.6 kV (E) as applicable
2.0 Duty type Heavy duty
3.0 No. of cores 3 cores
4.0 Reference standard IS:8130 – 1984

IS:5831 – 1984
IS:3975 -1988
IS:1554, part - 1, 1988
IS:3961 (Part-II) - 1967.
IS:7098 Part-I & II
IEC-60502
5.0 Conductor type Compact circular stranded (rm/V) aluminum conductor,

with extruded conductor shielding of semi conducting
material .

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Conductor construction as per IS 8130-1984.
6.0 Insulation type XLPE insulated, with insulation shielding over

individual cores, consisting of extruded semi
conducting compound, followed by lapped semi
conducting material and copper tape (non magnetic)
metallic screen, cores stranded together with a holding
tape provided with a common covering of extruded
inner sheath of type ST2 compound .
The cable shall conform to IS:7098(Part-2)-1985.
7.0 Armour Galvanized steel wire armoured .

For multi core cables , armouring shall be applied over
the inner sheath of flat steel wires (strips) .
Round steel wire armouring can also be offered.
For single core armoured cables non-magnetic armour
consisting of hard drawn flat or round aluminium wires
shall be provided.
8.0 Outer sheath PVC outer sheathed of type ST2 compound .

Black in colour .
Suitable chemicals shall be added into the PVC
compound of the outer sheath to protect the cable
against rodent and termite attack.
9.0 Miscellaneous Copper screen shall be suitable to carry 1 KA E/F

current for one second.
10.0 Temp. rise on 90 deg.C

continuous load
11.0 Oxygen index of outer Shall not be less than 29 at 27  2 deg. C.

sheath material for
XLPE Cable
12.0 Temperature index Not below 250C.
13.0 Max. conductor 250C

withstand temperature

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during short circuit.
7.2. FLAME RETARDANT LOW SMOKE (FRLS) CABLES
Sl.No. Parameter Description
1.0 Voltage Grade 1.1 kV grade
2.0 Reference standard Category AF as per IS : 10810

ASTM-D 2863 (Critical Oxygen Index)
ASTM-D 2863 (Temperature Index)
ASTM-D 2843 (Smoke density)
IEC 754-1 (Acid gas generation)
IEEE-383 (Flammability test on group of cables)
Swedish chimney test SS 424175, class F3.
(Flammability test)
IEC 332-1 (Flammability test)
IEC 332-3 (Flammability test)
IS 5831 (Fire resistant test)
3.0 Duty type Heavy duty
4.0 No. of cores Single or multicore as per requirement
5.0 Cross sectional area As per requirement.
6.0 Conductor type Annealed tinned copper conductor
8.0 Insulation type XLPE insulation
11.0 Sheath Specially designed with thermoplastic or thermosetting

materials , superior resistance to ignition and flame

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propagation with smoke emission and toxicity or

corrosive characteristics
Flame retarded
Oil resistant
12.0 Armouring GI wire / strip armoured as per requirement and size

(as specified in respective TS)
13.0 Test values Critical Oxygen Index : Minimum 29

Temperature Index : Minimum 250 deg. C
Smoke density : Minimum average light transmission
of 40%
Acid gas generation : HCl gas released 20% maximum
Flammability test on
group of cables : As per standards mentioned
Flammability test : As per standards mentioned
Fire resistant test : As per standards mentioned

8. ILLUMINATION
8.1. GENERAL
The lighting system inside and outside the station are designed based on the desired minimum
illumination levels recommended by IS.
The illumination system shall be designed as per IS:3646-1992. The minimum level of illumination,
type of fittings, maintenance factor to be considered is as given below:
Area Type of Light Fittings& Lamps Lux MF
level
(min)
Surface / recessed mounted
Control 300 0.75
luminaires with energy efficient LED
rooms/Work
tube. (CGL type LCTLR-36-
station/Lobby/ca
CDL&LCTLRF1-36-CDL).
nteen/ATM

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Surface mounted / Suspended

Electrical rooms 200 0.7
having PCC,
PDB tube. (CGL type LCTLR-36-CDL).
Surface / recessed mounted
Offices 300 0.75
with/without false
ceiling tube. (CGL type LCTLR-36-CDL).
Battery Room Industrial vapour proof IP55 luminaire with 100 0.6
39 W LED die case aluminium control gear
boxes at the ends with synthetic rubber
gasket.
Surface mounted / Suspended
Compressor 200 0.6
room
tube. (CGL type LCTLR-36-CDL).
Flood lighting Weather proof Flood light luminaire with 70 0.5
120W LED lamp, IP 65or better, integral
type with aluminium die cast housing. The
luminaire shall be complete with control
gear, driver &surge protector ,heat resistant
cover, prewired up to terminal block.
Bulk head luminaire (led) similar to Bajaj
Toilets 100 0.6
Cat. No. BGSLO-6W-WH RD
Street light 100W Flame proof street light Ex-d type As per IS
Fittings fixture with LED lamp, control gear in cast
0.6
alluminium allow LM6 enclosure and
toughened glass cover. The encloser shall
be of IP: 65 suitable for Zone 1& 2 gas
group IIA & IIB with all accessories.
Canopy Light Explosion cum weather proof 72 W LED As per IS 0.6

Fittings light fitting similar to Baliga Catalogue no.
ECRF-236
MF : Maintenance factor
The light fittings shall be complete with all accessories like electronic ballast, reflector etc.

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8.2. HIGH MAST SPECIFICATIONS

8.2.1. DESIGN CRITERIA :
The equipment shall be suitable for operation at Hazardous area. The ambient conditions for
design of equipments shall be taken as below:-
a) Design Ambient temperature : 50oC
b) Maximum humidity : 100%
c) Altitude : Less than 1000 mtr. At
sea level
d) Site condition : ----
e) Wind spped : 180 km/hr
8.2.2. STRUCTURE :
The High mast shall be of continuously tapered, polygonal cross section, at least 20 sided,
presenting a good and pleasing appearance and shall be based on proven In-Tension
design conforming to the standards referred to above, to give an assured performance, and
reliable service. The structure shall be suitable for wind loadings as per IS 875 Part 3 1987.
8.2.3. CONSTRUCTION :
The mast shall be fabricated from special steel plates, cut and folded to form a polygonal
section and shall be telescopically jointed and welded. The procedural weld geometry and
the workmanship shall be exhaustively tested on the completed welds. Mast can be
fabricated in multiple sections of length approximately 10 metres. Thus a 30 M can be
delivered in three sections. No site welding or bolted joint shall be done on the mast. The
minimum over lap distance shall be 1.5 times the diameter at penetration. The dimensions
of the mast shall be decided based on proper design and 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 strength of the entire section. The base flange shall be provided with supplementary
gussets between the bolt-holes to ensure elimination of helical stress concentration. For the
environmental protection of the mast, the entire fabricated mast shall be hot dip galvanized,
internally and externally, having a uniform thickness of 85 microns for thebottom section and
65 micron for the middle and top sections.
8.2.4. DOOR OPENING:

An adequate door opening shall be provided at the base of the mast and the opening shall
be such that it permits clear access to equipment like winches, cables, plug and socket, etc.
and also facilitate easy removal of the winch. The door opening shall be compete with a
close fitting, vandal resistant, weatherproof door, provided with a heavy-duty double internal
lock with special paddle key.

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The door opening shall be carefully designed and reinforced with welded steel section, so
that the mast section at the base shall be unaffected and undue buckling of the cut portion is
prevented. Size of door opening shall be around 1100 x 280 mm and shall be strengthened
if required to avoid buckling of the mast section under heavy wind conditions.
8.2.5. DYNAMIC LOADING FOR THE MAST:
The mast structure shall be suitable to sustain an assumed maximum reaction arising from a
wind speed as per IS 875 (three second gust), and shall be measured at a height of 10
meters above ground level. The design life of the mast shall be a minimum of 25 years.
8.2.6. LANTERN CARRIAGE:

Fabrication:
A fabricated Lantern Carriage shall be provided for fixing and holding the flood light fittings
and control gear boxes. The Lantern Carriage shall be of special design and shall be of
steel tube construction, the tubes acting as conduits for wires, with holes fully protected by
grommets. The Lantern Carriage shall be so designed and fabricated to hold the required
number of flood light fittings and the control gear boxes, and also have a perfect self
balance.
The Lantern Carriage can be fabricated in two halves and joined by bolted flanges with
stainless steel bolts and nylon type stainless steel nuts to enable easy installation or removal
from the erected mast. The inner lining of the carriage shall be provided with suitable
protective arrangement, so that no damage is caused to the surface of the mast during the
raising and lowering operation of the carriage. The entire Lantern Carriage shall be hot dip
galvanized after fabrication. The design shall provide a perfect balance for the lantern
carriage during raising and to lowering also.
Junction Box:
Flam Proof junction box (FLP), made of Cast Aluminium shall be provided on the Carriage
Assembly as required, from which the inter-connections to the designed number of the flood
light luminaries and associated control gears fixed on the carriage shall be made.
Raising and lowering mechanism:

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For installation and maintenance of the luminaries and lamps, it will be necessary to lower
and raise the Lantern Carriage Assembly. To enable this, a suitable Winch Arrangement
shall be provided, with the winch fixed at the base of the mast and the specially designed
head frame assembly at the top. Suitable limit switches shall be provided to trip the winch
motor at both top & bottom ends of the designed travel.
Winch:
The winch shall be of completely self sustaining type, without the need for brake shoe,
springs or clutches. Each driving spindle of the winch shall be positively locked when not in
use, gravity activated PAWLS. Individual drum also should be operated for fine adjustment
of lantern carriage. The capacity, operating speed, safe working load, recommended
lubrication and serial number of the winch shall be clearly marked on each winch.
The winch shall be self-lubricating type by means of an oil bath and the oil shall be readily
available grades of reputed producers.
The winch drums shall be grooved to ensure perfect seat for stable and tidy rope lay, with no
chances of rope slippage. The rope termination in the winch shall be such that distortion or
twisting is eliminated and at least 5 to 6 turns of rope remains on the drum even when the
lantern carriage is fully lowered and rested on the rest pads. It should be possible to operate
the winch manually by a suitable handle and by an external power tool. It shall be possible
to remove the double drum after dismantling, through the door opening provided at the base
of the mast. Also, a winch gear box for simultaneous and reversible operation of the double
drum winch shall be provided as part of the contract.
The winch shall be type tested in presence of a reputed Institution and the test certificates
shall be furnished before supply of materials. A test certificate shall be furnished by the
Contractor from the original equipment manufacturer, for each winch in support of the
maximum load operated by the winch.
Head Frame:
The head frame which is to be designed as a capping unit of the mast, shall be of welded
steel construction, galvanized both internally and externally. The top pulley shall be of
appropriate diameter, large enough to accommodate the stainless steel wire ropes and the
multi-core electric cable. The pulley block shall be made of non-corrodible material, like die
cast Aluminium Alloy (LM-6). Self-lubricating bearings and stainless steel shaft shall be
provided to facilitate smooth and maintenance free operation for a long period. The pulley
assembly shall be fully protected by a canopy galvanized internally and externally.

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Close fitting guides and sleeves shall be provided to ensure that the ropes and cables do not
dislodged from their respective positions in the grooves. The head frame shall be provided
with guides and stops with PVC buffer for docking the lantern carriage.
Stainless Steel Wire Ropes:
The suspension system shall essentially be without any intermediate joint and shall consist
of only non-corrodible stainless steel of AISI 316 or better grade.
The stainless steel wire ropes shall be of multi strand construction, the central core being of
the same material. The overall diameter of the rope shall not be less than 6 mm. The
breaking load of each rope shall have factor of safety of over 5 for the system at full load.
The end constructions of ropes to the winch drum shall be fitted with talurit.
The thimbles shall be secured on ropes by compression splices. Two continuous lengths of
stainless steel wire ropes shall be used in the system and no intermediate joints are
acceptable in view of the required safety. No intermediate joints / terminations, either
bolted or else, shall be provided on the wire ropes between winch and lantern
carriage.
8.2.7. ELECTRICAL SYSTEM,CABLE AND CABLE CONNECTION:
A suitable Flame proof terminal box shall be provided as part of the contract at the base
compartment of the high mast for terminating the incoming cable. The electrical connections
from the bottom to the top shall be made by special trailing cable. The cable shall be EPR
insulated and PCP sheathed to get flexibility and endurance, and have copper conductors.
The cable shall be of reputed make. At the top there shall be weather proof junction box to
terminate the trailing cable. Connections from the top junction box to the individual
luminaries shall be made by using 3 core flexible PVC cables of adequate size. The system
shall have in-built facilities for testing the luminaries while in lowered position. 2 No’s
Trailing cable shall be considered for making 2 lighting circuits.
Also, suitable provision shall be made at the base compartment of the mast to facilitate the
operation of externally mounted, electrically operated power tool for raising and lowering of
the lantern carriage assembly. The trailing cables of the lantern carriage rings shall be
terminated by means of specially designed, metal clad, multi-pin plug and socket provided in
the base compartment to enable easy disconnection when required.
A FLAME PROOF TYPE distribution board with suitably rated 3-phase incomer MCB and
separate MCB’s controlled feeders for lighting and power tool shall also be supplied. The
board shall incorporate timer for control of lighting (2 circuits) and control circuit for winch
operation with all necessary contactors etc. The board shall have IP 65 protection with

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rainwater protections canopy and epoxy powder coated suitable for outdoor mounting in
coastal area. The work shall also include necessary foundation cable glands etc. complete
as required.
8.2.8. POWER TOOL FOR THE WINCH:
A suitable, high-powered, electrically driven, internally mounted power tool, with manual over
ride shall be supplied for the raising and lowering of the lantern carriage for maintenance
purposes. The speed of the power tool shall be to suit the system. The power tool shall be
single speed, provided with a motor of the required rating. The power tool shall be supplied
complete with push button type remote control switch, together with 6 (six) meters of power
cable, so that the operations can be carried out from a safe distance of 5 (five) meters. The
capacity and speed of the electric motor used in the power tool shall be suitable for the lifting
of the design load installed on the lantern carriage.
The power tool mounting shall be so designed that it will be not only self supporting but also
aligns the power tool perfectly with respect to the winch spindle during the operations. Also,
a handle for the manual operation of the winches in case of problems with the electricity
operated tool, shall be provided and shall incorporate a torque limiting device.
There shall be a separate torque-limiting device to protect the wire ropes from over
stretching. It shall be mechanical with suitable load adjusting device. The torque limiter
shall trip the load when it exceeds the adjusted limits. There shall be suitable provision for
warning the operator once the load is tripped off. The torque limiter is a requirement as per
the relevant standards in view of the over all safety of the system. Each mast shall have its
own power tool motor.
8.2.9. LIGHTNING FINIAL:
One number heavy duty hot dip galvanized lightning finial shall be provided for each mast.
The lightning finial shall be minimum 1.2 M in length or as required so that the lantern
carriage also comes within the safety zone and shall be provided at the centre of the head
frame. It shall be bolted solidly to the head frame to get a direct conducting path to the earth
through the mast. The lightning finial shall not be provided on the lantern carriage
under any circumstances in view of safety of the system. 2 NO’S Copper jumpers shall
be provided from lighting final to the mast body.
8.2.10. AVIATION OBSTRUCTION LIGHTS:
2 No’s Neon type Aviation Obstruction Lights of reliable design shall be provided on top of
each mast.

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8.2.11. EARTHING TERMINALS:
Suitable earth terminal using 12 mm diameter stainless steel bolts shall be provided at a
convenient location on the base of the Mast, for lightning and electrical earthing of the mast.
The mast shall be provided with duplicate earthing including necessary earth pits as per IS.
8.2.12. FOUNDATION FOR HIGH MAST:
The scope also includes supplying all materials and casting of RCC pedestal foundation
along with necessary Anchor bolts etc.,
The detailed drawing considering wind speed for the pedestal foundation shall be submitted
and got approved by consultant/Owner before starting of the work.
8.2.13. DATA SHEET:
A technical data sheet covering all the main parts / components shall be SUBMITTED
ALONG WITH THE OFFER. (As per standards BSEN-10025, IS-875 & IS-2062).
8.2.14. LUMINAIRES:
Luminaries shall be specially designed with suitable lamp housing and control gears. The
luminaries shall be tested as per Indian standards and test reports shall be submitted for
approval. The luminaries shall be suitable for installation on high masts. The number and
type of light fitting shall be as per SOR. The Required lux level for each Mast shall be
between 20 to 30 lux.
8.3. LIGHT IXTURES, LAMPS AND ACCESSORIES:

8.3.1. GENERAL
i. All the luminaries shall be designed, manufactured and tested in accordance with relevant IS
specifications so far as they are applicable.
ii. All types of light fittings shall be supplied with lamps.
iii. All the luminaries shall be industrial type with LED with minimum burning time of 50,000
hours with no toxic content with a colour temperature (CCT)>=4000K&CRI above 80 . Power
factor shall be more than 0.9 and driver efficiency more than 86%. Junction Temperature
shall be kept as low as possible so as to increase performance and life time of LED and
ensure that the luminaries are as heat efficientaspossible.LED Light fittings shall be suitable
for operation at an ambient temperature of 50Deg.C.Heatsink temperature rise above
ambient shall be limited as per relevant available IS/IEC . For all outdoor fittings , surge
arrestors shall be provided.

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iv. All the light fixtures shall be complete with all parts along with LED lamps/tubes, drivers and
accessories for installation and efficient performance whether specifically mentioned in
the specification or not.LEDfittingsshallbeselectedsoastoprovidecorrectcolourappearanceand
renderingtoenableworkerstosee&judgequicklyandaccurately,detailsoftheir work such as
colour, brightness, shapeform etc.
v. Individual light fittings shall be provided with suitable arrangements for GI threaded conduit
entry of 19 mm dia unless otherwise specified. Terminals of all fittings shall be suitable for
taking 2.5 sq. mm flexible, copper conductor PVC insulated, FRLS-PVC sheathed cable.
vi. Fittings shall be supplied with all inter – connections made and fully wired up to the terminal
block and shall be suitable for mounting on wall / column / ceiling / suspension (from the
ceiling including suitable bracket).
vii. All the luminaries shall be commercial / industrial type as per specific requirement.
Specification for the various types of LED mentioned in the schedule of quantities shall be
followed. All the lighting fixtures shall be complete with all parts, including Earthing
arrangement and accessories for efficient performance whether specifically asked in the
specification or in the schedule of items or not.
viii. All live parts shall be provided with suitable sleeves to prevent accidental contacts. The
Earthing terminal in the fitting shall effectively earth the body of the entire luminaries
ix. The luminaries shall be suitably designed to provide economically the required level of
illumination on the working plane when mounted at normal standard height in accordance
with the type of fixtures.
x. The luminaries shall be suitable for operating at normal supply voltage of 240 V, single
phase, 50 Hz with voltage variation of +/- 10% or at voltages as specified. Electronic
Ballast’s/drivers shall be used for all fittings. P.F correction capacitor to improve P.F up to
0.95, electronic igniter, necessary connectors etc., shall also be provided where required.
xi. The clearance between the live parts and the enclosures earthing and other safety factors
shall be governed by the latest revisions of the IS specification and IE rules.
xii. Mounting accessories like chain, for fittings mounted in false ceilings anchor bolt and all
erection accessories required for complete installation is in the scope of the contractor. The
price for same shall be included in the fitting cost.
xiii. Down rods / chains for mounting light fittings and fans and GI conduits, brackets, flats,
hooks, channels, etc., also to be supplied and installed as required. The price for same shall
be included in the fitting cost.
xiv. All luminaries are to be supplied with required lamps as indicated in the drawings /
specifications.
xv. All discharge lamp fittings shall be supplied with suitable ballast, power factor improvement
capacitor, igniter, etc. The ballast terminals shall be made for various tapings for use on a
wide range of mains voltage making it versatile in application.
8.3.2. NON HAZARDOUS AREA LIGHT FIXTURES

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A. DECORATIVE LED LIGHTFITTING SIMILAR TO CGL CAT.NO. LCTLR-36-CDL /

LCTLRF1-36-CDL :
Decorative type light fitting suitable for energy efficient LED lamps with high efficiency
diffuser and CRCA powder coated body, IP20 or better f o r surface / recessed mounting
a c c o m m o d a t i n g all electrical accessories pre-wired up to a terminal block. It shall have
optimum glare control and shall be aesthetically appealing with distinguished looks. Fitting
type shall be similar to the type mentioned in the price schedule.
B. FLOOD LIGHT LUMINAIRE (LED) SIMILAR TO CGL CAT. No. LSFO-120-CDL :
Weather proof Flood light luminaire with 120W LED lamp, IP 65or better, integral type with
aluminium die cast housing. The luminaire shall be complete with control gear, driver &surge
protector, heat resistant cover, prewired up to terminal block.
C. AVIATION OBSTRUCTION LUMINAIRE (SUITABLE FOR NEON LAMP) :
Aviation obstruction lights shall consist of yellow painted cast alumnium body housing, with
led LAMP and heat resistant, clear, toughened, thick glass dome mounted on hinged die
cast aluminium ring secured to the body. The luminaire shall be provided with Neon spiral
plugged into spring loaded high tension nylon socket and wired up to the terminal block. The
luminaire shall be suitable for mounting on a pipe bracket.
D. BULK HEAD LUMINAIRE (LED) SIMILAR TO CGL CAT.NO. LBH-10-CDL :
The body of the fitting shall be made of epoxy powder coated die cast aluminium fitted with
acrylic diffuser and frame. Proper sealing of inside against outside influences like water
vapour etc., is to be achieved. The fitting shall be provided with electronic driver. The
housing shall have suitable conduit threaded entry and fixing lugs shall be provided for
mounting on wall / ceiling. All MS hardware parts shall be cadmium plated and passivated to
withstand corrosion. The fitting shall be weather proof IP:65.
E. STREET LIGHT POLE:
The Octagonal Poles shall be designed to withstand the maximum wind speed
asp e r IS 875. The top loading i.e area and the weight of Fixtures are to be calculate
maximum deflection of the poles and the same shall meet the requirement of BS: 5649Part
VI 1982. Each pole shall comprise of FLP looping/terminal box (IP:66-polycarbonate type)
clamped with top level 1200mm above ground level along with a suitable earth terminal. A
base plate 300 x 300 x 10mm welded to the bottom of the pole. The looping box shall be

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provided with a suitable bus bar arrangement to loop 3 to 4 cables (type and size shall be as
per schedule of items/drawings). 2A DP MCB and an earthing terminal shall be provided.
The pole shaft shall have octagonal cross-section and shall be continuously tapered with
single longitudinal welding. There shall not be any circumferential welding. The welding of
pole shaft shall be done by Submerged Arc welding (SAW) process.
The welding shall be carried out conforming to approved procedures and duly qualified by
third party inspection agency. The welders shall also be qualified for welding the octagonal
shafts.
Octagonal Poles : HT Steel Conforming togradeS355JO

Foundation Bolts : EN.8 grade.Base Plate : Fe410 conforming to IS 226 / IS 2062
The octagonal poles shall be in single section (upto11mtr).There shall not be any
circumferential weld joint.
The pole shall be provided with a cap having 3 nos. fixing bolts at 120 degrees apart, pipe
arm with suitable stiffeners shall be provided to mount the street light fitting. The dia of the
pipe shall be suitable to carry the weight of fitting etc and suitable for mounting the fitting.
The pole shall be provided with necessary cross arms as per schedule of items for mounting
one or more numbers of street light fittings where required. Both underground cable and
earth cable shall be terminated at the terminal/looping box. Further wiring to the light fixture
shall be done by three core flexible copper wire (2 core for power supply and third core for
earthing). The earth terminal at the terminal box shall be further connected to the earth
terminal on the pole by aluminium cable.
Steel octagonal pole cap and all other MS material shall be epoxy painted hot dip galvanized
to 80 micron thickness. All hardwares like nuts, bolts, etc shall be of stainless steel or zinc
passivated.
The octagonal poles shall be bolted on a precast foundation with a set off our foundation
bolts for greater rigidity. The civil work for street light pole foundation forms a part of
erection.
The poles shall be hot dip galvanized as perIS2629/ IS2633 /IS 4759 standards with
average coating thickness of 70 micron. The galvanizing shall be done in single dipping.
The scope also includes supplying all materials and casting of RCC pedestal foundation
along with necessary Anchor bolts etc.,
The detailed drawing considering wind speed for the pedestal foundation shall be submitted

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and got approved by consultant/Owner before starting of the work.
Steel tubular poles shall conform to IS 2713 Part II – 1980 with designation as specified in
the BOQ.
F. TIMER
Timer (Time switch) shall be accurate & quartz driven. The timer shall have an built in
chargeable Ni-Cd cells for 150 hours continuous operation in the event of power failure. The
timer shall be suitable for switching ON / OFF street lights, open area lights, boundary wall
lights etc., at predetermined time.
8.3.3. SOCKETS, SWITCHES,FANS AND OTHER INSTALLTION ACCESSORIES:

A. SOCKET OUTLETS:
i. FLUSH/SURFACE MOUNTING SOCKET OUTLETS (DECORATIVE TYPE)
6A / 16A, 6A, 240V, single phase, 3 pin (two pole and one earth) socket outlet shall be flush /
surface mounting type along with decorative type switch. The socket shall be 6A / 16A
combined (universal type) having 6 pin, or 16A, 3 pin with suitable piano type switch.
ii. INDUSTRIAL TYPE PLUG SOCKET OUTLET

10A/20A, 240V, single phase, 3 pin (two pole and one earth) industrial type socket outlet
with interlocked switch. The outer casing shall be made of non-corroding die cast aluminium
alloy, moulded of superior grade phenolic /polyester compound.
B. JUNCTION AND OUTLET BOXES :

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Junction and outlet boxes fabricated with sheet steel shall have a minimum thickness of
1.6 mm / polycarbonate unless otherwise specified in schedule of items. All these items
shall be painted whether indicated specifically in the BOQ or not. The JB shall have earthing
terminals & terminal block, required no. of knockouts for cable entry etc.,
The exact size and number of knockouts& cable glands shall be decided by the Contractor
as per actual requirement.
C. CONTROL SWITCHES :
i. DECORATIVE TYPE
Single pole decorative type, 6A or 16A switches shall be used for light point wiring in control
rooms, office premises/non plant buildings.
All branch switches shall be placed in line conductor of the circuit and no single switch or
fuse shall be inserted in the neutral conductor of the circuit.
ii. SWITCH BOARDS (FOR DECORATIVE SWITCHES AND SOCKETS) :

The switch board shall be made of 1.6 mm thick sheet steel and painted / polycarbonate
including supports for switches, sockets, fan regulator etc., but excluding front cover in
case of decorative switches & sockets which will be of FRP sheet of approved quality,
design and colour. Clear depth of the box shall not be less than 60 mm, but adequate for
easy mounting of fan regulators. All fittings shall be in flush pattern in case of concealed
wiring. The FRP cover sheet thickness shall not be less than 4 mm. No separate payment
will be made for switch boards as the cost of this has to be included along with the rate
quoted for socket, point wiring, switches and fans. In case of more numbers of sockets /
switches / regulators are to mounted in one location, these can be mounted in a bigger
size switch board with necessary clearance etc., between switches instead of individual
switch board for each switch. Sheet steel enclosure shall be painted with two coats of epoxy
paint above two coats of epoxy based primer.
iii. BOLTS & NUTS / BRACKETS / DOWNRODS / CHAIN:

All screws, bolts nuts and washers used for Illumination work shall be of brass or cadmium
passivated MS to resist corrosions. All brackets, down rods, chains used for suspension of
light fittings shall be made of MS Conduits / channels / angles / strips as approved by site
engineer. Two coats of epoxy spray painting shall be applied over two coat of epoxy based
primer for all accessories.
iv. CEILING ROSES / LAMP HOLDERS FOR POINT WIRING :
a. Ceiling rose may be used in the wiring, as required.

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b. Normally only one flexible cord shall be attached to a ceiling rose. Specially designed ceiling
roses shall be used for multiple pendants.
c. All ceiling roses shall be of three plate pattern.
d. All lamp holders shall be of brass and batten or angle type as required with shrouding.
v. CEILING FAN FANS AND REGULATORS :
a. All ceiling fans supplied shall be conforming to relevant IS and with capacitor starting, 5 star
rated suitable for voltage range of not less than 220 V to 240 V AC single phase supply.
b. Fans shall be supplied complete with fan motor, fan blade, insulated hangers canopy and
regulator along-with a down rod of suitable length as required. The speed regulators shall
be of electronic type for steeples variation from zero to 100%. All ceiling fans supplied shall
have double ball bearings.
c. All ceiling fans shall be wired to a junction box and suspended from a hook in shackle and
insulated from the same. All joints in the suspended rod shall be screwed and all joints or
bolts in connection there with shall in addition be secured by means of split pin.
d. The canopy at the top of the suspension rod shall effectively hide the suspension.
e. The lead-in wires shall not be smaller than 0.75 Sq.mm (24/0.2 mm) PVC insulated flexible
copper conductor cable and shall be protected from abrasion.
f. Unless otherwise stated, all ceiling fans shall be hung at 150mm above the light fitting level
or as directed by the Engineer in-charge. The length of the down rod supplied shall be
suitable for this purpose.
g. Generally the ceiling fans shall be mounted 2500/3000, above FFL. The down rod length
shall be considered based on roof profile (slope or flat).
vi. EXHAUST FAN :

Exhaust fan shall have totally enclosed with highly efficient heavy duty motor mounted on
ball bearing, precisely and dynamically balanced blades/impeller to ensure smooth and
trouble free operation, rigid frame with rubber pads for silent operation finished with epoxy
based painting for better chemical, mechanical and corrosion resistant. The exhaust fan
shall be supplied with wire guard/bird mesh screen as required.
The exhaust fan shall be provided with earthing terminal.
Battery rooms shall be provided with minimum two exhaust fan.
All toilet blocks / Pantry shall be provided with Exhaust fans.
8.3.4. CABLES & WIRES:

A. CABLES:

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Cables shall be used for power supply to lighting boards and all outdoor installations.
B. WIRES :
1100V grade PVC insulated FRLS, PVC sheathed round wire armoured PVC overall
sheathed cable with stranded copper conductors (YRY) not less than 2.5 sq mm cross-
section shall be used for wiring for connecting from distribution board tooutdoor light fittings
and not less than 4 sq mm cross-section for power circuits. Where the number of cables is
less it is permitted to directly fix the cables on GI saddles and a common clamp for the the
cables. Cables shall be cleated at intervals not exceeding 1000mm. Generally, cables shall
be laid in such a manner to avoid crossing / jumping of cables over each other and shall
provide a neat and tidy appearance. Suitable size compression brass glands shall be
provided for cable entry / exit.
C. POINT WIRING:
Supply and wiring of 1100V grade, FRLS, PVC insulated single core Copper conductor wire (without
joint) drawn into the 19 mm dia concealed PVC Conduit for Light points and 25mm dia. PVC conduit
for power points (including supply of conduit). The scope covers pulling the wire from switch box to
lighting / exhaust fan point through the conduit and connecting both the ends with all accessories like
bends, junction boxes and couplers, factory made covers for all the pull JBs, including breaking of
wall etc.
The wiring for lighting, fans and socket outlets shall be carried out on point wiring basis.
Point wiring shall be done in conduits using 3 runs of single core 1100V grade , FRLS,PVC
insulated stranded copper wire as per IS:694 as specified in BOM.
The 6A sockets shall be of universal type. The sockets shall be flush mounting type. Every
switchbox shall consist of 6A socket outlet controlled by a 6A switch.
The switchbox shall be suitable for concealed flush mounting in walls. Necessary chipping of
walls for installing the switchbox and making the wall good after installation of the switch box
shall be included in the scope. The switchbox shall be made from galvanized sheet steel and
shall have a provision for earthing from inside. The boards shall be covered with poly
carbonate front cover having good aesthetic look suitable for mounting modular switches
and sockets.
Point wiring shall include supply and installation of 1.5 sq.mm,2.5 sq.mm, 4 sq.mm & 6
sq.mm Cu wires, 19mm rigid PVC conduits and wiring accessories like pull box, ceiling
roses, fittings including circular/rectangular sheet steel/thermoplastic bends, tees, sockets,
adopters, reducers, saddles, distance pieces etc for concealed wiring as per requirements to
complete the lighting/fan/exhaust fan wiring of rooms. PVC insulated multi stranded copper
wires of 1.1 KV grade with ISI certification shall be used. The following colour code shall be
adopted for wiring:
Phase : Red/Yellow/Blue

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Single phase wiring : Black
Neutral : Green
Primary point is the light/fan point wiring from the switch box to one light fitting / fan via the
switch. Secondary points are light points looped from the primary light point or from the
nearest secondary light point in the same lighting circuit.
All electronic ballasts for light fittings shall be low loss type with total harmonic distortion not
more than 30% and power factor greater than 0.9.
D. TESTS :
All tests conducted shall be as per IS amended up to date. Type test certificates shall be
submitted at the time of approval of specific makes.
E. CONDUITS :
i. PVC CONDUIT
Rigid heavy duty PVC conduit as per IS : suitable for electrical wiring may also be used
wherever indicated in the approved drawings or specifically approved by Engineer. It shall
be of approved make.
ii. PVC CASING, CAPPING & ACCESSORIES
PVC casing, capping & accessories like Tees, elbows, JB’s shall be of heavy duty fire
retardant self extinguishing, Acid & Alkali resistant, PVC toughness that will not dent, snap-fit
covering, desiredcolour.
iii. GI PIPES
All the pipes supplied shall be suitable for cable drawing, without any internal burrs, smooth
internal surface and threaded at both ends with coupling at one end
Class ‘B’ type GI pipes as per IS shall be used for the following cable routes:
a. Cables running on floor shall be laid in buried pipes.

b. All cables laid upto a level +200mm from floor level shall be in GI pipes.
c. Cables crossing road, entering building from outside through wall/foundations etc.
shall be laid in GI pipes.
d. All GI pipes shall have a suitable fish wire for drawing cable.

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8.3.5. EARTHING:
Earthing shall confirm to IS 3043 – 1987 and relevant OISD.
A. EARTHING OF LIGHTING DISTRIBUTION BOARDS :
The lighting board shall be provided with two separate earth terminals. An earth bus bar of
appropriate cross section shall be provided inside the lighting board and connected to the
earth terminals provided on either side of the board.
Adequate number of holes / terminals shall be provided on earth bus with suitable provision
for terminating the earth wire.
GI strip / GI wire insulated single core cable of suitable size shall be used for earthing the
lighting board, by connecting the two earth terminals separately to the earthing main in the
shop / earth pit.
B. EARTHING OF LIGHT FIXTURES AND SOCKET OUTLETS :
The single core PVC insulated / bare copper wire or 14 SWG GI wire and the third core of
the flexible wiring cable shall be used for earthing the light fixtures and single phase socket
outlets etc.,
C. EARTHING OF METAL BOXES AND BRACKETS :
Not less than 14 SWG GI wire or suitable size PVC insulated copper wire shall be used for
earthing all metal boxes and brackets.
D. EARTHING OF STREET LIGHT POLES/SOLAR LIGHTING POLES/ FLOOD LIGHTING

POLES :
At every 5th pole including end poles a separate earth station shall be provided. The poles
will be earthed by connecting its earth terminal to the junction box through 8 SWG GI wire.
Apart from the above, continuous earthing connection from pole to pole shall be carried out
using single core PVC insulated PVC sheathed armoured cable with aluminium conductor.
The earth terminal at the junction box shall be connected to the main earthing ring through
GI 25 x 5 mm flat.
8.4. HAZARDOUS AREA ILLUMINATION:

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8.4.1. GENERAL :
All the equipment’s installed and accessories used shall conform to the requirements
stipulated under relevant OISD / IEC / Indian Standards for the type / category of installation.
All the equipments and accessories installed in these areas shall be certified by CMRS,
Dhandbad for using in that particular types of hazardous atmosphere like flammable gas /
Vapour or hazardous dust. All the equipments installed shall not attain more than the
maximum permissible surface temperature specified for that area elsewhere in the
specification, if not the maximum permissible temperature may be assumed as 100 degree
C. It shall be ensured that overheating / sparking whether in normal use or under fault
condition is confined within the approved housing of wiring system and electrical item
concurred. If any equipment is likely to produce more than the prescribed maximum
permissible surface temperature due to abnormal conditions of operation or during fault
conditions, all such fittings shall be fitted with a thermal device to disconnect the appropriate
circuit before the maximum safe temperature is exceeded.
This bimetal thermally operated cutout device shall preferably be included in the enclosure
containing choke and other control gears liable to be over heated. THIS THERMAL DEVICE
SHALL NOT BE AUTOMATIC SELF-RESETTING TYPE. If control gears are not integral
with the fitting the enclosure for the control gears also shall be suitable for use in that
particular type of hazardous atmosphere and certified by CMRS, Dhandbad. For all the
equipments where cast iron body is specified, cast Aluminium alloy (LM-06) is also
acceptable. All the equipments if constructed out of Aluminium alloy, its external surfaces
shall be smooth finished to be free from frictional sparking hazard. All the equipments shall
have markings, warning inscriptions and interlocks, specified as per relevant I.S, inscribed
either by raised lettering or cast integrally with or by a plate permanently attached to the
body of the fitting. Copy of CMRS, Dhandbad, and certificate for each type of fitting should
be submitted.
8.4.2. LIGHT FITTINGS :

i. FLAME PROOF STREET LIGHT FITTING SIMILAR TO BALIGA CAT.NO.FLPW-1095
100 W Flame proof street light Ex-d type fixture with LED lamp, control gear in cast
alluminium alloy LM6 enclosure and toughened glass cover. The enclosure shall be of IP: 66
suitable for Zone 1& 2 gas group IIA & IIB with all accessories.
ii. FLAME PROOF SIMILAR TO Baliga CAT. NO. ECRF-236

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The fitting shall have a Aluminium alloy LM 6 enclosure , toughened Glass Window and
Surface mounting arrangement with control gear housing the terminal box. The enclosure
shall be IP 66 suitable for Zone 1 with all accessories.
iii. INDUSTRIAL VAPOUR PROOF LIGHT FITTING
Industrial vapour proof IP55 luminaire with 2 x 36 W TFL diecase aluminium control gear
boxes at the ends with synthetic rubber gasket connected by MS pipe finished in hammer
tone grey.
8.4.3. SWITCHES, SOCKETS AND OTHER ACCESSORIES :
The enclosures shall be of cast iron construction having an integral terminal chamber. The
front cover shall be secured to the body either by a threaded joint or by special type screws.
The box shall have minimum two earthing provision outside and preferably one more inside.
The switches and sockets shall be supplied with suitable double compression FLP type
cable gland and cable entry / exit provisions shall be as per specific requirements. The
enclosure shall have suitable provision for mounting on wall / column. The contact of the
switches shall be suitable for heavy duty and shall be able to make and break the specified
rated current effectively. The enclosure shall be suitable to contain the spark / arc created
during the operation of the switch effectively from the outside atmosphere. The entire
equipment shall conform to the relevant standards and certified by the appropriate
authorities for use in hazardous areas having flammable gases or Vapour and explosive
dust.
All the accessories such as Pull/anchor/ceiling/junction/outlet boxes specified for use in

hazardous areas should conform to the relevant standards and certified by CMRS,
Dhandbad. The body of all the above boxes shall be made of cast iron or cast Aluminium
alloy and shall have a removable cover plate. The cover plate shall have either a threaded
joint or a screwed joint with the body. The number of cable entries shall be as per the
requirement.
8.4.4. FLAME PROOF EXHAUST FAN :
Exhaust fans shall have flame proof, highly efficient heavy duty motor mounted on ball
bearing, precisely dynamically balanced blades / impeller to ensure smooth to trouble free
operation, rigid frame with rubber pads for mounting to reduce vibrations for silent operation,
finished with stove enameled epoxy powder coated for better chemical, mechanical and
corrosion resistant. The exhaust fan shall be supplied with wire guard / bird mesh screen as
required.
8.4.5. FLAME PROOF MCB DISTRIBUTION BOARDS :

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All equipment shall be designed suitable for operation in hazardous areas having flammable
gases or Vapour and explosive dust. The distribution board shall be wall / floor mounted
type made of cast iron / cast Aluminium LM6 with anti corrosive and light grey epoxy coated
finish. The incoming cable terminals, outgoing cable terminals and the switch are all housed
in separate chambers. The operating handle of the incomer shall be suitably inter locked
mechanically with the door of the incomer. The boards are provided with neoprene gasket.
Suitable cable entries shall be provided for incomer and outgoing. The boards are provided
with 2 Nos. external and 1 no internal earth terminals. The entire equipment shall conform to
the relevant standards and certified by the appropriate authorities for use in hazardous
areas.
8.4.6. WIRING :
A. GENNERAL:
For general requirements for wiring refer to the details stipulated under specifications for
wiring for Ordinary (non-hazardous) area elsewhere in this specification.
Additional requirement for carrying out wiring in the hazardous areas are as specified below.
B. USING ARMOURED CABLES :
i. 1100V grade XLPE insulated FRLS PVC sheathed round wire armoured PVC overall
sheathed cable with copper conductors shall be used for wiring wherever surface laid cables
are specified for connecting from distribution board to light fittings and other equipment.
ii. While carrying out surface wiring using armoured cables, cable shall be supported 500mm
apart to avoid sag. The cables shall be neatly clamped and should not create a shoddy
appearance.
iii. The rate quoted shall include the cost of accessories required like FLP junction boxes,
saddles, consumables, etc., for supply and installation of complete wiring system.
iv. Cables shall be laid in such a manner to avoid crossing / jumping of cables and shall provide
a very neat and tidy appearance.
v. Suitable size double compression brass glands (Approved by CMRS as suitable for
flameproof area) shall be provided for cable entry / exit to any of the flameproof apparatus.
vi. The cables used shall have multi-strand copper conductor.
vii. Nylon/rawl plugs shall be used for fixing cables to ordinary wall / ceiling. The plugs shall be
fixed using the correct size of drills and screws as specified by the manufacturer. Using of
wooden plugs is not permitted.
C. WIRING USING PIPES :

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i. Wiring in the hazardous areas can be carried out using 1100V grade PVC insulated FRLS
PVC sheathed cable with copper conductor in surface laid solid drawn or ERW welded pipe,
if specified, for connecting from distribution board to other equipments in flame proof areas.
ii. Conduits shall be supported at a minimum distance of 1000mm horizontally and 500mm
vertically, Nylon / rawl plugs shall be used for fixing conduits on wall / ceiling. The plugs
shall be fixed using correct size of drills and screws as specified by the suppliers. Using of
wooden plugs is not permitted.
iii. Conduits shall be laid in such a manner to avoid crossing of conduits.
iv. Metal conduits are to be screwed tight to the apparatus. Conduit unions only are to be used
for jointing and couplers are not allowed.
v. Flexible conduits are NOT allowed for use in hazardous areas.
vi. Cables with multi-strand conductors only are permitted for use in conduit wiring system for
hazardous areas.
vii. The rates quoted for the conduit system shall include the cost of accessories required for
supply and installation of a complete conduit system e.g., saddles, consumables etc.,
D. CONTROL OF ELECTRICAL SUPPLY CIRCUITS :
i. The supply of electricity to a building or underground site containing explosives is to be

controlled by one or more master switches outside the building or underground sites. Master
switches should be in close proximity to each other, identified and capable of isolating every
conductor entering the building including the neutral of switches, starters, etc., If installed
inside the building, these should confirm to the category of installations.
ii. All circuits are to be provided with protection against over load and earth leakage. Over
current protection may be given by automatic circuit breakers complying with IS : 3842 (Part-
I) 1967.
8.5. CONTROL ROOM SWITCH BOARD;
Location Control room for controlling the lighting

fixtures
Type Flush mounted type
Construction Fabricated from 14 SWG MS sheet with 6mm

thick bakelite cover

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Shall have conduct knockouts on the sides.
Switch mechanism Modular switches shall be provided
Power source The switchboards shall be fed from SLDB of

respective area.
8.6. 240V SWITCH SOCKET OUTLET;
Type 1 pole, 3 pin with third pin earthed industrial

type receptacles.
Non-reversible, metal-clad, dust proof, industrial

type suitable for horizontal insertion.
Rating 240 V AC , 15A,
Construction Metal clad gasketted construction, weatherproof
All socket outlets shall be supplied with heavy-

duty type plug and cap with chain.
Isolation Switch Rotary type switch mounted flush in the socket

outlet box.
The isolating switches shall be manually

operated industrial type of category AC 22.
Protection Operating handle of the rotary switch shall be

fixed in such a manner that it shall not be
possible either to insert or withdraw the plug
without switching off the supply.
Cable entry Suitable for cable entry through 20mm dia.

conduit.
Mounting Wall / column mounting

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Inscription Inscription plate shall be provided indicating the

voltage and current rating of the switch socket
outlet.
Miscellaneous In hazardous area, flame proof switch socket

outlet shall be provided.
8.7. 240 V SINGLE / DOUBLE POLE SWITCHES:
Application The switches are intended for controlling lighting

circuits
Type Weather and dustproof and industrial type
Design The rotary or toggle switches provided shall be

of sturdy design
Standard As per IS : 6875 (Part-3) - 1980
Housing The unit shall be housed in cast iron or cast
aluminium box having gasketted, screwed front
cover plate, fixing lugs and suitable provision for
terminating conduit/cable at the top, bottom or
sides as specified.
Mounting DIN Channel mounting.
Single phase MCBs mounted adjacent to each
other and connected to different phases shall be
provided with adequate insulated phase barriers.
Terminal suitability Terminals suitable for aluminium conductor
cables.
9. ERECTION SPECIFICATION:
9.1. GUIDELINES FOR DESIGN OF SYSTEM AND ENGINEERING THE LAYOUT OF
ELECTRICAL EQUIPMENT.
9.1.1. General

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The tenderer shall execute the work at site based on layout drawings furnished by
consultant/client.
9.1.2. DESIGN REQUIREMENT FOR ELECTRICAL &CONTROL ROOM BUILDINGS
- All electrical room shall have adequate space to accommodate the electrical equipment
from the point of view of operation and maintenance, and conform to IE Rules &
Regulations.
- All electrical rooms shall be constructed with heatproof material at the roof if it is
exposed to sunlight.
- All Electrical buildings / MCC rooms shall be of civil construction, with suitable drainage
for rainwater.
- Suitable exhaust ventilation system shall be provided for rooms housing PDBs,
Emergency panel, Capacitor bank etc.
- Ceiling fans shall be provided in office rooms.
- Exhaust ventilation system for toilets, store rooms, etc.
- Entry/Exit for the electrical room shall be provide minimum 2500x2000 with MS doors.
All doors shall open outside.
- The height of rooms housing LT Panels, PDB, Capacitor bank etc shall be decided
considering minimum 5.0mtr clear height shall be provided.
- The wiring of light fittings in the buildings shall be concealed type. Modular switches
shall be used in the control rooms, office rooms, etc. (which are not required to glow
continuously) for switching ON/OFF the lights/fans.
-- Electrical rooms, control rooms shall be considered fire hazardous.
- Roofs of the electrical premises shall be fully watertight and moisture proof.
9.1.3. GUIDE-LINE FOR ERECTION OF ELECTRICAL EQUIPMENT AND ACCESSORIES

9.1.3.1. General

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All the electrical equipment shall be installed with proper care and as per layout drawings.
Minor modifications required at site shall be made by the contractor with approval of Owner
representative/Consultant for installation of the equipment. Care shall be taken for proper
handling of equipment and undue vibrations shall be avoided particularly in case of sensitive
equipment.
The contractor shall have valid electrical contractor's license valid for State Govt. and as well
supervisory licence. He shall have in his employment sufficient number of electricians and
supervisors holding valid licenses for HV and LV installations.
9.1.3.2. Rotating machines
The erection work of motors shall include checking of all motors before installation including
thorough cleaning and checking of bearings, replacement / rectification of defective items,
greasing of bearing, if required, making minor modifications in its mounting arrangement,
wherever required, assembling and its mounting on the motor base plate or on mechanical
equipment, as the case may be, including levelling and alignment, checking insulation
resistance and improving the same, if necessary, checking of internal connections etc.
All work associated with revisioning of motor shall also be included such as uncoupling and
removing of motor from mechanical equipment, disassembling, cleaning, checking of
insulation resistance and improving the same, if necessary, regreasing and replacing
defective items/bearings on foundation, wherever required, reassembling, placing, levelling,
aligning and fixing of coupling of the revisioned motor with mechanical equipment.
The height of the shaft of the motors shall correspond to the machine to be driven, if
discrepancies are encountered these shall be compensated by inserting machined metal sim
plates under the supports of the motor.
The motors mounted on the movable base frames / base plates shall be connected via
intermediate terminal boxes with flexible cables.
After the complete installation of the motors, all bolts and bolted joints of the mechanical and
electrical equipment shall be checked to ensure that they are done up tightly by torque
wrench. A further check shall be made to ensure that the armature can be easily rotated.
The insulation resistances of the coils and connecting leads within the machine shall be
checked against earth by a suitable megger. Insulation resistance if found less, the machine
shall be dried to achieve the desired value.
Space heaters of main drive motor required to be installed in motor foundation pits shall be
suitably and firmly mounted.

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For handling the machine with the crane, the slings, lifting cables etc. shall not be secured
around the shaft. However, the armature of disassembled machines may be lifted or
supported by the shaft.
The machine shall be lifted or lowered without shocks or quick jerks to avoid any damage.
9.1.3.3. Sheet metal enclosed panels
The base frames of all panels, shall be welded to structures or to the civil inserts provided on
the floor/walls. Fabrication of supports/frames, wherever required, shall be done by the
contractor.
The shipping section shall be placed in position before removing the protective covering to
eliminate scratch/damage. The shipping section shall be moved by using rollers under the
shipping skids wherever lifting cranes are not available. The contractor shall do the assembly
at site as per manufacturer's general arrangement drawings and installation instruction.
While assembling a complete board comprising several unit type cubicles, the board as a
whole shall be aligned. The panels shall be properly leveled prior to grouting the holding
down bolts or welding the panels to the inserts. All interconnection of busbars and wiring
between the panels shall be done as per manufacturer's instructions and drawings. Welding
work on the panels shall only be carried out after consultation with the Owner. Damage to
the paint due to welding shall be rectified by the contractor.
After mechanical installation of the board is completed, loose instruments shall be installed,
wherever required, and wires shall be connected to the instrument. The wiring of
intermediate terminal strips between two panels, wherever disconnected for transport, shall
also be connected.
9.1.3.4. Transformers
The transformer and its accessories and mountings like conservator, thermometers, silicagel
breathers, etc., delivered at site in separate packages, shall be assembled at site after
cleaning by the contractor in proper sequence as per manufacturer's drawings.
The oil conservator and the pipes shall be erected as shown in the manufacturer's drawings.

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Before the transformer is filled/topped with oil, oil samples shall be checked by the contractor
from each container. The oil shall possess the dielectric strength as per relevant IS/CEA. Oil
shall be filled upto the mark shown.
The contractor shall also test the oil from each transformer to determine its suitability for use.
If required, the contractor shall carry out drying and filtering operations as per IS code of
practice to ensure that moisture is completely removed and the oil is free from impurities.
This may be carried out by using oil filtering equipment to be provided by the contractor
having vacuum as well as heating arrangement. Only after the dielectric strength of oil and
other parameters are checked and approved, the external connections shall be made to the
transformers.
Any modifications to HT and LT terminal box to accommodate the number of cables to be

terminated shall be carried out by the contractor.
Naked light and flame shall never be used near the transformer.
9.1.3.5. Cable Installations
Concrete cable channels can be considered in case of lesser number of cables.
Laying of cables directly in underground or in trenches shall be considered where number of

cables is less. In such case, cable shall be laid in one layer only, more than one layer is not
permissible.
Cables in trenches shall be laid on 8 cm of riddled sand and covered with 8 cm of riddled
sand. Red Bricks shall be provided for covering these trenches. The maximum trench depth
shall normally be 1.5 m and thickness of top cover of 75 mm.
Installation of cables directly buried in ground shall generally conform to the requirements
given in IS: 1255 –1983.
9.1.3.6. HT cable termination accessories
The cable accessories shall include end termination kits and also any special tool and
tackles and accessories required for making the terminations.
The termination arrangement shall be complete with all fittings and consumables. For all
cables, a minimum extra length of 2 metres shall be left before termination.
The termination kit shall be of heat shrinkable type type.
The termination kits shall have the following features:
 Electrical stress control to be provided at the cable insulation shield terminus.

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 An external leakage insulation to be provided between the cable conductors and

ground.
 Adequate protection to be provided at the end of the cables against the entrance of
the moisture and, provision to maintain the constant pressure in the cable.
9.1.3.7. Exposed & Concrete conduits
Exposed conduits shall be laid along walls, floors, ceilings, on steel supports etc. as per
working drawings/site requirements in consultation with the supervisory personnel. The
conduits shall be neatly run and evenly spaced.
Fixing of conduits to the supports on wall, column, structure shall not be done by welding.
Exposed conduits shall be adequately supported by racks, clamps, straps etc.
Jointing of conduits shall be done only in straight portion and not in bend portion.
The contractor shall have arrangements at site for bending facilities for conduits as well as
dies for threading conduits of diameters and threads corresponding to the
standards. The threaded ends of conduits shall be painted with anticorrosive paint. The
outer ends shall be smoothened free of burrs and sharp edges. Bushings shall be fitted at
both ends of conduits.
Flexible metallic conduits shall be used for termination of connections to motors and other
electrical equipment like pressure switches etc. which need to be disconnected at periodic
intervals.
All conduits shall be effectively connected to the earth terminal of the equipment where it
terminates.
Both ends of conduits shall be suitably earthed. Earthing continuity to be maintained by

means of flexible wire wherever two conduits are joined with sockets.
Approved conduit bending machines to be arranged by the contractor shall be used for
bending conduits at site. The radius of any conduit bend shall be as per standards for
cabling. Bends shall be free from cracks, crimps or other damage to the pipe or its coating.
Annular space of used & un-used conduits should be sealed at both ends.
9.1.4. EARTHING AND LIGHTING PROTECTION

9.1.4.1. EARTHING
Entire system shall be earthed in accordance with the provisions of the relevant IEC
recommendations/ IS code of practice IS 3043-1987 and Indian Electricity Rules, so that
the values of the step and contact potentials in case of faults are kept within safe
permissible limits.

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Parts of all electrical equipment and machinery not intended to be alive shall have two
separate and distinct earth connections each to conform to the stipulation of the Indian
Electricity Rules .
All buildings as well as the electrical sub-stations and electrical rooms shall be provided
with a ring main earthing system each. Individual ring main earthing systems shall again
be interconnected as a network. The earthing system shall be provided to have overall
network earthing resistance shall be less than one ohm.
The ring earthing system around each building shall be laid at a distance of approximately
1.5 m from the building and at a depth of approximately 0.8m. The ring shall be bonded at
intervals to the building steel structures, reinforcement of building columns and also to
pipes, wherever they are crossing. The earth ring shall further be connected at intervals to
deep earthing electrodes to achieve a combined earth resistance of less than one ohm.
For the purpose of dimensioning the earthing lines/conductors, the duration of the earth
fault current shall be taken as 1 seconds.
For protective earthing separate conductor shall be used for flow of earth fault current as
elaborated below.
The LV side neutrals of the Distribution transformers & Gas Gen Set shall each be
connected to two separate isolated earthing electrodes. They shall also be connected with
the neutral bus of the corresponding switchgear and the switchgear neutral bus shall be
connected to the earthing ring at two different and distinct points. The fourth core of cables
for cables shall also be connected to the earthing mains. A continuous earth strip shall be
run in each side of cable trenches.
The power supply cables (LT) from the sub-station and the distribution cables to individual
motors shall have 4/3.5 cores.
LT power supply cables shall have four cores and the fourth core shall have cross-sectional
area of 50% of the other cores generally. The fourth core of the main supply lines shall be
connected to the solidly earthed neutral bar as well as at the earth bars in MCC/distribution
boards.
9.1.4.2. CONDUCTOR SIZE FOR GROUND CONECTIONS
For equipment ground connections, the minimum conductor sizes used should be as
follows:

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i. LT System:-
75 x 10 mm GI flat :
 Main earthing rings

 Main LT switch-boards
 Transformers
 Gas Gen Set
 Earthing leads to earth electrodes
ii. LT system where the voltage does not exceed 650V normally :
6 Sq.mm Stranded wire :
 Motors and starters upto and including 2.2kW, Light fitting, JBs, etc.
 Instruments and miscellaneous small items protected by fuses of ratings not
exceeding 15A.
16 Sq.mm Stranded wire :
 Motors and starters above3.7 kW and upto including 15 kW.
25 x 3 mm GI Flat :
 Motors and starters above15 kW and upto including 45 kW.

 LCB, Welding socket outlet, isolators, LDBs.
50 x 6 mm GI Flat :
 Motors and starters over45 kW and HT motors.

 MCC, PDB, MLDB.
 Main earthing ring for MCC room, in shop units / plant buildings.
 Cable tryas all around.
 Aux. LT switch board and other equipment protected by circuit breakers.
9.1.4.3. EARTHING ELECTRODES:
The earthing electrodes shall be of GI pipes 50 mm dia and about 4 mm thickness in one
piece provided with water holes and other filling devices. Earthing system for computers

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and microprocessor based equipment/ PCs shall be distinct and separate from the power
and lighting equipment earthing system.
Every electrical equipment shall have double earthing.
The earthing grid and the lightning grid shall be interconnected.
9.1.4.4. LIGHTNING PROTECTIN:
All buildings and plant structures vulnerable to lightning strokes owing to their height or
exposed situation shall be protected against atmospheric flash-overs and lightning strokes
in such a manner as to eliminate any danger to the personnel employed therein.
Stipulations of IS : 2309 - 1969 shall be followed.
A 'Faraday Cage' made of hot galvanised strip steel connected to all buried pipes and steel
structures crossing this cage ring shall be laid around each main building or plant unit as
earthing device. This shall be separate from the electrical equipment earthing ring main.
All lightning arrestor earth leads of the buildings and plant units shall be connected to this
cage ring.
Air termination network should cover all salient points of the structure. All metallic
chimneys, ducts and the like above the roof of the structure shall be bonded to and form
part of the air termination network. Vertical air termination points shall project at least 30
cm above the object on which it is fixed.
Down conductors shall follow the most direct path possible between air termination and
earth termination avoiding sharp bends. Down conductor shall have a testing point
adjacent to the earth electrode. Each conductor shall have an independent earth
termination. All earth terminations shall be interconnected.
Earthing electrodes and grid for lightning protection shall be distinct separate from the
earthing system for earthing of electrical equipment and at no place shall be connected to
other earthing system.
Earthing connection to equipment subject to movement, vibration and shocks, shall be

through flexible stranded conductors.
The termination of strips to the equipment shall be done by bolting and the wires shall be
terminated by compression lugs. Jointing of strips shall be done by welding for proper
continuity. All contact surfaces shall be thoroughly cleaned of dust and oil and after jointing,
the joints shall be given bitumen paint.
9.1.4.5. GUIDELINES FOR INSTALLTION OF EARTHING CONDUCTOR:

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Earthing conductors laid directly in ground for Lightning protection, shall be coated with
one coat of bituminised paints, be wrapped with one layer of bitumaetic tape laid on half
lapped and shall have a final coat of bituminised paint to prevent corrosion.
Earthing conductors run on walls/floors/cable and equipment structures etc. shall be

supported at suitable intervals and painted with black oxide paint.
All joints in all kind of Earthingconductors except at earthing electrode shall be welded and
painted black with bitumen paint.
At road crossings earthing strips shall be laid through conduits /concrete ducts.
Special earthing shall be provided for all electronic equipment as per manufacturer's
recommendations / practice.
10. TESTING:
Test of all equipment shall be conducted as per latest IS applicable. Tests shall also
confirm to International Standards IEC/VDE/DIN/BS (in case corresponding test are not
mentioned in IS).
All routine test shall be carried out at manufacturer’s works in the presence of Owner or his
representative.
The tenderer shall submit type test certificates for similar equipment supplied by him
elsewhere. In case type test certificates for similar equipment are not available, the same
shall be conducted in the presence of Owner or his representative if Owner so desires,
without any financial implications to the Owner.
All the equipment shall be tested at site to know its condition and to prove suitability for
required performance. The Factory tests, site tests and acceptance tests to be performed
by Contractor are detailed below.
The Contractor shall be responsible for satisfactory working of the complete system in an
integrated manner and its guaranteed performance.
10.1. TRANSFORMERS:
A. Routine tests
i. Assembly inspection / painting check.
ii. Measurement of winding resistance.

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iii. Measurement of voltage ratio and check of voltage vector relationship.

iv. Measurement of impedance voltage (Principal tapping), short circuit impedance and
load loss.
v. Measurement of no-load and current.
vi. Measurement of insulation resistance index.
vii. Dielectric test:
a) Induced over voltage withstand test
b) Applied voltage withstand test (H.V. power frequency test)
viii. Certification for off-load tap changer.
ix. Final documentation check.
B. Type tests
i. Temperature rise test

ii. Measurement of acoustic sound level
iii. Lightning impulse withstand test (if test certificates are not available)
iv. Short circuit test
v. Measurement of commutating reactance and determination of inductive voltage drops
(for thyristor converter transformer only).
10.2. LT switch gear:
A. Routine tests
i. Assembly inspection / painting check.
ii. Measurement of insulation resistance.
iii. Functional test including automatic bus transfer scheme.
iv. Polarity tests for CTs
v. Final documentation check.
B. Type tests
i. Temperature rise test for main and vertical bus bars.

ii. Short circuit test for main and vertical bus bars.
iii. Enclosure calss, degree of protection.
iv. Dielectric test including protective circuit.
10.3. Final Test of Materials of Grounding and lightning system

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i) Visual check
ii) Dimensional check
iii) Accessories fitting check
iv) Mechanical and electrical test (where applicable)
v) Final documentation check
10.4. CABLES
A. Shop Tests
a) The cables shall be subject to shop tests in accordance with relevant standards to
prove the design and general qualities of the cables as below:-
b) Routine test on each drum of cables.
c) Acceptance tests on drum chosen at random for acceptance of the lot.
d) High Voltage withstand test for HT cable (Hi Pot test).
e) Type tests certificates on each type of cable, inclusive of measurement of armour

D.C. resistance of power cables shall be furnished by Contractor
B. PACKING
i. Cables shall suit barrel diameter and securely clamped/fixed. The barrels must be sufficiently
strong to withstand mechanical shocks and shall effectively protect against transit.
ii. Both ends of cable shall be metal capped to prevent moisture ingression. Ends shall be kept
inside the cable drum in a manner so that these are accessible for testing.
iii. Cable drum identification/marking shall be as follows:
a) Makers name
b) Consignee’s full address
c) Type size and length of cables
d) Net and gross weights
e) Any other marking for shipping

f) Drum Markings
C. Drum Lengths

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i. LT Cables shall be delivered at sitepreferably on standard drums each containing

500 m or 1000 m cables, Where total quantity of a particular cable is less than 500 m,
the entire length shall be supplied in one drum.
ii. For 90% cable drum of each item of cable permissible tolerance is in length + 5% For
10% balance cable drums, Contractor shall ensure that each 500 m capacity drum
contains at least 250m and each 1000m capacity drum contains at least 500m cable
lengths. Overall tolerance for each item of cable is + 1% of total length.
10.5. Motors:
A. Routine Tests
The following are the routine tests carried out on each and every motor :
i. Measurement of resistance.
ii. Insulation resistance test .
iii. Motors are tested at 1/3 times the rated voltage for checking the ability of the motor to run
upto full speed , when switched in either direction .
iv. No load test .
v. High voltage test .
B. Type Tests
i. Measurement of rotor resistance .

ii. No load test
iii. Locked rotor test .
iv. Full load reading of voltage, current , power input and slip.
v. Temperature rise test.
vi. Momentary overload test .
vii. Insulation resistance test .
viii. High voltage test .
ix. Polarisation index test (for HT motors)
10.6. SITE TESTS AND CHECKS

10.6.1. General
All the equipment shall be tested at site to know their condition and to prove suitability for
required performance.
The test indicated in following pages shall be conducted after installation. All tools,
accessories and required instruments shall have to be arranged by contractor. Any other

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test that is considered necessary by the manufacturer of the equipment, Contractor or

mentioned in commissioning manual has to be conducted at site.
In addition to tests on individual equipment some tests / checks are to be conducted /
observed from overall system point of view. Such checks are highlighted under
miscellaneous tests but these shall not be limited to as indicated and shall be finalised with
consultation of Owner before charging of the system.
The Contractor shall be responsible for satisfactory working of complete integrated system
and guaranteed performance.
All checks and tests shall be conducted in the presence of Owner’s representative and test
results shall be submitted in six copies to Owner and one copy to Electrical Inspector. Test
results shall be filled in proper proforma.
After clearance from Electrical Inspector, system / equipment shall be charged in step by
step method.
Based on the test results clear cut observation shall be indicated by testing engineer with
regard to suitability for charging of the equipment or reasons for not charging are to be
brought by the Contractor.
10.6.2. Trial Run Test
After the successful test of each equipment as per standard test procedure, the entire control
system shall be put on trial run test on actual site conditions and operation of the system.
10.6.3. Acceptance Test
The acceptance test on the system shall be carried out by the contractor as per mutually
agreed test procedures to establish satisfactorily functioning of the system as a whole and
each equipment as part of the system.
10.6.4. Site tests
The tests to be carried out on the equipment at pre-commissioning stage shall include
following but not limited to the following:
Transformer:
i. IR test on each winding to ground and between winding.

ii. HV test with 2.5 KV megger for HV side and 500V for LV side.
iii. BDV test on oil samples.
LT switch board

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i. IR test.
ii. HV test with 2.5 KV megger.
iii. Functional test for all feeders.
iv. Check operation of contactors from local points.
CABLES
i. Visual check.
ii. Checking of continuity and IR values for all the cables before and after HV test.
iii. HV test and measurement of leakage current after termination of cable kits.
iv. Check for identification (tag number system) distance placement of cable marker, cable joint
etc. as per the cable layout drawing.
v. Check tightness of all connections.
EARTHING
i. Check tightness of all earth connections.

ii. Check earthing of all metallic equipment, cable trays, busbar supporting structures, building
column (if steel) all elect equipment, pipe lines etc. as per the drawing / specification.
iii. Measurement of earth resistance for each electrode .
iv. Measurement of total earth resistance.
MISCELLANEOUS
i. Checking of continuity of the system.

ii. Checking safe accessibility of all operating points.
iii. Check availability of emergency lighting.
iv. Check availability of control aux. supply.
v. Ensure availability of first aid box, fire fighting equipment, rubber mats, rubber glove.
vi. Check for safe movement of operators control room / switchgear etc., wrt proper illumination,
escape light uncovered openings provision of hand railings in stairs etc.
vii. Check proper covering of cable channels.
viii. Placement of shock treatment chart, danger boards provision of boards indicating ‘Man on
work’ Do not switch ON’ ‘Do not switch OFF’. ‘EARTHED’ etc.
ix. Check proper dressing of cables, mechanical protection of cables, placement of cable
markers.
x. Check sealing of all cable openings including conduits opening with fire resistance material.
xi. Check sealing of all openings at bottom of electrical panels.

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PREFERRED MAKE LIST
S.No ITEM PREFERRED MAKES

DESCRIPTION
1 11/0.433kV Viji Power Transformers Pvt. Limited/Flow Line transformers Pvt.

Distribution Ltd/Diamond Power Transformer/Mahalakshmi transformers / Kavika
transformer transformer/Techno Fabs/Voltech Manufacturing Company
Limited/Perfect Electricals

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2 11kV Termination 3M/RAYCHEM/CCI

Kit
3 HT XLPE Cables Universal/Polycab/KEI/KEC
4 LT Power Cable Universal/Polycab/KEI/KEC/Special CABLES

(FRLS)
5 LT Switchgear ABB/ C&S/ BCH/ Risha Control Engineering Pvt. Limited/ Siemens/
Lotus Power Gear
6 Flame proof light Baliga/Sudhir Switchgears Pvt. Ltd./Flexpro Electricals Pvt. Ltd./
fixtures FCG./ Bajaj Electricals Ltd./ Crompton Greaves Ltd.
7 Non Flame proof Bajaj/Crompton/Wipro/Philips/Osram/Sigma

Light Fixtures
8 High Mast/Street Philips/Bajaj/CGL/Wipro/Transrail/Tulip

Light Poles
9 Air Conditioner O General/ Daikin/ Hitachi
10 FLP Cable glands Baliga/ Flexpro/ Flameproof/ FCG/Dowells
11 Cable - Lugs Dowells/ Jainson
12 Cable tray Advance power product/Ercon Composite /India Electricals

Syndicate/MahavirEnggineering
Ceiling/Exhaust Khaitan Electricals Ltd./Havell’s/ Crompton Greaves Limited/Bajaj

13 Fans Electricals/USHA
Contactors - AC ABB/Siemens/Schneider/L&T/Control and switchgear

14 Power

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Control Intravidyut/Indcoil/Kappa/Kalpa/Indushree
15 Transformer
Earthing Materials Rukmani Electrical & Components Pvt Ltd./ Indiana Grating Pvt
16 Ltd./Any reputed make with ISI certification
Flame proof FCG/Flame proof/Flexpro Electricals/Sudhir/Baliga Lighting

17 LDB’s/ EquipmentsPvt. Ltd.
JB,s/Control
Station/ switches
Indicating Lamps Vaishno Electricals/Osram/Telemechanique/ABB/Esbee/Essen

18
Indicating Meters Conzerv(Schneider)/Rishabh Instruments Pvt. Ltd./

19 AE/MECO/Secure meters/ABB/Siemens
Miniature Circuit Siemens/L&T/Schneider/Indoasian/Havells/MDS(Legrand)/ABB/HPL

20 Breakers (MCBs) India
and Lighting DB
MCCB Siemens/L&T/Schneider/ABB
21
Protection BCH/L&T/Schneider/Siemens/ABB/Control & Switchgear

22 Relays - Thermal
Push Buttons Salzer/BCH/L&T/Essen/Technic/Vaishno/ABB/Control & Switchgear

23
Selector ABB/BCH/Kaycee/Siemens/Teknik/L&T/Control &

24 switches Switchgear/Vaishno/Salzer/Siemens
Switches - 5/15A Anchor/MDS Legrand/Precision/Cona

25 Piano/ Plate,
Switch Socket
Switch Socket Anchor/BCH/Essen/Best & Crompton

26 Outlet
Switch Socket Essen Engineering Company Pvt. Ltd./ Crompton Greaves Ltd./
27 Outlets BCH
(Industrial)

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ELECTRICAL WORKS
GI Pipes Tata Pipe/Jindal/GSI/Indus Tube/Swatik/Zenith

28
PVC pipes Finolex/Premier/Sudhakar/Kissan/Supreme

29
Saftey Items – Reputed make with ISI certification

30 Shock treatment
chart etc
Terminal Blocks Phoenix Contact/ Connect Well/Lapp/ S&S/ Wago /Elmex

31
Timer & Time ABB/BCH/L&T/Siemens / Essen/Telemecanique/Omron

32 delay relays
ELCB/RCCB ABB/Siemens/Schneider/MDS (Legrand)/L&T/Indoasian/HPL India

33
LIST OF STANDARD DRAWINGS
Sl No. Description Document No./ Drawing No. Rev.
1 SLD for PDB Panel for CNG station(Type-A) MEC/23RT /01/E1/D2/CN/ST/0413 Rev. 0
2 SLD for PDB Panel for CNG station(Type-B) MEC/23RT /01/E1/D2/CN/ST/0414 Rev. 0
3 SLD for PDB Panel for CNG station(Type-C) MEC/23RT /01/E1/D2/CN/ST/0415 Rev. 0
4 SLD for Emergency Panel (Type-A) MEC/23RT /01/E1/D2/CN/ST/0416 Rev. 0
5 SLD for Emergency Panel (Type-B) MEC/23RT /01/E1/D2/CN/ST/0417 Rev. 0
6 SLD for Emergency Panel (Type-C) MEC/23RT /01/E1/D2/CN/ST/0418 Rev. 0
7 SLD of LDB-1 MEC/23RT /01/E1/D2/CN/ST/0419 Rev. 0

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14 Marking of trenches for electric cables MEC/23RT /01/E1/D2/CN/ST/0426 Rev. 0
15 Typical Installation of Street Lighting Fixtures MEC/23RT/01/E1/D2/CN/ST/0427 Rev. 0

(Bracket Mounted) on pole for safe area
16 Typical section of cable trench in unpaved MEC/23RT/01/E1/D2/CN/ST/0428 Rev. 0
areas (2 Sheets)
17 Typical installation of lighting fixture on MEC/23RT/01/E1/D2/CN/ST/0429 Rev. 0
octagonal pole
(Sheet 1 to 3)
18 Flame proof lighting fixture mounting details MEC/23RT/01/E1/D2/CN/ST/0430 Rev. 0
19 Typical installation of flood lighting pole(with MEC/23RT/01/E1/D2/CN/ST/0431 Rev. 0

rungs)
20 Earthing of tanks and vessels MEC/23RT/01/E1/D2/CN/ST/0432 Rev. 0
21 Typical earth connection for street light pole MEC/23RT/01/E1/D2/CN/ST/0433 Rev. 0
22 Typical installation of lighting fixture on MEC/23RT/01/E1/D2/CN/ST/0434 Rev. 0

octagonal pole
23 Earth electrode in test pit MEC/23RT/01/E1/D2/CN/ST/0435 Rev. 0

24 Typical Electrical Earth pit MEC/23RT/01/E1/D2/CN/ST/436 Rev. 0
25 Typical Electronic Earth pit MEC/23RT/01/E5/D2/CN/ST/001 Rev. 0

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CHECK LIST
TO BE FILLED-UP BY TENDERER
Sl. Description Remarks
No.
1. No deviation from the Electrical Specification/SOR

2. Confirmation for Inspection of all electrical equipments
as per Specification/QAP.
3. Unpriced SOR enclosed with offer
4. List of similar electrical job undertaken during last three

years has been enclosed with the offer.
5. List of electrical personnel employed, with their qualification

& experience, has been enclosed with the offer.
6. Credential of electrical sub-contractor, enclosed with the
offer.
7. Photocopy of Electrical Contractor’s license - grade A has
been enclosed with the offer.

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SPECIFICATION FOR MECHANICAL WORKS

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PART-III

MECHANICAL WORKS

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Contents
1. INTRODUCTION .......................................................................................................................................
2. SCOPE OF WORK. ....................................................................................................................................
3. DETAILED SCOPE OF WORK UNDER THE PRESENT TENDER: .................................................................
4. Completion Time Schedule ...................................................................................................................
5. General Instructions to the Contractor................................................................................................
6. REFERENCE SPECIFICATION, CODES AND STANDARDS ...........................................................................
7. APPROVALS .............................................................................................................................................
8. STRUCTURES, SERVICES AND OTHER PROPERTY ....................................................................................
9. SAFETY ....................................................................................................................................................
10. PROGRESS OF WORK ...........................................................................................................................

1. INTRODUCTION
1.1. M/s GAIL Gas Limited, a wholly owned subsidiary company of M/s GAIL (India)
Limited, is engaged in development of CNG (Compressed Natural Gas) as fuel to

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commercial & private vehicles through filling stations in the automobile sector & PNG
(piped Natural Gas) to Industrial, household, commercial sector through City Gas
Distribution Networks (CGDN) at different Geographical Areas in the country.
PNGRB has awarded to GAIL Gas the work of development of City Gas Distribution
Network for Bengaluru Geographical Area (GA) comprising of Bengaluru Urban and
Rural Districts covering 4400 sq km in the state of Karnataka for distribution of CNG
and PNG to various consumer segments. Presently, GAIL Gas Limited is planning to
implement CNG & City Gas Distribution Network (CGDN) to supply Natural Gas to
domestic, commercial, industrial and automobile consumers distributed over the
Geographical Area (GA) of Bengaluru city.
1.2. GGL’S VISION: -

To provide compressed natural gas (an eco-friendly fuel) & related services in
Automobile, Domestic, Commercial and Industrial sectors in the state of
Karnataka.
1.3. GGL’S MISSION: -

To set-up at present infrastructure & services for Automobile Sector and provide
compressed natural gas (an eco-friendly fuel) in the city of Bengaluru,
Karnataka.
GGL have appointed MECON Limited to provide design, engineering and
project management services.
1.4. GENERAL INFORMATION:

This tender deals with various mechanical works involved in approximately 20
nos. of CNG online / daughter booster stations proposed in BPCL /IOCL /HPCL
retail outlets/DODO stations, 10 nos. of COCO CNG stations. All are located in
Bengaluru Geographical area in the state of Karnataka. The brief scope of work
is presented in Table-I.
Further, the contract will be valid for 15 months from the date of FOA (Fax of
Acceptance) and job will be intimated after award of contract for one or more than
one. of CNG stations in a phased manner depending upon the availability of Plots/
ROs by the Client within a time period of 15 months from the date of FOA (Fax of
acceptance), which shall be considered as the validity of the subject works contract and
the contractor will be provided with the site details along with the intimation. The
contractor shall have to deploy his manpower within seven days from the time of
intimation for execution of work by EIC/Client.
2. SCOPE OF WORK.
The broad scope of work under “Mechanical Works” is essentially but not limitedto
the following.
i) Supply and Laying of SS (SS316) tubes and SS compression ferrule fittings,

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valves, mass flow meter,Conductive core thermoplastic hose with break
away coupling within trenches/ above ground and pneumatic testing for
CNG application.
ii) Erection of mechanical equipment. Handling (including lifting and

transportation from Client's store within city to respective CNG stations) and
erecting in position, either on the foundation or on roof of office building at ~
3 to 4 m above ground level / top of structural platform (cascades only)/ on
top of CNG compressor. Contractor's scope includes supply of all material
and accessories including but not limited to any fixtures, clamps, gasket, nut
bolts, etc.. Scope also includes supply of all lifting tools / necessary
accessories and hiring of cranes for same.
iii) Supply, erection & commissioning of miscellaneous items as explained in
SOR and specification (like Tyre Inflator along with Air Compressor for tyre
inflating, Gas genset, Fire fighting equipment like DCP, Sand bucket, CO2
extinguisher etc.)
3. DETAILED SCOPE OF WORK UNDER THE PRESENT TENDER:
Detailed scope of work is divided under different sub-heads. List of sub-heads

along with different activities (with brief specification) is evolved and estimated
quantities are given. The tenderer has to quote on sub-head wise per unit rate as
mentioned.
Generally the following shall constitute the Contractor's scope of work but not
limited to as given herein:
3.1. SCOPE OF WORKS FOR SUPPLY, LAYING, TESTING & COMMISSIONING

OF SS TUBING
3.1.1. Supply of SS 316 tubes with SS ferrule fittings and SS ball valves, mass flow
meter, conductive core thermoplastic hose with breakaway coupling(above
ground / within trenches) for CNG application.
3.1.2. Receiving and upkeeping the materials procured by contractor in a good
condition.
3.1.3. Laying of SS 316 tubes with SS ferrule fittings and SS ball valves,mass flow
meter, conductive core thermoplastic hose with breakaway coupling(above
ground / within trenches) for CNG application.
3.1.4. SS tubes shall be clamped to the MS Angle (within trench)/ rails on above ground
at every 1000mm using of PVC heavy duty clamp of Swagelok/Parker/Dk-
Lok/Vaishnavi hydraulics pvt Ltd./Vardhaman bearings/ AK industries make. U-
Clamping with rubber sheet is not acceptable.It is not permitted toflatten Tubes

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for clamping purpose.
3.1.5. Carrying out pneumatic testing with Nitrogen at 280 bar(g) and purging with
Nitrogen as per the provided procedures elsewhere in the document; providing all
tools,tackles, instruments, manpower and other related accessories for carrying
out the testing of tubes.
3.1.6. Deputing of person during commissioning of CNG station (Actual gas charging in
SS tubing) and checking of gas leakage in SS tube/fitting.
3.1.7. Final clean up and restoration of site, facilities etc. as per the requirement of
Owner/ Engineer-in charge.
3.1.8. Submission of final material appropriation statements for all the materials procured
by contractor, returning surplus material to GGL stores, reconciliation of material /
consumables and obtaining 'No Objection Certificate' from GGL/ MECON.
3.1.9. Any other works not specifically listed herein but required for satisfactory Completion /
operation Safety/statutory maintenance of the works in all respects within specified
schedule at no extra cost to OWNER.
3.1.10. Preparation and submission of “As Built Drawings”.
3.2. LOADING, UNLOADING, TRANSPORTATION & ERECTION OF MECHANICAL

EQUIPMENT
3.2.1. Receiving of material from stores.
3.2.2. Loading of material / equipment on a trailer / truck from GGL stores and Safe
transportation to various sites.
3.2.3. Unloading, placement and alignment on foundation -either on ground or

aboveground (+ 3.5 m) on roof top / top of structural platform (cascades only)/ on
top of CNG compressor.
3.2.4. Making Transit Insurance of equipment from stores to site.
3.2.5. All equipment transported shall be securely boarded and transported without
causing any damage to equipment. Any damage caused during loading,
transportation & unloading shall be recovered from the contractor.
3.2.6. Leak testing of all equipment after erection as per standard practice and
instruction of engineering in charge.

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3.3. SUPPLY, ERECTION & COMMISSIONING OF MISCELLANEOUS ITEMS
3.3.1. Tyre inflator with Air compressor (Pump) : Supply, erection (at location indicated
by EIC), testing and commissioning of Air Compressor-cum-Pump with
accessories such as dispensing stand, hose, nozzle, valves, connectors etc
complete with Automatic Intelligent Tyre Inflating M/C [AITIM] to supply
compressed air for all types of vehicles that visit the station for refuelling of CNG
or other purposes.
3.3.2. Fire Fighting Equipment: Supply and installation of (at location indicated byEIC)
the following fire fighting equipment in various CNG stations.
i. 4.5 kg capacity CO2 type fire extinguishers confirming to IS 15683.
ii. 9 kg capacity dry chemical powder (DCP) type fire

extinguisher confirming to IS 15683
iii. 75 kg capacity trolley mounted dry chemical powder (DCP) type fire
extinguisher confirming to IS 10658.
iv. Fire buckets, 9 ltrs. capacity, made of galvanised mild steel (as per
IS: 2546) including supplying & fixing of MS angle iron stand to
accommodate 4 nos. of fire buckets and first fill with sand/water all
complete as per direction of Engineer In charge. (Note: One set of
Fire bucket consists of 4 buckets with stand).
3.3.3. Gas genset: Supply, erection (at location indicated by EIC), testing and
commissioning of 30 KVA/60 KVA gas genset with accessories such as filter,
regulators (Inlet pressure 14 to 49 kg/cm2(g)), ball valves and pipe
3.4. Survey, making arrangement of safety, security, temporary water &electrical

connections, traffic detour etc. setting out the piping GAD by laying out the plans
at site.
3.5. Preparing QAP and taking approval from MECON including Welder’s
qualification Test, Internal Test Plan, Hydrostatic Test Procedures, SS Tube
&Yard Pipe testing & procedures.
3.6. Taking all measures to provide safety to traffic, public, workmen operating
staff, equipment, and operation/ maintenance activities, underground/ above
Ground services and providing FIRE PROTECTION measures during
construction and any other activity to make the station functional in all respect.
3.7. To carry out all tests at worksite, approved laboratory and place of
manufacture/ fabrication; provide all test certificates from manufacturers
&supplier and offer inspection at all stages of procurement/ construction.

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3.8. To maintain and observe all statutory requirement with regards to labour laws,
taxation laws, local statutory rules and insurance requirements.
3.9. To hand over clear site to GGL/MECON after removing all debris subsequent to
completed works as per scope.
3.10. To submit daily, weekly and monthly progress reports and to attend review
meetings both at site and at project office and other discussions with GGL/
MECON/Statutory Authorities.
3.11. To transfer all Test Certificates, warrantees / guarantees including maintenance /

performance guarantees of various fittings /fixtures, equipment / material and
indemnify MECON / GGL of any liabilities of payments / dues to it’s suppliers,
manufacturers, agents etc.
3.12. Marking all as-built details on construction/ fabrication drawings/ data

sheetsissued by GGL / MECON and submission of as-built details and drawings
in six Sets.
4. Completion Time Schedule
Sl. Type of Station Completion schedule

No.
1. CNG COCO station 6 months from the date of intimation

at KIADB land,
Software park
2. CNG COCO station 5 months from the date of intimation for each CNG station
3. CNG stations in 3 months from the date of intimation for each CNG station
OMC ROs
4.1. The transportation and erection of cascades in each location shall be completed
within 7 (seven) working days from the date of intimation by the EIC / Client.
4.2. The supply and erection of Misc. items EXCLUDING Gas Genset in each location
shall be completed within 7 (seven) working days from the date of intimation by
the EIC / Client.
5. General Instructions to the Contractor
5.1. Plan and prepare a schedule for execution and work implementation as

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perQA/QC plans to be approved by MECON/GGL. Proper man power set up at
site by carrying out a pre-construction survey, establishing the site deviations,
requirement of site modifications in construction drawings, earth filling/ cutting
requirement etc.
5.2. Receiving the latest revision of all documents/ drawings from GGL/ MECON at the
commencement of work / during the course of construction and execution of
work at site.
5.3. In case any discrepancy is found between drawings & documents, the same
shall be brought to the notice of the Engineer-in-charge before execution of work
and decision of the Engineer-in-charge shall be final and binding to the
contractor without any extra cost implication to GGL.
5.4. The contractor has to make all shop drawings wherever necessary, at his
owncost, and get it approved by MECON/ GGL before commencement of that
work at site.
5.5. Specification and descriptions of various items are for identification of

materialand works to be carried out under them. No cost shall be quoted against
these unless mentioned.
5.6. Quantities as mentioned are indicative and can have a variation from the
quantities actually executed. The contractor is advised to work out the breakup of
individual work items and quantities at his own before quoting any rates. GGL
is not liable for any discrepancies in the quantities and no extra time or cost shall
be granted on this pretext.
5.7. The contractor has to obtain all types of statutory approvals including completion
certificate, approval from electrical inspector for electrical work ,electrical
Connection, water connection, fire department etc. and all other approvals that
might be required to commission the station, from various relevant authorities
during the course of work and after completion of works in co-ordination with
GGL/MECON without any cost implication to GGL.
5.8. The contractor has to arrange all tools and plants, site fencing material, lighting
arrangements, store, electricity and water at his own cost.
5.9. The contractor should quote keeping this in mind that no request for escalation
inthe cost shall be entertained under any circumstances by Owner after placement
of order.
5.10. The contractor is bound to carry out all on any number of sites simultaneously that
may be allotted to him.
5.11. The tender contains a set of key tender purpose drawings/ data.These
information/ details are for “Tender Purpose only”. The tenderer should visit
each location and acquaint himself with site conditions of each site. No
deviations and/or claims whatsoever of any kind and nature would be

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admissible.
5.12. The work shall be carried out in city conditions and generally close to the roads
and public services conveying a considerable volume of vehicular traffic and
human activity. It is deemed necessary that the tenderer considers the
“SAFETY” as the MOST IMPORTANT aspect of working conditions and is
required to include in his offer all costs (direct and indirect) towards observance,
compliance and provision of all safety appurtenances and norms.
5.13. Supplying SS tubes, fittings and other free issue items from GGL’s stores and
bringing it to site, keeping proper care of, storing the same till they are used for
construction and returning the unused material to the store.
5.14. Installing site markers, warning signs, fencing etc. and cleaning all unserviceable
materials, debris to designated disposal areas and obtain a No Dues Certificate
from the concerned authorities.
5.15. Handing over the completed works to GGL for their operation/ use purposes.
5.16. The Contractor has to prepare As-Built drawings, shop drawings,fabrication

drawings and submit them along with test certificates, guarantee cards/ warranty
cards/ service schedule any other purchase documents/ literature for all
equipment / fixtures / fittings installed at the time of completion of work.
5.17. Any other activity(ies) not mentioned/ covered explicitly above, but otherwise
required for satisfactory completion/ operation/ safety/ statutory/ maintenance of
the works shall also be covered under the Scope of Work and has to be
completed by the Contractor within specified Schedule of Items of Works at no
extra cost to GGL.
5.18. The contractor has to return all the drawings issued to him from time-to-time
along with the final bill to MECON / GGL after marking As-built dimensions and
details. The contractor is not permitted to make copies of any drawing/
document provided to hm.
6. REFERENCE SPECIFICATION, CODES AND STANDARDS
The contractor shall carry out the work in accordance with this Specification,
approved construction drawings issued by GGL, MECON’s Engineering
Standards or relevant BIS code as might be required.
Should the Contractor find any discrepancy, ambiguity or conflict in or between

any of the Standards and the contract documents, then this should be promptly
referred to the Engineer-in-charge (EIC) for his decision, which shall be
considered binding on the contractor.
7. APPROVALS

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Approval in principle for all work should be obtained from EIC prior to execution.
To ensure smooth execution of the work on a day-to-day basis, it will be the
Contractors responsibility to liaison with EIC / concerned engineer and obtain
necessary approvals.
8. STRUCTURES, SERVICES AND OTHER PROPERTY
8.1. Protection of Structures and Utilities
The Contractor shall at his own cost, support and protect all buildings, walls,
fences or other structures and all utilities and property which may, unless so
protected, be damaged as a result of the execution of the works. He shall also
comply with the requirements in the specification relating to protective measures
applicable to particular operations or kind of work
8.2. Interference with Traffic, Street Drainage and General Public
The Work shall be executed in such a manner as to cause a minimum of

inconvenience to persons requiring to use public or private roads, lanes,
thoroughfares, walkways, rights of use or passages through which the works are
to be executed. Closure of roads, etc., shall not be permitted without the
approval of the EIC.
The contractor shall conduct his operations at all times, with a view to minimizing
as far as practicable noise from construction and other objectionable nuisances
(eg. oil leakage, smoke, fumes.)
9. SAFETY
The Contractor shall conform to the requirements outlined in Preamble for safety
requirements. In addition, the Contractor shall observe safe working practices in
the storage and handling of pipes, SS tubes, flammable fluids, etc. and ensure
that smoking or naked flames are not permitted in the vicinity when these
worksare being executed.
The Contractor shall also protect all work sites with warning signs, barricades
and night lighting.
The contractor should ensure that the workers wear safety shoes and helmets
while carrying out any work under the present scope.
Where the EIC determines that the Contractor is performing the work in an
unsafe manner, he may suspend the work until the Contractor takes corrective
action.
Since the work shall be carried out in city conditions and generally close to the
highways/roads and public services conveying a considerable volume of
vehicular traffic and human activity, it is deemed necessary that the tenderer

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considers the “SAFETY” as the MOST IMPORTANT aspect of working
conditions and is required to include in his offer all costs (direct and indirect)
towards observance, compliance and provision of all safety appurtenances
andnorms.
10. PROGRESS OF WORK
The Contractor shall proceed with the Work under the Contract with due
expedition and without delay.
The EIC may direct in what order and at what time the various stages or parts of
the work under the Contract shall be performed.
If the Contractor can reasonably comply with this direction, the Contractor shall
do so. If the Contractor cannot reasonably comply, the Contractor shall notify
the EIC in writing giving reasons.

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PART-III :Mechanical Work

JOB SPECIFICATIONS FOR
MECHANICAL WORKS IN CNG STATIONS
CONTENTS
SECTION A Specifications for Supply of SS Tubes, SS Fittings ,SS Valves&

Conductive core thermo plastic hose with breakaway coupling
SECTION B Specifications for SS Tube Laying and Testing
SECTION C Specifications for Erection of Mechanical Equipment
SECTION D Specifications for Supply, Erection & Commissioning of

Miscellaneous items
MECHANICAL WORKS

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SECTION A. Specifications for Supply of SS Tubes, SS Fittings , SS
Valves & Conductive core thermo plastic hose with
breakaway coupling
CONTENTS
1.0 SCOPE OF SUPPLY OF SS TUBES, VALVE & FITTING
2.0 TECHNICAL SPECIFICATION FOR SS TUBES
(TS No. MEC/TS/05/62/035)
3.0 TECHNICAL SPECIFICATION FOR SS BALL VALVES
(TS No. MEC/TS/05/62/048)
4.0 TECHNICAL SPECIFICATION FOR SS FERRULE FITTINGS
(TS No. MEC/TS/05/62/047)
5.0 TECHNICAL SPECIFICATION FOR THERMO PLASTIC HOSE WITH

BREAKAWAY COUPLING
(TS No. MEC/TS/05/62/049)
1. Scope of supply of SS Tubes, SS Valves & SS Fittings
The contractor has to supply SS Tubes, SS Valves & SS Fittings strictly as

per technical specification no. MEC/TS/05/62/035, MEC/TS/05/62/047 &
MEC/TS/05/62/048 attached.
The SS Tubes, valves and fittings are to be laid, tested and commissioned as
detailed in SECTION - B. The balance items are to be re-conciled and submitted to

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Gail Gas stores in good condition. The uncountable material beyond the permissible
limits as specified in clause no. 6.0 of SectionB would not be paid.
The contractor is required to purchase SS Tubes, SS fittings & SS Valves as per

the quantities given in Schedule of Rates (SOR) from the approved vendor list
enclosed. The contractor shall take prior approval before placement of order and
get the QAP approved by MECON / Gail Gas. The inspection of materials and / or
scrutiny of documents would be carried by MECON / Gail Gas / Third Party
Inspection Agency appointed by contractor at his own cost.
FOR SS TUBES
FORCNG REFILLING STATIONS

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GAIL GAS LIMITED


(TS NO. : MEC/TS/05/25/035)
MECON LIMITED
Contents of TS No. MEC/TS/05/25/035
Sl.No. Description Page No.
1.0 SCOPE OF WORK
2.0 CODE & STANDARD
3.0 PRECEDENCE
4.0 DEVIATION
5.0 SAFETY

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6.0 SPECIFICATION
7.0 DOCUMENTATION
8.0 PACKING & SHIPMENT
9.0 GUARANTEE
1. SCOPE OF WORK
1.1. The scope of the tenderer will include manufacture/ supply, inspection/testing/
marking/ packaging/ handling and despatch of SS tubes, asindicated in the Bill
of Quantities meeting all the requirements as per ASTM A269.
1.2. All codes and standards for manufacture, testing, inspection etc. shall beof latest
edition.
1.3. Purchaser reserves the right to delete or order additional quantities duringexecution
of order, based on unit rates and other terms & conditions inthe original order.
2. CODES & STANDARD
Items Applicable Codes and Standards

Tubes ASTM A269, ANSI B31.3
3. PRECEDENCE
In case of any conflict between this job specification and other document,the

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following order of precedence shall apply :-
i. Job Specification
ii. International Standards/ Codes Applicable
4. DEVIATION
Deviations if any required by Tenderer shall be separately furnished against
each clause giving reasoning for each deviation. Tenderer to note that except the
deviations furnished by them, Tenderer’s offer shall be deemed to be in total
conformity with the enquiry specifications.
5. SAFETY
5.1. All tubes shall be designed as per applicable code & standards.
5.2. All part/ component shall meet the requirement for the specified
area’sClassification.
5.3. Area classification shall be Class-I, Division-I ; Group-D as per NEC orZone-I
Group IIA/ IIB as per IS/ IEC Specification or equivalentspecifications.
6. SPECIFICATION
All the items shall be suitable for compressed natural gas service andmeet following
specifications.
6.1. Tube material shall be stainless steel as per ASTM A269 (Grade TP 316).
6.2. Tubing material shall have minimum molybdenum content 2.5%, carboncontent of
max. 0.030%.
6.3. Tube shall be bright annealed.
6.4. Tube shall be seamless.
6.5. Tube hardness shall be less than Rb 80. Tubes shall be NACE MR 0175certified
for hardness. Hardness test shall be carried out on each tube.
6.6. All S.S.tubes shall be online 100% eddy current Tested as per ASTM A1016. In lieu
of eddy current Test / non-destructive electric examination,each tube shall be

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hydrotested as per requirement of ASTM A1016 clause no.26, at a hydrotest
pressure of 350 kg/cm2(g). However, it shall beensured that the test pressure does
not result in stresses exceeding theyield strength at test pressure.
6.7. Tolerance on outer diameter shall be ± 0.08 mm.
6.8. Tube shall be of minimum5 to 6 meter in length.
6.9. Minimum thickness shall be as per following table.
Tube OD Minimum Wall Maximum Allowable

Thickness Working Pressure psig
1” 0.120” 4700
¾” 0.095” 4700
½” 0.083” 4700
3/8” 0.065” 4800
¼” 0.035” 4800
Note: Bidder to reconfirm maximum allowable working pressure for each tube size.
6.10. Following documents/ certificates to be submitted.
i. Chemical composition for heat

ii. Chemical composition for products
iii. Tensile test
iv. Hardness test
v. Flaring test
vi. Leak test
vii. Visual inspection and dimensional check
6.11. Tubing should be clearly marked with the specifications given in theinspection
certificate with heat code, lot code, outer diameter and wallthickness with inspection
certificate no.,
6.12. Tubes should be supplied with both ends plugged.
7. DOCUMENTATION
Following test certificates shall be furnished alongwith shipment.

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7.1. Test certificate of visual, chemical, mechanical testing(incl. tensile,hardness,
flaring and leak test).
7.2. Manufacturer’s standard shop inspection & test report for all items.
7.3. The test report for specified tests.
7.4. Third party inspection report as applicable to meet the requirements ofspecified
codes & standards as applicable.
8. PACKING & SHIPMENT
8.1. All the items shall be suitably wrapped and packaged to with stand roughhandling
during ocean shipment and inland journey. Tubes should be supplied with both
end plugged.
8.2. The item shall be properly tagged and package separately to facilitateeasy
identification.
8.3. Items shall be wrapped and packaged in such-a-way that they can bepreserved in
original as new condition.
9. GUARANTEE
9.1. Manufacturer shall guarantee that the design, materials, manufacturingand testing
of tubes conform to the requirement of this specification. Manufacturer shall
replace all tubes free of costs which fail during field pressure testing or do not
perform satisfactorily due to inadequate engineering, substandard material and
poor workmanship.
9.2. The manufacturer shall guarantee against any defect, failure

ormalfunctioning occurring during 12 months from the date
ofcommissioning or 24 months from the date of supply whichever is earlier.

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GAIL GAS LIMITED

SS FERRULE FITTINGS
FOR
CNG REFILLING STATIONS
(TS NO. : MEC/TS/05/25/047A)
MECON LIMITED

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Contents of TS No. MEC/TS/05/25/047A
1.0 SCOPE OF WORK
2.0 CODE & STANDARD
3.0 PRECEDENCE
4.0 DEVIATION
5.0 SPECIFICATION
6.0 MARKING, PACKING & SHIPMENT
7.0 DOCUMENTATION
8.0 GUARANTEE
1. SCOPE OF WORK

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1.1. The scope of this specification covers the requirement of design,manufacture/
inspection/ testing at works/ marking/ packaging/ andsupply of high pressure
SS Ferrule Fittings.
2. CODES & STANDARD
The latest edition of the following standards are referred to in this

specification

Bar Stock ASME SA-479-316 or DIN 4401 or BS:970-316-S31
Forging ASME SA-182-316 or DIN 4401 or BS:970-316-S31
Thread NPT ANSI B 1.20.1
3. PRECEDENCE
3.1. In case of any conflict between this job specification and other document,the
following order of precedence shall apply:
i. Job Specification.
ii. International Standards/ Codes Applicable.
4. DEVIATION
Deviations if any required by Tenderer shall be separately furnished against

each clause giving reasoning for each deviation. Tenderer to note that except the
deviations furnished by them, Tenderer’s offer shall be deemed to be in total
5. SPECIFICATION
All the items shall be suitable for compressed Natural Gas service
andmeetfollowing specifications.
5.1. Materials
5.1.1. Fittings shall be manufactured from the following materials :-

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i. Bar stock shall be as per BS:970-316-S31, DIN 4401 or ASME 479-316 but
with carbon content less than 0.05% to provide increasedresistance to
corrosion.
ii. Forgings shall be as per BS:970-316-S31, DIN 4401 or ASME SA-182-316.
5.1.2. The fittings end connections shall be compatible to tube of hardness<Rb80.
5.1.3. All component parts of the fittings shall be of the same material.
5.1.4. The ferrule material shall be able to withstand an atmosphere of NaturalGas, oil and
moisture without rusting.
5.2. Design & Manufacture
5.2.1. All fittings shall be designed in conformance with the requirements ofASME B 31.3
and applicable standards. Area classification applicable for all items shall be Class-
1, Division-1, Group-D as per NEC or Zone-1 GroupIIA/ IIB as per IS/ IEC
specification or equivalent specification. All fittings shall be designed so that all
parts/ components meet the requirements for the specified area classification.
5.2.2. The SS fittings shall be of flareless design and four piece construction, consisting
of front and rear ferrules, nut and body suitable for use on SS tubes conforming to
ASTM A269 TP316.
5.2.3. Fittings shall be rated for at least the design pressure as stipulated in thematerial
requisition. The design of fittings shall ensure that they shall becapable of holding
full tube burst pressure after only one and a quarterturn pull up of the nut.
5.2.4. The threaded ends of fittings shall be NPT as per ANSI B1.20.1.
5.2.5. The fittings shall hold the tube with collecting action producing a firm gripon the
tube without substantially reducing the tube wall thickness.
5.2.6. Fittings shall not torque the tubing during original or subsequent make-upof the
connection and should use geometry for inspection before and after makeup.The
fittings shall not require disassembly for inspection before or after makeup.
5.2.7. All tube fittings shall be guageable for sufficient pull up after one and a quarter
turn. All tube fittings shall have a guageable shoulder and there will be no radius at
the point where the shoulder meets the neck of the fitting body.
5.2.8. The gap inspection gauge shall be easily insertable at finger tight position of nut.
The gap inspection gauge shall not be insertable between the nut and shoulder of

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the fitting after completing only one and a quarter turn pull up of the nut.
5.2.9. The tube seat counter bore in the body shall be faced flat 90° to the axis of the
tubing to minimize tube expansion and subsequent galling.
5.2.10. The sealing and gripping power of the fitting shall be controlled such that the action
between ferrules will overcome commercial variations in tubing wall thickness,
hardness, diameter and installer skill.
5.2.11. The seal contact areas of the fittings body shall have a machined finish of32 Ra or
better.
5.2.12. The fittings body shall have no machined stop or shoulder to precludeadditional
tightening in subsequent make-up.
5.2.13. Front Ferrule
i. The front ferrule shall effect a long, smooth repeatable seal bycontact with
body and a grip hold on the tube surface.
ii. The front ferrule shall always remain in a sprung condition tocompensate for
thermal stresses and to accomplish repeated makeand break.
5.2.14. Rear Ferrule
i) The rear ferrule shall collect the tubing surface, improving theperformance of
the tubing in systems of high impulse or vibration.
ii) The rear ferrule shall have a machine recess on the inside diameter and
shall have complete surface hardening so as to substantially reduce the
required pull up torque. Both the requirements i.e. complete surface
hardness and machined recess shall be met for all rear ferrules.
5.2.15. Nuts shall have silver plated threads to act as a lubricating agent to avoidgalling and
to reduce tightening torque.
5.3. Inspection and Testing
5.3.1. The fitting shall have type approval to either of ASTM F1387/ECER110 test
protocolswitnessed by any one of following auditing/inspection agencies.
i. ASME
ii. British Standard institute
iii. Det Norske Veritas (DNV)

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iv. Lloyd’s Register
v. TUV
5.4. Test Reports and Certificates
5.4.1. The manufacturer shall furnish test procedure and typical test reports ofall tests
conducted on fittings as per the requirements of clause 5.3.
6. MARKING, PACKING & SHIPMENT

6.1. Heat code traceability number shall be stamped or etched on both bodyand nut of
each fitting.
6.2. Replacement nuts and ferrules shall be packaged in a manner so as toallow safe
and simple replacement.
6.3. All the items shall be suitably wrapped and packaged to with stand roughhandling
during ocean shipment and inland journey.
6.4. Item shall be properly tagged and package separately to facilitate

easyidentification.
6.5. Items shall be wrapped and packaged in such-a-way that they can bepreserved in
original as new condition.
7. DOCUMENTATION
7.1. All document shall be furnished in English language only.
7.2. Following test certificates shall be furnished alongwith shipment.
i. Test certificate of chemical, mechanical testing.

ii. Manufacturers standard shop inspection & test report.
iii. The procedure and certificates to be submitted as per therequirements
of clause 5.4 of this specification.
8. GUARANTEE
of fittings comply with the requirement of this specification and applicable codes

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and standards. Manufacturer shall replace all fittings which should result defective
or fail during field pressure testing or fail to perform satisfactorily due to
inadequate engineering, substandard material and workmanship.
8.2. The manufacturer shall guarantee against any defect, failure or

malfunctioning occurring during 12 months from the date of
commissioning or 24 months from the date of supply whichever is earlier.

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GAIL GAS LIMITED

FOR
SS BALL VALVES
FOR
(TS NO. : MEC/TS/05/25/048)
MECON LIMITED
Contents of TS No. MEC/TS/05/25/048

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1.0 SCOPE OF WORK 32
2.0 CODE & STANDARD 32
3.0 PRECEDENCE 32
4.0 DEVIATION 32
5.0 MATERIALS 32
6.0 DESIGN & MANUFACTURER 33
7.0 INSPECTION & TESTING 33
8.0 OTHER REQUIREMENTS 34
9.0 TEST REPORTS & CERTIFICATES 34
10.0 MARKING, PACKING & SHIPMENT 34
11.0 DOCUMENTATION 34
12.0 GUARANTEE 35

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1. SCOPE OF WORK
1.1. The scope of this specification include design, manufacture/ supply,inspection/
testing/ marking/ packaging/ handling and despatch of SS BallValves as per relevant
codes.
1.2. Purchaser reserves the right to delete or order additional quantities duringexecution
of order, based on unit rates and other terms & conditions inthe original order.
2. CODES & STANDARD

Valves MSS-SP-99
3. PRECEDENCE
3.1. In case of any conflict between this job specification and other document,the
following order of precedence shall apply :
3.1.1. Job Specification.
3.1.2. International Standards/ Codes Applicable.
4. DEVIATION
Deviations if any required by Vendor shall be separately furnished against each

clause giving reasoning for each deviation. Vendor to note that except the
deviations furnished by them, Vendor’s offer shall be deemed to be in total
5. MATERIALS
5.1. The valve body shall be made out of material conforming to ASTM A479Type 316
5.2. Material of construction of ball shall conform to ASTM A276 Type 316.
5.3. Material of construction of seat shall be PEEK.
6. DESIGN & MANUFACTURE

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6.1. All ball valves shall be designed in conformance with the requirements ofASME
B31.3, MSS-SP-99 and other applicable code and standards. Area classification
applicable for all items shall be Class-1, Division-1, Group-Das per NEC or Zone-1
Group-IIA/ IIB as per IS/ IEC specification or equivalent specification. All fittings
shall bedesigned so that all parts/ components meet the requirements for the
specified area classification.
6.2. Valves shall be rated for a maximum working pressure of 5000 psig andshall be
capable of operation between a temperature range of (-40)° to250°F.
6.3. Valves shall have spring loaded PEEK seats allowing seal-ability over thefull
pressure range at any port and low operating torque over the fullrange of
pressures and temperatures.
6.4. Elastomeric seals, which require no packing adjustment, shall be used.
6.5. Valves stem shall be of bottom loaded and blow out proof design.
6.6. Ball shall be blow out proof and trunnion mounted when it is specified in SOR.
6.7. Valves shall have positive wrench/ handle stops, Phenolic black wrench/handle
shall be provided. Wrench/ handle shall indicate the direction toflow. IN the case of
three way valves the stem shall also provided a visualindication of flow direction if
the handle is removed.
7. INSPECTION AND TESTING

7.1. The valve manufacturer shall submit typical type test reports for thefollowing test
carrier out on similar valves :-
i. Hydrostatic seat leak test shall be carried out with de-ionisedwater. There
shall be no detectable set leakage at 1.1 times the rated pressure of the valve.
ii. Gas pressure test for seat and shell shall be carried out withnitrogen at 1000
psig. There shall be no detectable externalleakage. Maximum allowable seat
leakage shall be 0.1 atm-cc/min.
8. TEST REPORTS & CERTIFICATES

8.1. The manufacturer shall supply material compliance certificates.
8.2. The valve manufacturer shall provide test procedure and valve inspectionand test
report for type tests carried out on similar valves as per therequirements of clause

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7.
9. MARKING, PACKING & SHIPMENT

9.1. Heat code shall be marked on valve body to facilitate tractability.
9.2. All the items shall be suitably wrapped and packaged to with stand rough handling
during ocean shipment and inland journey.
9.3. Each item shall be properly tagged and package separately to facilitate easy
identification.
9.4. All Items shall be wrapped and packaged in such-a-way that they can be preserved
in original as new condition.
10. DOCUMENTATION
10.1. All document shall be furnished in English language only.
10.2. Prior to shipment, manufacturer shall submit following test certificates and
documents.
i. Test certificate of chemical, mechanical testing.

ii. Manufacturers standard shop inspection and test reports.
iii. The procedure and certificates to be submitted as per therequirements of
clause 8.0 of this specification.
iv. Manual for installation, erection, maintenance and operating instructions
including a list of recommended spares for valves.
11. GUARANTEE
of fittings comply with the requirement of this specification and applicable codes
and standards. Manufacturer shall replace all fittings which should result defective
or fail during field pressure testing or fail to perform satisfactorily due to
inadequate engineering, substandard material and workmanship.
11.2. The manufacturer shall guarantee against any defect, failure or

malfunctioning occurring during 12 months from the date of
commissioning or 24 months from the date of supply whichever is earlier.

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GAIL GAS LIMITED

FOR
CONDUCTIVE CORE THERMOPLASTIC HOSE
WITH BREAKAWAY COUPLING

FOR

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(TS NO. : MEC/TS/05/25/049)
MECON LIMITED
CONTENTS
1.0 SCOPE
2.0 CODES AND STANDRADS
3.0 SPECIFICATIONS
4.0 TEST REPORTS & CERTIFICATES
5.0 MARKING,PACKING & SHIPMENT
6.0 WARRANTY

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1. SCOPE
1.1. The scope of this specification covers the requirements of design, manufacture /
inspection / testing at the works / marking / packaging / and supply of flexible fill
hose with breakaway coupling for loading and unloading of mobile cascades with
all auxiliaries and features required for efficient and safe operation.
2. CODES AND STANDARDS
Unless otherwise specified elsewhere in this specification Flexible fill hose with
breakaway coupling and their installation shall confirm to the latest revisions of
codes and standards listed below.
ITEM APPLICABLE CODES & STANDARDS
HOSE(For CNG Application) NFPA-52, AGA1-93, ANSI-4.2112.52
END CONNECTIONS ASTM A 276, ASTM A479, ASTM A262,
Practice-A to E and or EN ISO 3651-2
THREAD NPT ANSI B 1.20.1

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3. SPECIFICATIONS
The specification described herewith are intended to give vendor the technical and
operating conditions of the flexible fill hose. Vendor may indicate in his offer, the
additional features, which his flexible fill hose has in terms of better design,
enhance reliability etc,.However such feature may be accepted subject to client’s
review and approval.
Each flexible fill hose should have the following specifications:-
i) The core material shall be non-metallic, electrically conductive,

thermoplastic flexible hose of min. 5.0m length for CNG Service with break
away coupling along with Quick connect body & stem (End connection:½"
Tube OD for stem & ½”NPT (F) for body, Material : SS316; Rated pressure :
5000 PSI @ 70°F Temperature: 0°F to 400°F) .One end of the hose shall be
1/2' OD tube and other end of the hose shall be 3/4" OD.Supply and
assembling of all necessary fittings with the hose for making the end
conncetions as indicated above are in the scope of contractor.
ii) Two or more layers of fibre reinforcement.
iii) Thick layer of abrasion resistant Polyurethane black cover to prevent
abrasion and display better wear resistance shall be provided on the hose.
iv) Electrical conductivity shall comply with AGA1-93.
v) End connections shall be SS 316 material confirming to relevant design
standards as specified above.
vi) The whole assembly shall be rated for a working pressure of 5000 psig and
shall be rated for temperature range of -40 to 250oF.
vii) Vendor shall also include supply of Breakaway coupling suitable for NGV
industry in each hose.
viii) Specific conductivity of filling hose shall be 0.512 Mega ohms for lengths
upto 180” (approx. 4.5 mtr.) and 3.5 Mega ohms for length over 180” and up
to 1200”( approx. 30 mtr.)
ix) Minimum Burst Pressure of Flexible Fill Hose shall be four times the working
pressure.
4. TEST REPORTS AND CERTIFICATES
i) The manufacturershall supply material compliance certificate.

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ii) The manufacturer must submit product type test reports for the following
tests conducted on CNg hoses.
a. Hydraulic Burst pressure test.
b. Hydraulic proof pressure test.
c. Hydraulic leakage test.
d. Change in length test.
5. MARKING, PACKING AND SHIPMENT
i) All hoses shall be duly marked with the manufacturers name, series ,
material, hose size and all relevant standards applicable.
ii) All the items shall be suitably wrapped and packaged to withstand rough
handling during ocean shipment and inland journey.
iii) Each item shall be properly tagged and packaged separately to facilitate
easy identification.
iv) All items shall be wrapped and packaged in such a way that they can be
preserved in original as new condition.
6. WARRANTY
i) Manufacturer shall guarantee that the design , materials, manufacturing and
testing of CNG hoses comply with the requirement of this specification and
applicable codes and standards. Manufacturer shall replace if resulted
defective or fail during field pressure testing or fail to perform satisfactorily
due to inadequate engineering, substandard material, and workmanship.
ii) The manufacturer shall guarantee against any defect, failure or
malfunctioning occurring during 12 months from the date of commissioning
or 24 months from the date of supply whichever is earlier.

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MECHANICAL WORKS
SECTION B.SS TUBE LAYING AND TESTING
CONTENTS
1.0 SCOPE OF WORK AND TECHNICAL SPECIFICATION
2.0 INSTALLATION PROCEDURE
3.0 REMAKE OF FITTINGS
4.0 REFERENCE SPECIFICATION, CODES AND STANDARDS
5.0 SCOPE OF SUPPLY
6.0 SCRAP AND EXCESS MATERIAL
7.0 HIGH PRESSURE GAS LEAK TESTING PROCEDURE

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1. SCOPE OF WORK AND TECHNICAL SPECIFICATION
1.1. LAYING OF SS TUBE
Laying, testing and commissioning of SS tubes and fittings complete with all
supports. The SS tube fixing clamps from approved vendors shall be procured
and installed by the contractor. Payment shall be at the rate for the work set out in
the agreed Schedule of Rates.
Contractor shall engage GAIL GAS LTD./MECON approved sub-contractor for this
specialised work. The list of parties are enclosed in Annexure-I.
1.2. SCOPE OF WORKS: FOR LAYING, TESTING & COMMISSIONING OF

SSTUBING
Generally the following shall constitute the Contractor's scope of work but not
1.2.1. SS tubes shall be clamped at every 1000 mm by the heavy duty PVC tube
clamps of approved make.The practice of flattening tubes for clamping purposes
shall not be permitted.
1.2.2. Tubes shall be bent using tube benders only and any hot bending will be totally
rejected. Tubes shall be cut using pipe cutting device. Hot cutting is not allowed.
1.2.3. Carrying out pneumatic testing at 280 bar and purging with nitrogen at 2 bar as
per approved procedures; providing all tools, tackles, instruments, manpower and
other related Accessories for carrying out the testing of tubes. Leakages, if any,
observed during testing shall be rectified without any additional cost to owner.
1.2.4. Start-up and commissioning assistance.
1.2.5. Handing over the completed works to GAIL GAS LTD. for their operation/ use
purposes.

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1.2.6. Final clean up and restoration of site, facilities etc. as per the requirement of owner /
Engineer-in charge.
1.2.7. Preparation and submission of “As Built Drawings”.
1.2.8. Co-ordination as required with other agencies/Contractor(s) till the time the
commissioning operations are complete.
1.2.9. Any other work not specifically mentioned herein, but required for the satisfactory
completion/ operation/ safety/ statutory/ maintenance of the works shall also be
covered under the scope of work and has to be completed by the Contractor
within specified schedule at no extra cost to GAIL GAS LTD.
2. INSTALLATION PROCEDURE
2.1. TUBE END PREPARATION
2.1.1. Cut the ends square with a hacksaw and a suitable guide.Tube cutters are
satisfactory for most tube materials but tend to work harden stainless steel.
Assuch proper care shall be exercised while cutting the SS tubes to
avoidthehardening.
2.1.2. Burrs must be removed inside and outside for proper entry into fitting to prevent
contamination and/ or restricted flow. ‘Swagelok’ / ‘Parker’ deburring tool shall
be used.
2.1.3. Remove all fittings, chips, and grit before attachment of fittings.
2.2. ASSEMBLY
2.2.1. Tube line fabrication must be accurate so that the tube end easily enters
thefitting in proper alignment. Do not force an improperly fitted tube line into
the fittings
2.2.2. Ensure that the tube end is bottomed against the shoulder in the fittingbody. Thisis
necessary to prevent movement of the tube while the nut forces the ferrule togrip
the tube and to seal through any imperfections that may exist on the outsidetube
surface.
2.2.3. Never permit the fitting body to rotate during tube end make-up, use
twowrenches. Assemble port connectors to components first and hold with a
wrenchwhile making up the tube joint. All types of union bodies must be held
while eachof the tube ends is made up.
2.2.4. Never attempt to make up by torque.
2.2.5. Always turn the nut the prescribed amount regardless of torque required.

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Fittingend plugs required only 1- ¼ turn from finger tight make up in all sizes.
3. REMAKE OF FITTINGS
A disassembled joint can be remade, simply by retightening the nut tothe

position of the original make up. For maximum number of remakes,mark the
fitting and nut before disassembly. Before retightening, make sure the assembly
has been inserted into the fitting until the ferrule(s) seats in the fitting. Retighten
the nut by hand. Rotate the nut with a wrench of the original position as indicated
by the previous marks lining up. (A noticeable increase in mechanical resistance
will be felt indicating the ferrule is being re-sprung into sealing position.) Then
snug the nut 1/12 turn (1/2 hex flat) past the original position.
4. REFERENCE SPECIFICATION, CODES AND STANDARDS
The Contractor shall carry out the work in accordance with this specification,
MECON's Engineering Standards, ASME B 31.8 - Gas Transmission and
Distribution Piping Systems, Oil Industry Safety Directorate (OISD) norms.
Should the Contractor find any discrepancy, ambiguity or conflict in or between

any of the Standards and the contract documents, then this should be promptly
referred to the Engineer-in-Charge (EIC) for his decision, which shall be
considered binding on the contractor.
5. SCOPE OF SUPPLY
5.1. SUPPLIED BY THE CONTRACTOR AT HIS OWN COST AS PART

OF THISSPECIFICATION:
The procurement and supply of SS tube clamps at the appropriate time of all the
materials and consumables except for the materials specifically enlisted under
Owner's scope of supply, shall be entirely the Contractor's responsibility and its
rates of execution shall be inclusive for all these items, as follows but not limited to
these:
i. Heavy duty PVC clamps for tubes, anchor bolts of various sizes for fixing to
concrete structure.
ii. Primer and finishing paints.
iii. All material for minor civil works like grouting etc.,
iv. Minor structural steel for fabrication of tube/ tray supports like MS plates,GI
plates, flats, pipe etc.,
v. Nitrogen for Pneumatic testing and for purging.

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vi. All items not expressly mentioned in the Contract but which are
necessary for the satisfactory completion and performance of the Work under
this Contract.
Note: Samples of all the consumables items / test certificates required to be

approved by EIC.
6. SCRAP AND EXCESS MATERIAL
Every month the Contractor shall submit an account for all the materials issued to
him by the owner in the standard proforma prescribed for this purpose by the
Engineer-in-charge.
On completion of the work, the Contractor shall submit material appropriation
statements for all the materials issued by the Owner in the standard proforma.
The following scrap allowances are permissible.
ITEM UNACCOUNTABLE SCRAP
Tube 1% 1% (Less than 0.3 m)

Valves 0% 0%
Ferrule Fittings 0% 0%
All excess materials and scrap shall be returned after duly accounting for, to the
GAIL GAS LTD. stores. Where materials are to be weighed before return, the
Contractor shall be responsible for making necessary arrangements for weighing
etc. The contractor shall not use scrap sections obtained during the course of
construction for fabrication of temporary supports or other items without prior
written permission of Engineer-in-Charge.
If the Contractor fails to return the surplus material aforesaid, the Owner will
charge the Contractor for such unreturned material at penal rates, whichwill be
deducted from whatever amount is due to the Contractor. In case any material
issued by the Owner deteriorates during storage by the Contractor, new material
will be issued to him if available at penal rates, but delay in procuringsuch
materials will be at the Contractor's account only. Any damaged valve and
ferrule fittings should not be used and shall be returned to GAIL GAS LTD. stores.
7. HIGH PRESSURE GAS LEAK TESTING PROCEDURE WITH NITROGEN.
 Pressure testing of Gas line to be started after completion of installation.

 All gas piping connections, valves, and appliance connections and valves
are inspected visually for tightness and good condition.
 A gas pressure gauge is connected in the line. The calibration certificate
of theguage shall be submitted to Mecon / Gail gas Limited for review
before start of the testing.

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 The gas service valve is opened to permit gas to flow into the gas piping
distribution system, and then the valve is closed again, securely.
 The gas pressure gauge should read gradual increase in pressure.
 The tube shall be pressurised to 60 bar gradually and hold for 30 minutes.
Leak testing shall be carried out with soap solution at all joints of Valves,
Regulators& Fittings.
 If any leak is found, tube shall be depressurised and leak arrest shall be
done. Leak arrest by using Teflon tape is not acceptable.Ensure Leak
arrest is done at 60bar at all the joints.
 The tube shall be pressurised to 100 bar gradually and hold for 30
minutes. Leak testing shall be carried out with soap solution at all joints of
Valves, Regulators& Fittings.
minutes . Leak testing shall be carried out with soap solution at all joints
of Valves, Regulators& Fittings.
minutes. Leak testing shall be carried out with soap solution at all joints of
Valves, Regulators& Fittings. Pressure reading shall be noted down every
30 minutes.
done. Leak arrest by using Teflon tape is not acceptable.Tube shall
be pressurised again and Ensure Leak arrest is done at 280bar at all the
joints.
 Final leak testing at 280 bar shall be witnessed by Mecon/Gail gas
Limited.

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SECTION C.
ERECTION OF MECHANICAL EQUIPMENT
CONTENTS:
1. SCOPE OF WORK FOR LOADING, UNLOADING, TRANSPORTATION

&ERECTIONOF EQUIPMENT.
2. EQUIPMENT WEIGHTS & SIZES.
SECTION-C
LOADING, UNLOADING, TRANSPORTATION & ERECTION OF MECHANICAL

EQUIPMENT
1. SCOPE OF WORK:
1.1. Generally the following shall constitute the Contractor’s scope of work but not

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i. Receiving of material from stores.
ii. Loading of material/ equipment on a trailer / truck from stores. Safe
transportation to various sites.
iii. Unloading, placement and alignment on foundation -on ground or on
above compressor at +3.5m or above ground at +3.5 m at roof top of
office building (cascade only). / top of structural platform (cascades only)/
on top of CNG compressor.
iv. Transit Insurance of equipment from stores to site.
v. All equipment transported shall be securely boarded and transported
without causing any damage to equipment. Any damage caused during
loading, transportation & unloading shall be recoverable from the
contractor.
vi. All the equipment shall be leak tested after erection as per instruction of
engineering in charge and standard practice.
2. Equipment weight & sizes
Sl. Equipment Size Weight/

No. Unit
Appx.
1. Cascade 4500 L (water 5.5 m X 2.0m X 2.0m (H) 9.0 T
capacity) Approx.
2 Cascade 3000 L (water 4.0m X 2.0m X 2.0m (H) 6.0 T
capacity) Approx.
All excess, unutilized or defective materials and scrap shall be returned after duly
accounting for, to the GAIL GAS LTD. stores. Where materials are to be weighed
before return, the Contractor shall be responsible for making ecessary
arrangements for weighing etc.
The contractor shall not use scrapped or defective materials obtained during the
course of construction for fabrication of temporary supports or other items without
prior written permission of Engineer-in-Charge.
If the Contractor fails to return the surplus material aforesaid, the Owner will
charge the Contractor for such un-returned material at penal rates, which will be
deducted from whatever amount is due to the Contractor. In case any material
issued by the Owner deteriorates during storage by the Contractor, new material
will be issued to him if available at penal rates, but delay in procuring such
materials will be at the Contractor’s account only.
Contractor to arrange all equipment & tools such as cranes, winch, lifting hook

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etc and skilled & semiskilled manpower and consumables for erection of all the
mechanical equipment.
SECTION - D
SUPPLY, ERECTION & COMMISSIONING OF MISCELLANEOUS ITEMS
CONTENTS:
1. AIR COMPRESSOR-CUM-PUMP
2. FIRE FIGHTING EQUIPMENT
3. 40 KVA/60KVA SOUND-PROOF ACOUSTIC GAS GEN SET

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SUPPLY, ERECTION & COMMISSIONING OF MISCELLANEOUS ITEMS
1. Air compressor (Pump)with Automatic Intelligent Tyre Inflating M/C (AITIM):

Contractor will supply, erect at prepared location,testand commission an Air Compressor-cum-
Pump with Accessories such as dispensing stand, hose, nozzle, valves, connectors etc
complete with Automatic Intelligent Tyre Inflating M/C [AITIM].
Air compressor - cum- pump shall supply compressed air for all types of vehicles that visit the
station for refuelling of CNG or other purposes.
Details of air compressor along with inflator:

Type Drive - V belt drive
Electrical Supply - 415V/3ph/50Hz
Discharge pressure - 12 kg/cm2
Motor - As per manufacturer
Make - Ingersoll Rand/Elgi/KPCL/CP
Display - Digital in both system [MKS & CGS]
Alarm - Digital & Sound
Control - To stop filling of air on alarm/set point.
Housing - Steel/ Fibre glass- coated/painted in approved colours with

GAIL GASLTD. Logo.
Dispensing Hose - Non -conductive.
AITIM - PrecisionTesting Machines Pvt Ltd,

NewDelhi/Instrument Research Association Pvt.
Ltd,Bangalore/or any other approved make.
Note- One-year spares shall be supplied along with those

foraccessories.
2. Fire Fighting Equipment:

Contractor will supply and erect at designated locations the fire fighting equipment.
The details of the fire fighting equipment are given below.

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10.1.1. Fire Fighting Equipment: Supply and installation of (at location indicated by EIC) the following
fire fighting equipment in various CNG stations.
i. Portable-High Pressure Type – 4.5 Kg. capacity CO2 Fire Extinguisher. Extinguisher and
hardware/ bracket required for fixing to wall.
S. Description GAIL Gas Requirements

N.
1 Type of Extinguisher Portable-High Pressure Type – 4.5 Kg. capacity CO2 Fire
Extinguisher Whether Seal is provided to indicate that
Extinguisher has not been used
2 Standard IS 15683:2006
3 Body Seamless Manganese Steel-ISI marked confirms to
IS:7285
4 Extinguishing Medium CO2 Gas (Purity as per IS: 15222-99.5%)
5 Discharge Valve(Wheel Confirms to IS:3224
Type)
6 Discharge Horn Non-Conductor Of Electricity-Polyethylene
7 Siphon Tube Aluminium
8 Discharge Hose Wire braided Of Length 1m,ID:10mm
9 Wall mounting Bracket Mild steel (Powder Coated)
10 Minimum effective Discharge Minimum : 8 Sec. (Actual : 14 Sec. approx)
Time
11 Bulk Range of Discharge Minimum 2 meter (Actual : 2 meter approx)
12 Percentage of Discharge Not Less than 95 % (Actual : 96% approx)
13 Fire Rating 21B
14 Temperature Range -30 °C to +55 °C
15 Working Pressure 60-70 bar
16 Pressure Test 250 bar
17 Fill Density Not to Exceed 0.667 percent
18 Leakage test By Dipping in water leakage to checked
19 Partial discharge The second pressure or weight shall not be less than 75%
of the first after interruption of the Discharge.
20 Burst test of Hose Minimum Burst Pressure of 275 bar

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21 Extinguishers also pass A) Resistance to Temperature changes
through the Following Tests B) Resistance to Impact test
(Type tests) C) Tapping Test
D) Resistance to Vibration test
E) Intermittent Discharge test
F) Fire performance test
G) Maximum Service Pressure
22 Maximum Diameter of Fire 140±10 mm
Extinguisher
23 Overall Height of Overall Height of Extinguisher 700 mm (Approx.)
Extinguisher
24 Shell thickness 4.0mm or 4.2mm (Minimum)
25 Full weight of cylinder 16.4 kg or 17.0 kg (Approx)
26 Color Of Extinguisher body Painted With Durable Enamel PO red shade No.538 of
IS:5
27 Accessories (brackets & Provided
screws)
28 Inspection & Testing As per approved GTP
29 Finish PO Red as per IS : 5 (Shade 538 )
30 Marking As per IS 15683:2006
31 Approvals BIS
32 Maintenance, Care and As per IS 2190
Refilling
33 Packing Jute Bags (Length:890 mm Width:280 mm)
34 Documents to be provided  Hydrotest Certificate of the fire
along with supply. extinguisher.
 Manufacturing / Batch certificate
Shelf Life Certificate.
 Warranty / Guarantee Certificate
of one year
ii. 09 kg Capacity Dry Chemical Powder (DCP) type fire extinguish DCP Fire Extinguishers,
StoredPressureType Extinguisher and hardware/ bracket required for fixing to wall.

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S. Description GAIL Gas Requirements
N.
1 Type of Extinguisher Stored Pressure type Dry Chemical Powder
FireExtinguisher -09 Kg. capacity
2 Standard Conforming to IS: 15683:2006 and IS marked.
3 Body Fabrication, Antirust Coating & Painting, Stamping,

Working Pressure, Burst Pressure, calibrated Pressure
Gauges, Stickers etc strictly as per IS Standard.
4 Dry Chemical Powder Mono Ammonium Phosphate base Dry Chemical Powder,
(DCP) IS 14609 (latest amendments) marked & shall not be more
than 06 months old at the time of supply at GAIL Gas
Office.
5 Pressure relieving device PSV/ Device for releasing excess pressure complying with
IS standard requirement.
6 Spare 1. 01 Discharge tube with every extinguisher.
2. Clamps for Wall Mounting
7 Stamping on extinguishers As per IS with Trademark, Manufacturers name, Number,

IS Mark, capacity etc.
8 Documents to be provided  Valid IS Certificate.
along with the offer  Details of Extinguishers/ Brochure
 PO document for supply to other Oil & Gas /
Hydrocarbon Industries.
9 Documents to be provided  Hydrotest Certificate of the fire
along with supply. extinguisher.
 Manufacturing / Batch certificate
Shelf Life Certificate.
 Warranty / Guarantee Certificate
of one year.
iii. 75kg DCP fire extinguisher shall conform to IS2171 and shall meet the following requirements:

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S.N. GAIL Gas Requirements

1 The extinguisher shall be made of 6mm thick MS sheet (BQ plate and design of
vessel as per IS2825) with radiography quality welding. The extinguisher shall
conform to IS 10658 -1999. Extinguisher shall be treated to operate in anti-
corrosive environment. Nonmetal parts shall be of gun metal. Design calculations of
2 The minimum length of the hose shall be 5m with bursting pressure not less than
5kg/cm2.
3 Drain plug provided on the body shall have a minimum diameter of 25mm.
4 The nozzle shall be of trigger controlled and capable of discharging powder as per
ISI specification
5 Automatically and manually operated safety relief valve to be provided as per IS
10658:1999.
6 Pressure gauge shall have minimum 50mm dia and range from 0 to 42kg/sq cm to
be provided on the body.
7 The extinguisher shall be mounted on a robust trolley having two heavy duty
bearing fitted with rubberized wheels and strong handles for easy mobility
8 ISI marked CO2 gas cylinder shall be of 2kg capacity and shall be approved by
CCOE with protector and thermal insulation to be fitted with ISI marked wheel type
valves
9 Dry powder provided shall conform to IS 4308. The powder shall be packed in
plastic rigidex material type bags with heavy duty LD lines hermitically sealed. The
materials of the packing and sealing shall be made in such a way that if the pack is
kept inside water bucket for 24 hours not a single drop of powder shall remain
unaffected against moisture. The DCP shall be of Potassium Base.
10 The extinguisher shall be painted with two coats primer (red outside) and then final
coat of fire red painting by spray method. The color’s shall conform to IS 5 (latest
edition).
11 As per IS2825 DPT of filet welds of all nozzles and attachment shall be carried out
and no discontinuation in welding will be permitted.

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12 Certification that every fire extinguisher shall be made with radiographic quality
welding has to be provided and all the design fabrication shall conform to IS: 2825.
The radiography has to be performed for 10% of the weld joints and 50% for T
joints. Design calculation shall be submitted along with the offer.
13 Extinguisher shall be hydro tested at 30kg/cm2 and should not develop any leaks at
this pressure.
14 The bottom ring shall have permanent punching at the bottom ring is required.
Manufacturers name.
Year of manufacturing.
Manufacturer’s serial number.
PO No. & Date.
Date of hydraulic test shall be written with space for writing the subsequent dates for
hydraulic test.
iv. Fire buckets, 9 ltrs. capacity, made of galvanised mild steel (as per IS: 2546) including
supplying & fixing of MS angle iron stand to accommodate 4 nos. of fire buckets and first fill with
sand/water all complete as per direction of Engineer In charge. (Note: One set of Fire bucket
consists of 4 buckets with stand).

3. SPECIFICATION FOR GAS GENERATOR SET (40KVA&60KVA)
1. SCOPE
This specification covers the design, engineering, shop testing, supply, erection, testing and
commissioning of 415V, 3 phase, 30 KVA gas generator set for CNG station along with all required
accessories including integral AVM pads, AMF Panel and weather and sound proof acoustic
enclosure.
The rating applies for supplying continuous power at variable load for unlimited annual hours. A
10% over load is allowed for up to 1 hour in every 12 hours.

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2. CODES AND STANDARDS
The Gas generator set with all its components shall comply with Environmental (Protection) 3rd
Amendment Rules 2016 and all other latest applicable standards, regulations and safety codes in
the locality where the equipment shall be installed. The equipment shall comply with following
British standards, Indian standards or equivalent British or International Standards with latest
revisions.
o ISO 3046/1
o BS 5514
o AS 2789
o DIN 6271
o ISO 8528/1
o ISO 8528-5
3. GENERAL
3.1. The Gas Generator set shall be outdoor type complete with suitable acoustic enclosure, to limit
noise level to 75 db at 1 metre from the enclosure surface. Gensets should be provided with integral
acoustic enclosure at the manufacturing stage itself. The set shall consist of Gas Engine coupled to
suitable alternator having self, brush less/ static excitation system with PMG and include all
necessary accessories and control panel as specified and as required.
3.2. The engine and generator shall be mounted on an integral robust fabricated steel frame with anti
vibration mounting pads. No separate foundation will be provided. Required set of foundation bolts,
nuts and washer etc. And set of spanner and tools shall be supplied by the bidder.
3.3. The gas genset should meet CSA,UL, NFPA or other comparable safety standards.
3.4. The generator set shall be factory built and production tested.
3.5. The generator set shall be capable of taking the block loading in single step.
3.6. The generator shall have integral vibration isolation.
3.7. The generator shall have advanced Digital Controller for the engine and alternator combine with
LED display unit for display of system parameters and fault indication of both the engine/ alternator.
3.8. The generator set shall have cooling system rated for 50oC ambient temperature.

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3.9. The generator shall have a test certificate confirming the generator load parameters.
3.10. The generator shall have auto start feature with programmed cranking cycles.
3.11. The generator shall have package mounted line circuit breaker for protection.
3.12. All the electrical/instrumentation fittings / equipment, junction box shall be flame proof and shall bear
valid certification.
3.13. The generator set shall have a spark arrestor and a catalytic converter fitted on it.
3.14. Lifting lugs must be provided for safe handling and the gas generator shall be mounted on the iron
base frame which shall be grouted on the concrete foundation.
3.15. The material used for station piping shall be carbon steel for connection between GAIL GAS’s tap-
off point and gas genset inlet / metering device.
4. GAS ENGINE
4.1. The generator set shall be powered by proven field tested 4 stroke, min. 4 cylinder, water cooled
gas engine suitable for operating on natural gas with a power output of at least 5% more than the
maximum power required by the alternator along with all standard engine components and shall
have following features:
a. Internal Exhaust system with approved spark arrestor and catalytic converter.
b. The gas engine shall be suitable for block loading in one step and supplied with electronic
isochronous governor for optimum fuel, spark performance and frequency regulation of + 1%.
c. Residential grade silencer.
d. 70A / 12V battery Charging Alternator.
e. 12V starter motor.
f. High engine temperature safety & shutdown.
g. Low lube oil pressure safety & shutdown.
h. Dry type air filter.
i. Cartridge type lubrication oil filter.
j. The generator set engine should be fitted with 3-way catalytic converter capable of reducing
NOx, CO and HC by over 70%.
k. The catalyst supplier should have its product validated by ARAI.
l. The generator set shall have a gas train to operate at an inlet gas pressure of 14 to 49
kg/cm2(g). Any facility required for reduction in the pressure from the gas inlet pressure for the
operation of gas generator shall be to the bidder scope.
m. The generator set shall be able to operate on the following gas configuration;
Component Average Gas Composition (Mol%)
Methane (mol%) 95
CO2 (mol%) 0.06

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Ethane (mol%) 3.84
Propane (mol%) 0.73
i-Butane (mol%) 0.11
n-Butane (mol%) 0.12
i-Pentane (mol%) 0.02
n-Pentane (mol%) 0.02
Nitrogen (mol%) 0.1
NOTES:
 O2 not more than 0.5% mole. Total non hydrocarbon not more than 2.0%
 Total S including H2S not more than 10 ppm by weight
 H2S not more than 4 ppm by volume.
 Moisture content in the range 112 to 114 kg/MMSCM
5. LUBE OIL SYSTEM
Automatic pressure lubrication system shall be provided. Bidder shall also indicate the specific lube
oil consumption and capacity of the lube oil tank.
6. ENGINE STARTING SYSTEM

Starting of gas engine shall be by electrical starting system. Electrical starting system shall comprise
of a starter motor, batteries, battery charger and all the necessary instruments and accessories.
Batteries and battery charger shall be supplied by the bidder.
7. AIR INTAKE AND EXHAUST SYSTEM

Air intake filter and silencer shall be provided. The exhaust system shall consist of an exhaust gas
driven turbo charger/ naturaly aspirated, exhaust gas silencer, necessary piping, adapters,
accessories etc.
8. GOVERNING SYSTEM
The gas engine should have electronic isochronous governing. Governor shall be provided for
keeping constant speed within permissible limits with variable load. The governor shall be electronic
type..it shall be capable of operating on isochronus mode i.e. the speed of the engine (frequency of
the generator set) shall remain constant irrespective of the load on the gas generator set upto 100%
capacity. RPM indicator and tacho generator to trip the gas generator set during over speed shall
also be provided.
9. DIGITAL CONTROLLER

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The digital controller shall be integrally mounted on generator set and shall have automatic start
function with provision for manual start / stop / reset and auto options as per technical specs /
features listed below:
a. The digital controller shall have self diagnostics and test function.
b. Digital controller shall have LED to display Engine parameters like running hours, crank
cycle status, Diagnostics.
c. LED shall also display communication faults like
i. High engine Temperature.
ii. Low oil Pressure.
iii. Fail to start (Over crank safety)
iv. Over speed
v. Over frequency
vi. Over voltage
vii. Under frequency
viii. Under voltage
ix. High battery voltage
x. Low battery voltage
xi. Auxiliary fault.
d. Digital Controller shall preferably have a MMI membrane keypad for configuration and
adjustment of features like
i. Password protection for Menu access
ii. System configurations like system voltage, Phase and
iii. Frequency settings etc.
10. ALTERNATOR (Power output @ 0.8 power factor)
The alternator shall be designed for the specified rating voltage etc. and shall be single bearing with
class ‘H’ insulation with 13 deg. temp. riseas per NEMA MG1-1.66,IEEE & ANSI standards.
The alternator shall be suitable for continuous operation at 415V, 3 phase, 4 wire system, 50 Hz,
0.8 pf(lag).
The Alternator should be able to take the 100% load in single step.
The alternator shall have following features:

 Brush type, screen protected, revolving field, self excited, self regulated through an DVR
/AVR.
 It should have PMG (Permanent Magnet) excitation incorporated for block and motor loads.
 Sustained short circuit current of upto 150% of the rated current upto 5 seconds.
 It should have vacuum impregnated windings with fungus resistant varnish for use in humid
areas.
 It should have self ventilated and drip proof construction.
 It should have Superior voltage wave form from a two-thirds pitch stator and skewed rotor.
 + / - 1% voltage regulation (max.)
 IP:23 enclosure
 Two nos. body earthing terminals which shall be separate from the neutral terminal.

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 Permissible overload 10% for one hour in 12 hours of duration.
11. AMF Panel with Mains By pass
Control Panel shall be suitable for 415V, 3 Phase, 4 Wire, 50Hz, 0.8PF, fabricated out of 2.0mm
CRCA MS Sheets, free standing, floor mounting (inside- side acoustic), front hinged, indoor use,
cubicle type, bottom gland plates for Cable connections, dust & vermin proof with Powder Coated
painting complete with internal wiring, ferrules, inscription plates etc. The push button, lamps will be
finalized during detail engineering .
Fuse less design shall be considered.
12. PERFORMANCE REQUIREMENTS
The unit shall be capable of starting from cold condition.
The unit shall be capable of a peak output of 10% in excess of the rated output for a period of one
hour out of a total 12 consecutive hours of operation, without exceeding permissible temperature
limits and with a fairly clear visible exhaust.
The unit shall operate upto 110% of the rated speed over the entire range of output without undue
vibration and noise.
Slam shut off valve or an alternate arrangement should be provided to shut off the supply of gas in
case gas pressure exceeds the specified limits.
Proper filter shall be provided before gas regulating unit to ensure protection against any foreign
material.
2 nos. ball valve shall be provided for isolating the gas supply from gas genset as and when
required.
Any item not mentioned and required for proper functioning of the gas genset / gas train shall be
provided free of cost by bidder.
The bidder would be required to submit test certificate of all the equipments in gas gensets / gas
train.
The filter should be hydro tested up to 1.5 times of the line pressure at its installation point.
The bidder would be required to submit calibration certificates of pressure gauges and other
installed instruments as applicable and submit the detailed P&ID & GAD.
Bidders shall submit the TPI report for inspection of all items of gas gensets and the gas gensets as
a whole equipment under operating conditions.

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13. WIRING
All control wiring inside the controller shall be carried out with 2.5 sq.mm 1100/650 V grade PVC
insulated copper wires.
14. CONTROL SYSTEM
The gas generator set will be normally at rest when the station A.C. supply is available from normal
power source. In case of main AC power supply failure, the Gas Generator shall be stated as
follows.
On failure of normal station A.C. power supply, Gas Generator set shall start automatically.
When gas Generator set is running & grid power restores, the load shall be transferred to grid
automatically and the Gas Generator set will stop after a preset time.
Three attempt starting facility shall be provided for the Gas generator set. In case, the gas engine
fails to start and reach rated speed within 30 seconds, it shall be disconnected and locked out
automatically.
15. BASE FRAME
Skid mounted type base frame, fabricated from suitable size MS channel, of heavy side members
and cross members, providing common bed for engine and alternator, directly coupled together.
The base frame shall have provision for grouting the set on grouting bolts as well as fixing on Anti-
Vibration Mounts. Provision shall also be made in the base frame for lifting the set.
16. AVM PADS
Vibration Mounting Pads, as recommended by the set manufacturer shall be supplied with the GC
set.
17. ACOUSTIC ENCLOSURE

The generator set comprising of engine coupled with alternator for each set should be placed inside
an acoustic enclosure having the following salient features :
i. The enclosure shall be of modular construction with provision to assemble and dismantle
easily at site. There should also be adequate provision for taking out the equipment for
maintenance / repairing jobs and reinstalling the same after necessary corrective action.
ii. The engine generator shall be factory enclosed in not less than a 12 guage cold rolled steel
enclosure constructed with corner posts, uprights and headers. The roof shall aid in the
runoff of water and include a drip edge. The weatherproof and corrosion resistant acoustic
enclosure should be duly surface treated, phosphate and finally powder coated for long
lasting finish. The sheet metal components should preferably be hot dip, seven tank pre-
treated before powder coating with special pure polyester based powder.
iii. The sound proofing of the enclosure should be done with self extinguishing high quality rock
wool / mineral wool/PU foam confirming to IS 8183. The rock wool should be further covered

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with fibre glass tissue and perforated sheet. The silencer must be such that sound level is 75
dbAat 1 meter from the enclosure surface.
iv. Exhaust silencer shall be provided of the size as recommended by the manufacturer and
shall attenuate the sound to the level noted above. It shall be supplied with a flexible,
seamless, stainless steel exhaust connection as well as with all internal pipe work. A rain
cap will be supplied to terminate the exhaust pipe. These components must be properly
sized to assure operation with minimum back pressure and high sound when installed. The
canopy should be finished in synthetic enamel paint incorporating rust inhibitors and
aluminium sprayed silencers and spark arrestors to guarantee a superior and long lasting
finish.
v. The temperature inside the enclosure should be suitable for human comfort. The
temperature of exhaust line should not exceed the self ignition temperature of the fuel gas. A
high temperature trip system (to shut down the engine by cutting off fuel supply to the engine
through the solenoid valve) with variable setting connected to a thermostatically controlled
blower must be provided for eliminating excessive heat dissipated by the engine within the
acoustic enclosure. Suitable continuous on line temperature monitoring and control system
with alarm and shut down mechanism should be provided.
vi. There should be a provision of emergency shutdown of the generating set (Prime mover)
from outside the enclosure.
vii. The enclosure should be complete with power and control wiring between control panel and
alternator and other components like blowers etc. with proper size copper cable. The cables
should be terminated using gland and tinned copper sweating sockets and run through
guard pipe.
viii. The enclosure should have sufficient space in and around the generating set to facilitate
maintenance and operation of the set.
ix. The control panel for the Generating set should be installed separately on the same skid in a
different enclosure (which need not be acoustic). The connection from the alternator and
control panel should be carried out with 3.5 core 120 sq.mm PVC insulated, PVC sheathed
armoured copper cable and cable should be terminated with proper size of tinned copper
sweating socket and cable glands at alternator and panel end.
x. All the terminal boxes / junction boxes etc, the battery and self starter connection terminals
and its components should be housed inside DGMS approved intrinsically safe enclosure.
18. PACKING AND DESPATCH

The unit shall be packed suitably to facilitate installation and transportation. During transport, care
shall be taken to avoid damage to paint or accessories of the equipment if any damage is caused
during transport, the vendor shall repair the same , free of cost.
19. TOOL KIT

Special tool kit, if any, for the Gas generator set shall be supplied.

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20. TESTS & INSPECTIONS

Following tests shall be carried out in GAS Generator:
Routine tests for engine like fuel consumption test at 100% & 50% load for 12 hrs each, 24 hrs
running test at 75% load , etc. as per relevant Indian / International standards / manufacturer’s
standards.
Routine tests for alternator, as per latest IS-4722 or other applicable Indian standards like insulation
resistance and high voltage test etc.
8 hour run test with the set completely assembled at works / site with full load and 10% overload. All
parameters will be recorded in presence of the customer’s representative.
Bidder shall submit copies of routine and type test certificates for approval in required sets before
dispatch.
Following inspections shall be carried out in gas generator:
Bidder shall arrange for below mentioned inspection at factory
a. Visual
b. Dimensional
c. Fitment & alignment
d. Guaranteed parameters.
e. Painting thickness
f. Vibration
g. Sound level
Bidder shall submit the following documents before dispatch:
a. Outline dimensional drawings with general arrangement

b. Piping flow sheets and piping layout.
c. Electrical wiring and schematic diagram along with cable schedule and general arrangement
drawing for control panel.
d. Foundation drawings.
e. Fuel oil system with instrumentation and control with write-up.
f. Lube oil system with instrumentation and control with write-up
g. Governor system and voltage regulator write-up.
h. Gas Gen set instrumentation and control system with write-up.
21. CERTIFICATION
21.1. Bidder shall be responsible for obtaining all statutory approvals, as applicable for all electrical,
instruments and control systems.
21.2. Bidder shall supply type test certificate incompliance to Environmental (Protection) 3rd Amendment
Rules 2016
21.3. In general, the following verification shall be provided by the bidder.

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a. For all flame proof equipments manufactured within India, the testing shall be carried out by any
of the approved testing houses –central Mining Research institute (CMRI) / ERTL etc,.
b. For all intrinsically safe equipment manufactured within India, the testing shall be carried out by
any of the approved testing houses –central Mining Research institute (CMRI) / ERTL etc,.
ANNEXURE - I
LIST OF SUPPLIERS OF MAJOR BOUGHT-OUT ITEMS
SI.No. Item Description Preferred make
1. Fire fighting a. Nitin Fire Protection Pvt. Ltd., Mumbai

equipment b. Safex Fire Services, Bombay
c. Cross fire (India), Gurgaon
d. Zenith fire services,Bombay
e. Steelage industries Ltd., Chennai.
f. Atlas FiretechPvt. Ltd, Delhi

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2. List of parties for a. M/s Techsol Engg Services (I) Pvt Ltd, M/s Equipment
laying SS tubing fabricators, Kannamangala post, Whitefield-Hoskote road,
Bangalore-560067 -http://www.ef-india.com / (Contact
:Mr.Ravi, Mobile no.9845125348/ Mr.Porus Shroff (Director),
Mobile no.9845031272).
b. M/s CCD Technical solutions Private limited, No.10, PKM

road, Athipet, Chennai-600058 -http://www.ccdtechnical.com
/ (Contact :Mr.Gurumoorthy, Mobile no.950007659/
N.G.Kumar, Mobile no.9840999270).
c. Nichepro Technologies & Consultancy,# 3, 6th Cross,

Guptha Layout, Halasuru, Bangalore –
60008,karthik@nichepro.in,Karthik :- +91 9900087357
d. Shree Manjunatha Engineering Works ,#301, 1st floor,

1st Cross,Vidya Nagar, OPP: SKF Bearings, Bommasandra,
Director :- Mr.Veerabhadrapa,veerabhadrappa.v@
gmail.com,vennu@smesolutions.co.in,
smesvennu@gmail.com, +91-9845590232, +91-
8884600170.
e. Sri Lakshmi Engineering Contractors, No. 116, J.B.

Link Road IVth Phase, Bommasandra Industrial Area,
srilakshmiengcon@gmail.com, Proprietor :- Mr. Sasi.D,Mob:-
+919036009595.
Note: If a bidder wishes to do the job by themselves or any

other sub-contractor, they need to get prior approval from
GAIL Gas / MECON after submitting credentials for the
same
a. M/s Parker Hannifin India Pvt. Ltd.,Plot EL-26, MIDC, TTC,
3. SS fittings & Industrial Area, Mahape,Navi Mumbai - 400 701 ,Tel. No. :
Valves
022- 5907081/82 Fax No. : 022-55901080 ,E-mail :
parker@vsnl.com / aoke@parker.com
Thru representative
M/s Super Technical (India) Pvt. Ltd.,
501, Samarpan Complex, New Link Road,Chakala, Andheri
(E), Mumbai -400099
Ph: 022 - 2832 3760 / 61, Fax: 2832 3759 ,Email Id
:sales@supertechnical.in

b. M/s Swagelok,
Thru Bangalore Representative:
M/s Bangalore Fluid System components Pvt. Ltd.,

#1,Doddanakkundi Industrial area,

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MahadevapuraPost,Bangalore – 560048
Tel No.080-42669100
Mobile: 91 9686700138
Email: bangalore@swagelok.com
c. M/s SSP. U.S.A

Thru Indian representative
M/s Oiltech Consultancy Services,
11, VeenaBeena, Guru Nanak road, Bandra (W), Mumbai -
400 050 (India)
Tel.No.:022-56936500,56964146(D) ,Fax No. : 022-
26514429/26405644
E-mail : ashisn@oiltechconsultancy.com ;
oiltech@vsnl.com
d. M/s Dk-lokCorp.,South Korea only for SS fittings

METCO MARKETING (INDIA) PVT LTD
104,Niraj Industrial Estate, Off Mahakali Caves Road,
Andheri(East), Mumbai-400093, INDIA
Tel : +91 22 4073 8484 Fax : +91 22 66938485
E-mail : dipen@metcoindia.com Homepage
: www.metcoindia.com
Techsol Engineers
No. 94, 4th Floor, 2nd Cross, MLA Layout, R.T. Nagar,
Bangalore, Karnataka 560032
Tel : +91 8861200084 87 Fax : +91 80 23535285
E-mail : contact@techsolengineers.com
e. M/s Hylok, South Korea only for SS fittings
M/s SSSP Technologies ( Hy-Lok)
130 Sahid Dinesh Gupta Road,(29,Sahid Dinesh Gupta
Road), Behala ,Jadu Colony, Kolkata -700 034,India, m- 91
98306 88788
e-mailid:- spban1958@gmail.com,

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phalgunibanerjee943@yahoo.in
a. M/s Sandvik Steel Asia Pvt. Ltd.

4. SS Tube
Steel Division, Mumbai-Pune Road, Dapodi, Pune-
4110212,India
Tel. No. : 020-27104562, 27104568 Fax No.: 020-27145022,
27145339
E-mail : genny.dcruze@sandvik.com ;
siddarth.mittal@sandvik.com.
b. M/s Tubacex India,

402-A, Platina-G block ,Bandra-Kurla complex, Bandra (E),
Mumbai-400 051, Ph No.022-40015 300, 022-40015 350
Email:
sales@tubacexindia.com
c. Ratnamani metals & tubes ltd.

Address : 17, Rajmugat Society,

Naranpura Cross Roads,
Ahmedabad - 380 013
Gujarat (India).
Telephone : +91-79-2741 5501/2/3/4
Fax : +91-79-2748 0999
E-mail : info@ratnamani.com
Swagelok/ Parker/ Dk-Lok/ Vaishnavi hydraulics Pvt. Ltd./

5. SS Tube clamps Vardhaman bearings / AK industries
KPCL/Elgi/Ingersoll Rand/ Chicago Pneumatic

6. Air compressors
Precision testing machines Pvt. Ltd./ Instrument Research

7. Automatic Association Pvt. Ltd
Intelligent tyre
inflator (AITIM)

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Swagelok/ Parker/Eaton Synflex / OPW
8. CNG high pressure
hose
Shiva Gen Set(Green Power) / Kohler generators/M/s Enerzea
9. Gas generator power solutions Pvt.Ltd./ Cyra Engines Pvt. Ltd./Perfect gas
generators/Prakash diesels Pvt.ltd/Cooper Corporation

Page 321 of 378

C
CNG O

Page 322 of 378

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PART-IV
INSTRUMENT WORKS

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SPECIFICATION FOR 3KVA UPS
1.0 SCOPE
The intent of this specification is to define the requirements of uninterrupted

power supply system and the associated battery bank sets. Tenderer's scope of work includes
design, manufacture, testing, packing and delivery to site and installation, testing &
commissioning of the complete UPS system with battery banks etc. as per this specification& data

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sheet.
2.0 STANDARDS
2.1 In general the equipment covered by this specification shall, unless otherwisespecified, be in line
with the requirement of any of the latest applicable standards of
a) Bureau of Indian Standards

b) British Standard Institution
c) American Standard Institution
d) International Electro Technical Commission
e) IEEE
2.2 Wherever the requirements in this specification are in conflict with any of the above Standards, the
requirements under this specification shall be binding.
3.0 GENERAL REQUIREMENTS
UPS shall be provided with SMF (Sealed Maintenance Free) battery with backup time of 4 Hrs on
rated load. The UPS shall be as per IEC standards. The UPS shall include power input device,
surge protection device at the input of UPS & SCVS, input isolation transformer, rectifier unit,
battery unit, inverter unit, static switch, automatic by-pass unit with SCVS. Facility shall be
provided for manual transfer of load from inverter to bypass.
The output voltage of the UPS shall be 230V AC, 50Hz, single phase. The UPS shall RS-485
communication for status indication. The operating temperature range shall be 0-50 deg.C with 95%
RH Non-condensing. The maximum noise shall be 60db @ 1mtr distance. The UPS shall have
finish RAL-7032 or equivalent international code. The battery shall be installed in floor mounted
racks.
3.1 Basic Particulars for Design
a) Suitable for commercial application.

b) Single-phase voltage and frequency controlled output.
c) Suitable protection shall be provided in the control circuit to guard against instability of
phase controlled rectifier due to electrical oscillation, which may be present in input supply
as caused by emergency Gas Genset.
d) The load shall normally be fed from the inverter.
e) Battery shall be suitable to maintain the power supply in the event of mains failure or
battery charger failure for the time period specified
f) Static by pass switch to connect the load to the mains supply through static voltage
stabilizer or hot standby UPS, as per the configuration, without interruption to the load in the
event of inverter failure.
3.2 Rectifier/ Battery Charger
1. Transient and surge protection circuit in input circuit to protect UPS from surges and

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voltage spikes.
2. Automatic boost and float charging control
3. Charger shall simultaneously supply entire power necessary for inverter and to keep the
battery of required capacity in fully charged condition. Provision for automatic charging in
both float and boost shall be made.
3.3 Constructional Features
1. Free standing, floor mounted indoor type and complete with all interconnection
2. Dust and vermin proof
3. Units shall be self contained and serviceable
4. Suitable for non air conditioned room.
3.4 Battery unit
Ampere-hour capacity of the battery shall be selected on the following basis:

a) Aging factor of 1.0
b) Battery state of charge factor of 1.0
c) Temperature correction factor of 1.0
d) Backup time 240 minutes at full load
e) Overload Factor of 1.0
f) Minimum end cell voltage shall be 1.85 V per cell for SMF LA/VRLA battery.
g) Load break switch fuse unit in sheet steel enclosure shall be provided near
the battery bank for isolation.
h) Battery stands in multi row/ single tier formation. Stand Material shall be as per battery
manufacturer’s standard.
4.0 DRAWINGS AND DOCUMENTS
4.1 The following documents shall be submitted along with the offer:
a) List of two years operation and maintenance spare.
b) Technical data sheet and check list duly filled.
c) Space requirement for UPS & auxiliary panels and battery bank
4.2 The following drawings shall be submitted for approval on awardof contract.
a) G.A. of panel, battery stand,

b) Bill of Material.
c) Schematic & Wiring diagram for reference.
d) Sizing calculation.
4.3 Final drawings, operation & maintenance manual and erection Instructions shall be submitted along
with dispatch of equipments in three sets in hard copy & two sets in soft copy (CD/DVD).
5.0 INSPECTION

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5.1 The contractor shall submit Quality Assurance Plan (QAP) for respective equipments within 3
weeks of award of contract. QAP shall be prepared and furnished by the contractor in MECON
Form No. 11.20(4.4) F-10 along with their internal in process quality checks.
5.2 Batteries shall be tested for type and Àcceptance Test’/ Routine Test at battery manufacturer’s
works and test reports shall be submitted for review and approval.
5.3 Final acceptance testing along with the batteries shall be done at site. Site acceptance test
procedure shall be submitted by the Contractor along with
QAP.
6.0 PACKING AND DESPATCH
The equipment shall be properly packed for transportation by ship / rail or trailer. The equipment
shall be wrapped in polythene sheets before being placed in crates / cases to prevent
damage. Crates / cases shall have skid bottoms for handling. Special notations such as
“Fragile’, “This side up” “Centre of gravity”, “’Weight’, “Owner’s particulars”, ‘PO nos.”’ etc,
shall be clearly marked on the package together with other details as per purchase order.
Contractor shall supply above packed material at required place as specified elsewhere.
DATASHEET FOR 3 KVA UPS
UNINTERRUPTED POWER SUPPLY

1.0 INPUT POWER SUPPLY
1.1 Voltage/ Phase / Frequency 230 V AC (+)10% & (-)15% 1Ph,, 50 Hz ± 6%
1.2 System fault level 50 kA for 1 Sec
2.0 SITE CONDITION
2.1 Design Maximum 50˚C
95% RH ( max. humidity and temperature do not occur at
2.2 Max. Relative humidity
same time)
3.0 OUT PUT REQUIREMENT
3.1 Voltage / Phase / Frequency 230V ± 1% AC, Single phase, 50 Hz ± 0.1%
Pure Sinusoidal Wave
3.2 Output waveform Voltage distortion (THD): Less than 3% for linear
loads& Less than 5% for non linear loads.
Transfer time between AC
3.3 0 ms (bumpless)
and Battery modes
4.0 SYSTEM REQUIREMENTS
4.1 Rating (KVA at 0.8 pf.) As per SOR

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The inverter circuit should be IGBT based, fully
4.2
Type of inverter microprocessor controlled with latest proven technology
125% of the rated output for 10 minutes & 150% for 1
4.3 Overload capacity
minute.
>90% for normal load and not below 85% for 25%
4.4 Inverter efficiency
of load
4.5 Type of enclosure Unitized, Floor mounted
4.6 Internal protection All live parts shrouded
Doubly Earthed (Two distinct terminals to be made
4.7 Earthing
available)
4.8 Crest Factor ≥3:1
4.11 Overall efficiency >80%
4.12 Connectivity Serial port RS232/ 485.
5.0 Battery Bank
5.1 Type of Battery As per SOR
6.0 Distribution boxes
6.1 Distribution Board Details
(1) UPSDB 230 V, Single Phase (1 No.) :
Incomer : DP MCB
Outgoing : 5nos, 6A and 3 nos. 10A MCBs
With 20% spare feeders of each type

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SPECIFICATION FOR
2x6 kVA & 2X 7.5 KVA PARALLEL REDUNDANT UPS
1.0 SCOPE
The intent of this specification is to define the requirements of uninterrupted

power supply system and the associated battery bank sets. Tenderer's scope of work includes
design, manufacture, testing, packing and delivery to site and installation, testing &
commissioning of the complete UPS system with distribution boards and battery banks etc. as per
this specification & data sheet.
2.0 STANDARDS
2.1 In general the equipment covered by this specification shall, unless otherwise specified, be in line
with the requirement of any of the latest applicable standards of
a) Bureau of Indian Standards

b) British Standard Institution
c) American Standard Institution
d) International Electro Technical Commission
e) IEEE
f) NEMA
2.2 Wherever the requirements in this specification are in conflict with any of the above Standards, the
requirements under this specification shall be binding.

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3.0 GENERAL REQUIREMENTS
UPS for the automation shall be parallel redundant with load sharing. UPS shall be provided with
SMF (Sealed Maintenance Free) battery with backup time of 4 Hrs on rated load. The UPS shall be
as per IEC standards. The UPS shall include power input device, surge protection device at the
input of each UPS & SCVS, input isolation transformer, rectifier unit, battery unit, inverter unit,
static switch, automatic by-pass unit with SCVS. Facility shall be provided for manual transfer of
load from inverter to bypass.
The output voltage of the UPS shall be 230V AC, 50Hz, single phase. The UPS shall provide RS-
485 communication for status indication. The operating temperature range shall be 0-50 deg.C with
95% RH Non-condensing. The maximum noise shall be 60db @ 1mtr distance. The UPS shall
have finish RAL-7032 or equivalent international code. The battery shall be installed in floor
mounted racks.
Separate feeders for both UPS systems and the SCVS shall be considered which is useful in the
maintenance of input feeders.
The UPS shall have the following salient features:

* Bumpless switchover of load on either UPS, on failure of the other UPS.
* Bumpless switchover of load on battery, on failure of incoming mains
* Bumpless switchover of load on SCVS, on failure of both UPS& battery.
Power from the UPS shall be distributed through Power Distribution Board (PDB) . Power supply
distribution shall be through circuit breaker. Spare feeders of 20% shall be provided for future expansion
in the PDB. PDB shall have voltage meter, ammeter and visual indication of power supply failure.
3.1 Basic Particulars for Design
a) Suitable for industrial application.

b) Automatic selection of available phase (out of three phases) in case of outage of power
supply of the phase in use for feeding incoming power supply to the UPS.
c) Single-phase voltage and frequency controlled output.
d) Suitable protection shall be provided in the control circuit to guard against instability of
phase controlled rectifier due to electrical oscillation, which may be present in input supply
as caused by emergency Gas Genset.
e) Parallel hot redundant system with automatic static bypass, common DC battery and solid-
state voltage stabilizeras per data sheet and drawing.
f) The load shall normally be fed from the inverter.
g) Battery shall be suitable to maintain the power supply in the event of mains failure or
battery charger failure for the time period specified
h) Static by pass switch to connect the load to the mains supply through static voltage
stabilizer or hot standby UPS, as per the configuration, without interruption to the load in the
event of inverter failure.
i) AC Distribution board as per data sheet.

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j) Noise level at a distance of 1 m. from UPS panels shall not exceed 65dB.
3.2 Rectifier/ Battery Charger
1. Switched ON through a MCCB.

2. With transient and surge protection circuit in input circuit to protect UPS from surges and
voltage spikes.
3. Automatic boost and float charging control
4. Protective features:
- Maximum current limiting
- Over temp. trip.
- Boost charging and float charging current limiting with back up protection against
overcharging.
5. Charger shall simultaneously supply entire power necessary for inverter and to keep the
battery of required capacity in fully charged condition. Provision for automatic charging in
both float and boost shall be made.
3.3 Inverter
1. DC/DC converter for voltage control

2. Control electronics
3. Series reactor and parallel filter
4. Output transformer
5. Protection against the following:
- Abnormal output voltage
- Over load trip
- Low battery voltage
6. Meters
- For output voltage
- For output frequency
- Ammeter
- Battery current and voltage with indication of status - "in charge" or "discharge".
7. Static by-pass switch
- Static switch automatically switches the load to the reserve power supply or the
mains whenever there is failure in inverter supply to the load.
- Retransfer of load from stabilized bypass supply to the inverter in auto as well as in
manual mode.
- High-speed fuses shall be provided for protecting the thyristors against accidental
overload.
3.4 Constructional Features
1. Free standing, floor mounted indoor type and complete with all interconnection with lifting
hooks

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2. Dust and vermin proof
3. Sheet steel clad mounted on 100 mm base frame
- Minimum 2 mm thick for panels
- Minimum 1.6 mm thick for doors and side covers
4. Units shall be self contained and serviceable
5. The arrangement and layout shall facilitate easy and convenient supervision of the unit
while running as well as quick detection of disturbances and troubleshooting.
6. Copper earth bus bar shall run throughout the length of Panels. All doors & non-current
carrying parts shall be suitably earthed.
7. The maximum and minimum operating height of the switches shall be 1800mm and 300mm
respectively.
8. Enclosure conforming to minimum IP-31 class.
9. Units shall be provided with cooling fans and louvers.
10. Suitable for non air conditioned room.
11. Interior and exterior colour shall be RAL 7035.
3.5 Battery unit
3.5.1 Ampere-hour capacity of the battery shall be selected on the following basis:
a) Aging factor of 1.0

b) Battery state of charge factor of 1.0
c) Temperature correction factor of 1.0
d) Backup time 240 minutes at full load
e) Overload Factor of 1.0
f) Minimum end cell voltage shall be 1.85 V per cell for SMF LA/VRLA battery.
g) Load break switch fuse unit in sheet steel enclosure shall be provided near
the battery bank for isolation.
h) Battery stands in multi row/ single tier formation. Stand Material shall be as per battery
manufacturer’s standard.
4.0 DRAWINGS AND DOCUMENTS
4.1 The following documents shall be submitted along with the offer:
a) List of two years operation and maintenance spare.
b) Technical data sheet and check list duly filled.
c) Space requirement for UPS & auxiliary panels and battery bank
4.2 The following drawings shall be submitted for approval on award of contract.
a) G.A. of panel, battery stand, ACDB

b) Bill of Material.
c) Schematic & Wiring diagram for reference.
d) Sizing calculation.

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4.4 Final drawings, operation & maintenance manual and erection Instructions shall be submitted along
with dispatch of equipments in three sets in hard copy & two sets in soft copy (CD/DVD).
5.0 INSPECTION
5.1 Inspection and testing of equipment shall be carried out by the owner/ consultant at the works of
the contractor on final product to ensure conformity of the same with the acceptable criteria of
technical specification, approved drawings and national/ international standards.
5.2 The contractor shall submit Quality Assurance Plan (QAP) for respective equipments within 3
weeks of award of contract. QAP shall be prepared and furnished by the contractor in MECON
Form No. 11.20(4.4) F-10 along with their internal in process quality checks.
5.3 ‘Type test' including 12 hr. heat run test shall be conducted on one UPS System of each rating and
‘Routine test’ on the remaining.
5.4 Batteries shall be tested for type and Àcceptance Test’/ Routine Test at battery manufacturer’s
works and test reports shall be submitted for review and approval.
5.5 Final acceptance testing along with the batteries shall be done at site. Site acceptance test
procedure shall be submitted by the Contractor along with
QAP.
6.0 PACKING AND DESPATCH
The equipment shall be properly packed for transportation by ship / rail or trailer. The equipment
shall be wrapped in polythene sheets before being placed in crates / cases to prevent
damage. Crates / cases shall have skid bottoms for handling. Special notations such as
“Fragile’, “This side up” “Centre of gravity”, “’Weight’, “Owner’s particulars”, ‘PO nos.”’ etc,
shall be clearly marked on the package together with other details as per purchase order.
Contractor shall supply above packed material at required place as specified elsewhere.

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2x6 kVA & 2X 7.5 KVA PARALLEL REDUNDANT UPS
UNINTERRUPTED POWER SUPPLY

1.0 INPUT POWER SUPPLY
1.1 Voltage/ Phase / Frequency 415 V AC (+)10% & (-)15% 3Ph,, 50 Hz ± 6%
1.2 System fault level 50 kA for 1 Sec
2.0 SITE CONDITION
2.1 Design Maximum 50˚C
2.2 Max. Relative humidity 95% RH ( max. humidity and temperature do not occur
at same time)
3.0 OUT PUT REQUIREMENT

3.1 Voltage / Phase / Frequency 230V ± 1% AC, Single phase, 50 Hz ± 0.1%
3.2 Output waveform Pure Sinusoidal Wave
Voltage distortion (THD): Less than 3% for linear

loads& Less than 5% for non linear loads.
3.3 Redundancy Switching between Bumpless
both UPS
3.4 Transfer time between AC and 0 ms (bumpless)
Battery modes
4.0 SYSTEM REQUIREMENTS
4.1 Rating (KVA at 0.8 pf.) As per SOR
The inverter circuit should be IGBT based, fully

4.2
Type of inverter microprocessor controlled with latest proven technology
125% of the rated output for 10 minutes & 150% for 1

4.3 Overload capacity
minute.
Parallel Redundant with static bypass & Dual
4.4 Mode of operation
Redundant rectifier
>90% for normal load and not below 85% for 25%
4.5 Inverter efficiency
of load
4.6 Type of enclosure Minimum IP-31
4.7 External Cable Connection Bottom entry only
4.8 Internal protection All live parts shrouded

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Doubly Earthed (Two distinct terminals to be made
4.9 Earthing
available)
4.10 Cooling Forced ventilation with fans
4.11 Noise Level <65 dB at full Load from 1 mtr distance

4.12 Crest Factor ≥3:1
4.15 Overall efficiency >90%

4.16 Connectivity Serial port RS232/ 485.
5.0 Rectifier/Charger
5.1 Automatic phase selection

Yes
device
5.2 Input Power factor >0.8 (minimum) at rated load
Input current THD (Total
5.3 Harmonic Distortion) at
<= 25%
nominal load
125% minimum for 10 min.
5.4 Overload Capability
150% minimum for 1 min.
5.5 Inrush current Limited by soft-start circuit
5.6 Output voltage tolerance +/- 1%

<1% with battery connected
5.7 DC voltage ripple
<2 % Without battery connected
6.0 Bypass
Static bypass to provide an un interruptible transfer of

load in case of failure of any system component or
6.1 Automatic Bypass
malfunctioning or overload & the load shall return on the
UPS when the malfunctioning or overload is cleared.
6.2 Input connection Separate for each UPS

The switching time from
6.3 No break type
inverter to bypass & vice versa
6.4 Manual/Maintenance Bypass Shall be provided
150% (minimum) for 1 minutes, 125% (minimum)
6.5 Overload on bypass
for 10 min.
7.0 Battery Bank
7.1 Type of Battery As per SOR

8.0 Alarms, Indications and LCD Display

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8.1 Digital panel Meter with LCD a) Input AC Voltage, current, frequency
display shall be provided for b) Output AC Voltage, current, frequency.
monitoring c) Mains ON/OFF,
d) Inverter ON/ OFF
e) Battery voltage low
8.2 Audible Alarms With LCD a) Mains Failure

Display- b) Battery Low
c) UPS fault (Continuous)
9.0 Protective Features
9.1 Input Mains Over voltage, under voltage, phase failure
Over voltage, short circuit, overload, over

9.2 Inverter
temperature
Under voltage at battery terminal, Battery over

9.3 Battery
charge, Battery Over current
Maximum current limiting
Over temp. Trip
9.4 Rectifier & Battery charger Boost charging and float charging current limiting
with back up protection against over charging.
10.0 Distribution boxes

10.1 Distribution Board Details
(1) UPS DB 230 V, Single Phase (1 No.) :
Incomer : 2 nos DP MCB ( one is dedicated for CCTV
PDB & another is for Instrument works)
Outgoing : 11 nos, 6A and 6 nos. 10A MCBs Instrument
works and 10A MCBs for CCTV as per SOR quantity.
With 20% spare feeders of each type

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MASS FLOW METER
1. SCOPE
1.1. This Specification covers Design, Manufacture, testing, Supply & Transportation, Unloading at
project site of Mass flow meter (Model CNG 50 with integral local display) based on Coriolis

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principle of Micro motion, USA with F-series 2700 transmitter to be used in CNG mother stations of
City Gas Distribution project for Bengaluru.
2. GENERAL
2.1. Mass flow meter shall be based on Coriolis principle. Installation and manufacturing of Mass Flow
meter shall be as per AGA-11. While installing special care shall be taken to isolate the mass flow
meter from piping vibration.
2.2. Each Mass flow meter shall include a sensor with integral transmitter i.e meter electronics certified
intrinsically safe / explosion proof by statutory authority suitable for the required hazardous area as
per IS-2148 / IEC-79. Also the offered sensor and the transmitter shall be weather proof to IP65 or
better as per IS-2147/IEC-529. Statutory authority for local installation is CCOE.
2.3. Offered mass flow meter shall be necessary for Custody Transfer application but not exceeding
0.5% of span.
2.4. Calibration for the offered mass flow meter shall be in Kg/hr, cumulative flow. MFM with head
mounted integral local display to indicate flow rate (Kg/hr), cumulative gas (in Kgs) etc.; inbuilt
totalizer non-volatile & non-resettable type; suitable for hazardous area classification.
2.5. Flying lead type electrical termination is not acceptable. All electrical connections shall be ½” NPTF.
Cable glands shall be provided for electrical power, signal and control connections. Cable glands
shall be double compression type and certified weather proof and explosion proof for the required
area classification as per IS-2147 and IS-2148.
2.6. Offered mass flow meter shall be completely free from corrosion of measuring tube due to
alternating stresses continuously occurring in the tube. Also measuring tube shall be completely
free from erosion, which may result due to fluid velocity.
2.7. The design of meter electronics shall be in compliance with the electromagnetic compatibility
requirements as per IEC-801.
2.8. Meter electronics shall include all the associated pre-amplifiers, converters, line riser etc. and shall
have enough diagnostic facility to correct live zero, variation, meter factor etc with the help of
Laptop. Output of the mass flow meter RS485 type to PLC shall be utilized.
2.9. Installation details like straight run requirements, recommendation for horizontal/ vertical installation,
minimum distance between upstream and downstream pipe bends from mass flow meter to be
provided.
2.10. Laying of 2 nos of GI conduits from each dispenser to Modem in control room is in Bidder scope.
2.11. Vendor shall calibrate each Mass flow meter at his shop or any recognized test house with the fluid
(Use design process conditions) for which it is to be used as per Clause no.9 of MPMS (Draft

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standard Nov.2000) or as per ISO 4185 STD. In case it is not possible to calibrate the Mass Flow
Meter with actual fluid. Vendor must indicate
a) Fluid used for calibration
b) Correction factor / Adjustment required for actual process fluid. In any case, in accuracy
when extended to actual process shall not exceed the specified limits (as per manufacturer’s
standard).
2.12. Vendor shall submit the following test certificates and test reports for purchaser’s review:-
a) Material test certificate with detailed chemical analysis from foundry (MIL certificate)
b) Certificate of radiography / x-ray from any welded joint.
c) Hydrostatic test report with pressure of 1.5 times the design pressure.
d) Calibration report including calibration factors for each mass flow meter
e) Certificate from statutory body for offered sensor and transmitter for required area
classification.
2.13. CERTIFICATION:
The requirement of statutory approvals for usage of equipment / instruments / system in electrically
hazardous area shall be as follows:
a) The vendor shall be responsible for obtaining all statutory approvals, as applicable for all
instruments and control systems.
b) Equipment’s / instruments / systems located in electronically hazardous area shall be
certified for use by statutory authorities for their use in the area of their installation. In
general, the following verification shall be provided by the vendor.
 Bidder shall provide certificates (from BASEEFA FM, UL, PTB, LCIE etc.) from
country of origin for all intrinsically safe / flameproof protected by other methods
.Equipment / instrument / systems, which are manufactured outside India, if required,
bidder shall provide necessary certification / approvals / authentication, for all such
intrinsically safe / flame proof equipment / instrument / systems, by the Indian
authority-Chief controller of Explosive (CCOE), Nagpur, India.
 For all flame proof equipment manufactured within India, the testing shall be carried
out by any of the testing houses- central Mining Research Institute (CMRI) / ERTL
etc. The items shall in addition bear the valid certification from CCOE.
3. Specification for MFM:
3.1. Specifications of MFM sensor (Coriolis CNG series sensor:1/2-inch (15mm); 316L stainless steel):
a) Coriolis CNG series sensor: ½-inch (15mm).
b) 316L stainless steel.
c) Process connections: ¾-inch NPT female adapter ; or ¾” OD X ¾” OD . If MFM comes with
¾” NPT Female adapter, then 2 nos. of male connectors of ¾” NPTM X ¾” OD SS fittings of
required pressure rating are to be supplied by the vendor along with MFM.
d) Compatible size 12VCO union fittings.
e) Case options: Standard case.

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f) Electronic Interface; For integrally mounted 2700 transmitter
g) Approvals: ATEX equipment category 2 (zone 1 ) / PED compliant.
h) Language: English installation manual.
i) Factory options: Standard product
3.2. Specifications of MFM transmitter (Coriolis Flow & density transmitter):
a) Coriolis Flow & density transmitter
b) Mounting / housing material: Integral mount transmitter.
c) Power: 18 to 100V DC and 85 to 265V AC; self switching.
d) Display: Backlit dual line display for process variables and totalizer reset.
e) Output: One mA; One frequency; RS485.
f) Conduit connections: ½-inch NPT.
g) Approvals: ATEX-Equipment category 2 (Zone 1- Flame proof terminal compartment).
h) Language: English installation manual and English configuration manual.
i) Software options : Weights & Measures custody transfer and meter verification, hardware
locking & software locking arrangement required.
j) Standard product.
For applications requiring simultaneous monitoring of multiple flow variables
a) Selected combinations of outputs including milliamp, frequency, and discrete I/O.

b) Modbus, HART, wireless HART, FOUNDATION field bus and PROFIBUS-PA digital
communications.
c) Simultaneously outputs multiple variables, including mass flow rate, volume flow rate, Gas
standard volume flow rate, density, temperature and drive gain.
d) Compact, integral mounting to sensor with 360 degrees of rotation.
e) Class I, Division 1/ Zone 1 local operator interface.
f) View process variables, handle alarms, control totalizers, meter configuration and more.
g) Interface functions shall be customized and password protected.
h) Shall support English language.
i) 20 Hz / 100 Hz selectable response time.
4. Coriolis true Mass Flow Meter with integral display unit should be provided to ensure accuracy and
direct Mass Flow measurement shall confirm to AGA 11 standard. Mass flow meter (Indicating
Type) should be designed for custody transfer metering of CNG and meet the following
requirements:
Principle of metering – Coriolis

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Flow rate : 1 to 100 kg/min.
Accuracy : -/+ 0.5% (inclusive of linearity, hysteresis & repeatability error)
Repeatability : -/+ 0.3% or better
Zero stability: 0.01 kg/min or better
Pressure rating:
Flow tube rating : Max: 345 bar, Normal: 255 bar.
Process fluid temperature : -40 to +125oC.
Ambient temperature limits: -20- to +60oC.
Materials of construction:
Wetted parts : SS 316L
Sensor housing : 304L stainless steel
Totaliser – Non resettable type

Enclosure – IP65 or better, NEMA 4 & Ex. Proof for transmitter and sensor.
Pressure & temp influence – Nil.
Calibration traceability – NIST/NMI/PTB/ISO/IEC 17025
Pressure rating of wetted parts – 5200 psi at 25oC as per ANSI B 31.3/ASME
EMI effect on sensor and Transmitter – To the requirement of EMC to latest IEC/EN standard
Vibration effect –As per IEC 68.2.6 / SAMA PMC 31.1 (1980) or latest standard.
Approval – ATEX/CSA/FM/CENLEC/SEV
W&M- Statutory authority of country of origin and from ministry of consumer affairs, Govt. of India.
Output – RS 485 / frequency.
Output to be available –RS 485 / frequency / Analog duly programmed.
Each flow meter should be provided with a liquid crystal display (LCD) for ongoing flow monitoring
and totaliser.
Mass flow meter shall have diagnostic facility to check live / dynamic zero, configurable parameter,
constants etc through laptop.
Provision for sealing /locking of mass flow meter / transmitter shall be provided to avoid possibility of
tempering during use of MFM.
CALIBRATION & CERTIFICATION:

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Mass Flow Meter shall be calibrated at minimum six points (Flow range 0 to 100 Kg/min) and
calibration certificate shall be valid at the time of Supply. If any of the calibration certificates is not in
order, the supplier should replace the affected equipment with valid certificate at supplier cost. The
calibration certificates should be presented upon at the time of delivery to site.
A documentation and obtaining statutory approval from the country of origin is in vendor’s scope.
The offered Mass flow meter must be approved and certified for specified flow and accuracy by
recognized and/or other statutory authorities (of the Country of Origin).
The meters shall be type approved by Weights and Measures department (Ministry of Consumer
affairs, India). Supplier shall furnish certificate of stamping & sealing of individual meters by Local
Weights & Measures department, India along with certified calibration curve of individual meters.
5. DATASHEETS
Vendor shall furnish all the filed data sheets for the approval of MECON/GGL. Vendor shall clearly
indicate deviation if any in the respective data sheet.
GENERAL 1. Tag no. *
2. Service CNG
3. Line size & Schedule *
HAZ LOC 4 Elctrical Area IEC Zone 2 Gr.

Classification IIA/IIB
SENSOR 5. Type Coriolis
6. Function Mass flow
7. Connection size / rating ¾” tube OD, 5200

psig
8. Body material 316 SS
9. Sensor housing material SS Hermatically

leads sealed
10. Sensor / Wetted parts 316 SS

material
11. Enclosure WP to IP 65 of
better ingress
protection.
12. Intrinsic safety Required
13. Range Min. Max. Kg/h * *
14. Accuracy +0.5% flow rate

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15. Conduit connection ½” NPTF
16. Jacketing Required.
TRANSMITTER 17 Function Transmitter
18. Load driving capability in 600

Ohms
19 Output type *
signal/protocol
20 Enclosure Flameproof + WP
(IP 65 or better)
21 Intrinsic safety Required
22 Power supply *
23 Conduit connection ½” NPTF
24 Mounting location *
25 Max. Distance Allowable - *

sensor to transmitter
26 Tx to control room *
receiver
27 Power consumption in *
Watts
FLUID 28. Fluid - State CNG-gas
29 Flow: Min./Nor./Max. Kg/h As per TS
30 Pressure: Operating: Kg/cm2(g) As per TS

Maximum
o
31 Temperature: Operating: C As per TS
Maximum
32 Operating relative density
33. Relative molecular mass
34. Operating Viscosity cP
35 Maximum allowable Kg/cm2(g)

pressure
OPTIONS 36 Filter / Mesh size
37 Mounting brackets Required
38 Inter Connecting cables Required

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39 Cable glands/size Required
40 Switch /type
Contact rating
41. Accessories for hot tap
OTHERS 42. Manufacturer *
43. Model No. Meter *
44. Converter *
‘*’ Vendor to indicate

Vendor list of Bought out items:

UPS System and M/s Emerson (VERTIVO)/ M/s APlab / M/s Hi-rel
Inverter
Batteries (Lead Amco batteries Ltd./ Exide Industries Ltd./ HBLNIFE power system Pvt.
acid) Ltd./ Amara Raja Batteries Ltd.
Batteries (Nickel Amco batteries Ltd../ HBLNIFE power system Pvt. Ltd
Cadmium)
Mass flow meter Micro motion (CNG 50with 2700 transmitter)

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FOR
CCTV CAMERA SURVILLENCE &
RECORDING SYSTEM (CSRS) AT CNG STATIONS
1.0 Introduction
1.1 The Closed Circuit Television (CCTV) Surveillance System & Recording System shall be IP based
CCTV System with IP digital cameras or analogue cameras with IP encoders with monitors,
control, video recording and switching equipment suitable for continuous operation in CNG
Stations.
The primary objective of implementing a CCTV system is to ensure effective surveillance of an

area under all foreseeable weather conditions and operational & safety enhancements. This shall
also create a record for post event analysis.
2.0 Scope of Supply and Services
2.1 The Bidder’s scope for CCTV Surveillance System (CSRS) includes detailed design and detailed
engineering to ensure satisfactory performance. The Bidder’s scope also includes Procurement,
Manufacture, Assembly, Integration, Factory/Shop Testing, Packaging, Forwarding, Supply,
Insurance, Custom clearance (if any), Unloading at site, Storage, Field-testing,
Installation/Erection, Pre-commissioning, Commissioning, Stabilization of the complete system,
supply of Spares, Documentation, Training, Scheduled backup & Supply of data storing media for
backup, refresher training during warranty period etc. for the successful operation of CCTV
Surveillance System. The complete requirements shall be executed with single point
responsibility.
2.2 The CCTV Surveillance System primarily includes Charged Coupled Device (CCD) type Pan–Tilt-
Zoom IP Based Cameras housed in weather proof, explosion and inflammable proof
environment, video Monitors, CCTV Cabinet with Network Recording System, Control System,
CAT6 Network System, Software for operation, control, utility software for infrastructure
management, like network & security management, Video Analytics Application Software,

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Encoders, Network Video Recorder, all necessary accessories and fitting hardware,
brackets/poles together including foundation /piling, masonry/civil work, Installation. The Bidder
shall also include such of those items and accessories not mentioned here but required for
satisfactory operation of the system for security, surveillance.
2.3 This document is intended to define the minimum requirement for the design of the CSRS for supply
and installation of complete field work including all necessary network switches, cables, patch
cords, adaptors, junction boxes along with support, GI conduits, ducts, trenches including road
crossings for entire CNG complex.
2.4 Preparation and submission of all necessary documents during various stages of the project as
listed in this tender document.
2.5 Training of Owner’s operating, security as well as maintenance personnel for complete system.
2.6 Inspection and testing of all components, sub-assemblies and complete assemblies of items
manufactured at Bidder’s works, and other sub-Bidder’s works in accordance with approved
QA/QC procedure.
2.7 Obtaining all necessary approvals, authorization and certification from local government / local
statutory bodies, authorized inspector and third party inspection agency as applicable.
2.8 Bidder shall include in the bid, list of specific deviations, separately, if any, to this specification and
all attachment thereof, otherwise, the offer will be deemed to be in compliance with complete
tender and its attachments and subsequent claims for extra scope will not be considered.
2.9 The scope of supply also includes the commissioning/start up, mandatory spares and special tools.
2.10 The quantity of various items mentioned in this tender document may vary +/-10%. Bidder shall
accommodate these changes with out any cost implications.
2.11 Bidder shall incorporate all the necessary changes in the sequence of operation for CCTV
Surveillance System (CCTV) at site as per GGL/MECON’s requirement.
2.12 CCTV Surveillance System (CCTV) shall have capability to integrate with GGL’s specific computer
systems with out any additional cost to GGL for remote monitoring of system through internet.
2.13 The CCTV System should have sophisticated tracking analytics with powerful filtering to detect
significant activities in the station and alert approaching or breaching perimeters, people running
or loitering, left item / abandoned baggage alarm etc.
2.14 The offered system shall have facility of exporting any portion of stored clipping for a desired period
on CD/DVD or USB supported external drive (pen drive, portable hard drive etc.)
2.15 The Closed Circuit Television System (CCTV system) shall provide an online display of video & IR
images on monitor. Remotely controlled cameras with suitable lenses shall be used to view
specific areas of interest.
2.16 32” LED-LCD video display shall be provided with suitable mounting bracket /supports and
connected to the NVR shall be located at Control Room/ Office room as instructed by GGL.

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2.17 The cameras envisaged for CNG Station in areas of hazardous nature shall be of Explosion proof
type.
2.18 The UTP Cables shall be Cat 6 or better and as per industry standard.
2.19 The Cameras shall be connected through IP onto a dedicated LAN/common network with video
recording, archiving and management system and global viewing of these installation wise
across the CNG Station on the CCTV LAN/ Network.
2.20 The “Schedule of Quantities” lists all the possible items, however any balance items which are not
explicitly spelt out here, but are required to make the system complete in all respects and meet
the technical requirements in this tender document shall also be included under the respective
items. Bidder shall list out the same and submit it with the offer.
2.21 Power Supply requirement of the CCTV System shall be from a UPS Distribution system. For this
purpose, One No. of UPS supply feeder of 230V, Single phase shall be made available to the
successful Bidder, at the Control Room. Further distribution shall be in the scope of the Bidder.
3.0 Applicable Codes, Standards, Abbreviations & Definitions
3.1 International Codes and Standards
3.1.1 The CCTV Surveillance System (CCTV)) shall be designed, manufactured, assembled and tested in
accordance with the latest codes standards of the Standards Institution, Institute of Electrical
Engineers and Manufacturer's association of the country where they are manufactured / country
of principals. They shall also conform to the relevant standards of the Bureau of Indian Standards
(BIS) wherever applicable, so that specific aspects under Indian conditions are taken care.
3.1.2 The CCTV Surveillance System (CCTV) shall also conform to the latest Indian Electricity Rules as
regards safety, earthing, Ethernet surge & lighting protection and other essential provisions
specified there in for the installation and operation of electrical equipments.
3.1.3 Entire CCTV Surveillance System (CCTV) & all equipment shall comply with the statutory
requirements of the Government of India and the State Government of Karnataka.
3.1.4 The Bidder shall execute the job to comply with the requirements of the relevant regulations or acts
in force in the area together with design specifications with respect to:
a. Indian Factories act
b. Regulations laid down by Factory Inspector of State Indian Standard Specifications
c. Oil Industries Safety Directorate norms.
3.1.5 All design, materials, equipment, construction, workmanship and installation shall conform to or
exceed the requirements of applicable sections of the codes, standards and references as listed
below:
3.1.6 The equipment specified is to be designed in accordance with the applicable standards listed below.
a. Bureau of Indian Standards (BIS)
b. International Electro-technical Commission (IEC)

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c. Institute of Electrical electronic Engineers (IEEE)
d. Instrumentation Society of America (ISA)
e. National Fire Protection Agency (NFPA)
f. Open Software Foundation (OSF)
3.2 Conflicting Requirements
In the event of any conflict between the tender documents and related standards and codes or
any other attachment to this tender, the Bidder shall follow the following documents in the order
of their priority:
a. Statutory requirements.
b. Tender documents.
c. Codes and standards.
In case of contradiction between any specification, Bidder shall refer the matter to GGL/MECON
for clarification. GGL’s decision in this regard shall be final and binding.
3.3 Precedence of Codes, Standards and Specifications
It is the main responsibility of Bidder to inform the GGL/MECON of any deviations from or
exceptions to the listed specifications, codes and standards. Non-listing or non-specification of
exception(s) or deviation(s) by Bidder in the bid proposal document will be taken by
GGL/MECON, as being in full compliance with the specifications, codes and standards listed.
If there is a conflict between the various codes, standards, specifications and the attached
drawings, the following shall govern:
Bidder shall seek GGL/MECON’s final interpretation of any conflicts prior to the execution of
work.
Rework of engineering and relevant scope arising out of underestimation shall be done at no
additional cost to the GGL.
As a minimum, all equipment shall be designed, manufactured and delivered in accordance with
the relevant section of the national/international Codes, Standards and Regulations as listed
above. The latest editions of Codes, Standards including all addenda, supplements
4.0 General Service Conditions
4.1 Indoor Control Room Requirements
4.1.1 The CCTV Cabinet /Control room will be air-conditioned.
4.2 Power Supply
4.2.1 The Power supply for the CCTV System shall be from UPS system at one point with 230V AC +/-
5%. based on the requirement and sizing calculation. Further providing power distribution board
with required MCBs for power distribution to the CCTV System and modification in existing UPS
DB in existing CNG stations to feed power to new supplied UPS DB to cater power to CCTV
system shall be in Bidder’s scope.

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4.2.2 Failure of any critical unit/ component of the system eg. Cameras, NVR, Communication systems
etc., annunciation shall be provided in the CCTV Video display monitor. The hardware, software,
cabling and terminations for this, shall be in scope of the Bidder.
4.3 RFI/EMI Immunity
Radio Frequency Interference (RFI) and Electro Magnetic Interference (EMI) requirements in
accordance with IEC 61000-4 shall be strictly followed.
4.4 Transient and Surge Protection
All cameras and field devices shall be protected from high voltage and lightning surges through
use of SPDs. The system shall internally be protected against system errors and hardware
damage resulting from
• Electrical transient on power wiring,
• Electrical transient on signal wiring,
• Connecting and disconnecting devices or removing or inserting printed circuit boards in the
CCTV Surveillance System (CSRS).
4.5 Noise Limit
Where applicable, equipment noise limits shall comply with equipment noise level-standard
specification of ISA and local statutory regulations. In no case it should exceed 78 dB for outdoor.
4.6 Earthing
4.6.1 Each cabinet shall be provided with segregated earthing systems. Segregation shall be as follows:
• Electronic or Instrument earth: The instrument signal cable shields shall be connected to the
instrument clean/signal ground earth bar.
• Electrical safety and cabinet steelwork earth: The safety-grounding from all doors, racks,
gland plates and other metallic device shall be connected to safety earth bar.
• CCTV System earthing shall be connected to Electronic Earthing System.
4.6.2 The Bidder shall hence ensure that all requirements for system earth and earth bonding are
considered and included in the system. Bidder’s earthing arrangements in cabinets should be in
accordance with electrical standards.
4.6.3 All doors, swing frame and removable cabinets shall be provided with earth studs, which shall be
strapped to the main frame using flexible braided copper wire.
4.6.4 Screens for field cables shall be connected to the clean earth on the termination cabinet only.
Screens for cables from other control cabinets shall be connected in the system. Screens for
inter system cables shall be connected at one end only.
4.6.5 All instrument chassis earth in the field is in Bidder’s scope of supply.
4.6.6 The Following minimum degree of Protection as per IEC 60529 shall apply to all the Instrumentation
equipment.
• Indoor Equipment/Panel-IP 42
• Outdoor Equipment/Panel/JB-IP 66/IP65

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5.0 Closed Circuit Television (CCTV) System
5.1 General :
5.1.1 Bidder shall engineer, supply, install, test and commissioning the CCTV Surveillance System
(CCTV) at the CNG Station. The purpose of the CCTV System is to monitor the facility operations
& security surveillance from location such as control room, security office place to keep eye on
major operational areas of importance to the daily running of the station & perimeter by installing
cameras for round the clock monitoring, resulting to enhancement in the Operational & Safety
needs.
5.1.2 It is intended to install CCTV system with video analytics for object tracking, Material movement,
Recognition of persons and objects including vehicles, people/vehicle counting, motion detection
& tracking, object classification, loitering, camera tampering, trespassing, virtual tripwire, etc.,
through high quality images inside the station. The recording of the scene can be used in
investigation, recreating the scene and establishing the truth.
5.2 CCTV Requirements
5.2.1 The complete CCTV system with all required accessories, video connectors, patch connectors,
patch leads, mounting and fitting hardware, plugs, sockets, and any hardware/software, supply of
cables, network components, etc. as required for complete installation of the System under this
contract.
5.2.2 The CCTV system shall consist of outdoor ex-proof and weatherproof high speed day night fixed
cameras with integrated vari focal lens & dome type PTZ cameras, colour 32”LED-LCD Video
display monitors and control keyboard located in control room (CR) and at Security Room/control
room as instructed by GGL.
5.2.3 The CCTV System shall be based on a digital network solution that enables video, data and/or
audio streaming over an IP network.
5.2.4 The system shall support both, digital IP and analogue cameras incorporating video encoders,
network video recording system, digital and/or analogue monitors with backup, control keyboard,
display unit and all necessary equipment for the required applications.
5.2.5 The entry and exit points perimeter walls, station activities shall be constantly monitored through
High sensitive CCD cameras using fixed focal length/ zoom lens (as required) and motion
detection software.
5.2.6 All cameras shall be linked to the unit or local security control room through Virtual Matrix which
shall enable the operator to switch on any camera on any monitor by a simple drag and drop
action.
5.2.7 Pictures from various cameras locations shall be displayed on Video monitors on a programmed
sequence and in short selectable time intervals with facility of automatic switch over to the area
of intrusion or threat on receipt of alarm signal from the effected sensor(s).

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5.2.8 Facility shall be provided for multi-view display on Video monitor. It is also possible to have free
enlarged view and freezing of picture on video monitor from any camera and also its video
recording if required.
5.2.9 The system shall be scalable to accommodate future addition of Cameras.
5.2.10 The cameras shall be mounted suitably on MS poles or Guy Wire Supported Tower or Self
Supported Tower of adequate height (to fulfill hazardous area requirement as per Oil/Gas
Industry norms.)
5.2.11 All accessories and fitting hardware such as brackets / poles together with associated masonry work
are included in the scope of work. No separate payment would be made under this head.
5.2.12 The cameras shall be provided with ID date/time stamp generators & create tamperproof records
for post event analysis.. The cameras shall be designed to withstand all weather conditions,
including storm. The IP rating and mounting details shall therefore take this into consideration.
5.2.13 GGL/MECON shall confirm areas of CNG Station to be monitored during detail engineering;
however, the cameras shall cover the areas as indicated in the enclosed typical drawing as
minimum, and are indicative, bidder to finalize exact location based on site conditions like line of
sight, maximum area coverage & no blind spot/area etc. Based on the bandwidth requirement
per camera, the No. of cameras per loop shall be finalised including consideration of 20%
bandwidth for future.
5.2.14 The CCTV system should permit a minimum recording of 15 days of each camera. As a default, the
video signal recording shall be configured based on the change of movement only to minimise
the memory usage & traffic loading on the network, however based on operational needs &
during system setup it shall be configured for continuous recording for selected cameras.
5.2.15 The network video recorder shall be installed that shall allow the storage of time-lapse and time
stamped digital video images from all cameras.
5.2.16 System should facilitate viewing of live and recorded images and controlling of all cameras by the
authorized users. The Authorization shall be using a Pass Word.
5.2.17 All necessary cables including Power, networking and video / communication cables shall be
considered which shall be laid in GI Conduits & Mounting structures and accessories shall be
provided by the Contractor as per requirement.
5.3 CCTV System Description
CCTV Equipment
5.3.1 The CCTV central control equipment and NVR shall be installed in a standard cabinet located in the
Control Room. This cabinet shall also house all the termination equipment required for the CCTV
monitor and the interface equipment.
5.3.2 At each location, video signals and camera control signals from each camera shall be routed
directly on a local Ethernet to a video unit using CAT6 cable. All cameras on each location shall

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be powered through power cable. The video unit shall also control the zoom, and alarm functions
for each local camera.
5.3.3 Cat6 UTP cable and the3CX 2.5 mm2 Power cable shall be laid directly from the CCTV rack located
in the electrical Room to each camera. Complete cabling & cabling accessories are in the scope
of bidder. Bidder shall provide interface equipment between the CCTV cameras and video unit
equipment. This interface equipment shall allow video from each camera to be transmitted to CR.
5.3.4 Bidder shall provide all the interfacing hardware and software necessary with this equipment to
enable control room operators and maintenance personnel to monitor and control all cameras of
the facility.
5.3.5 Mounting of fixed & PTZ cameras shall be engineered and provided on structures /poles. Poles
shall be designed as per IS 875.The scope includes supply, erection and installation, supply of
suitable brackets / stands , wiring , necessary civil works, etc, In case existing or new structures
is available then cameras shall be installed on it. The mounting location need to be firmed up
during detail engineering.
5.3.6 The CCTV system shall be IP based possible for viewing at 4 CIF as a minimum & of 1.3 mega pixel
as maximum resolution and recording of video at 4 CIF and configurable FPS based on camera
locations with H-264/MPEG-4 compression format. Bidder to quote for total storage capacity of
min 4 TB,
5.3.7 System supplier & Manufactures shall submit country of origin for all items listed in SOQ. Due to
prime importance of reliability of entire system, GGL/MECON reserves the right to emphasis on
particular country of origins to bidders.
5.3.8 All software and firmware upgrades shall be free of charge during the Warranty period. Vendor
should ensure backward compatibility with all the hardware and other software.
5.3.9 The warranty shall consist of repairing/replacing defective parts for a period of 2 years from the date
of supply.
5.4 TECHNICAL SPECIFICATIONS
5.4.1 CCTV Camera Specifications — Fixed type
Sl. Features /Parameters

No.
1. Camera shall be IP based 1/2” or better CCD/CMOS with 54OTVL resolution,

color, progressive scan, day/night. The camera shall have IR filter which shall
switch from colour to monochrome automatically by either sensing the
illumination level or via the alarm input.
2. Camera should have the feature of MPEG-4 & H.264 compression
3. The camera shall have wide dynamic range & 18-bit or better advanced digital
signal processing maximizes the information visible in the picture even with

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strong backlighting. Camera should have the feature of 2-way audio
4. Camera should be able to capture up to 21 fps at 704 X 576 (4 CIF) / full 1280
x 1024 mega pixel resolution.
5. Camera should feature with the following functions of
 Auto white balance

 Auto exposure
 DC auto iris
 Configurable compression ratio
 Support for multi data-stream.
The camera shall have smart BLC to compensate the image without
compromising the dynamic range.
6. Camera must have the features of I/O control of alarms, lighting
7. The camera should also have a Programmable day/night settings and

automatically switch to enhanced low-light conditions.
8. Camera should have the capability of Image transfer via HTTP, FTP or RTP
9. The feature of the Camera control should be such that it must function via
HTTP, XML-RPC, Telnet or Microsoft COM
10. Camera should have the feature of Security / password protection
11. Camera should have the following FCC Class B, CE & UL Certification of
equivalent
12. Camera should be CS lens mountable standard, C-mount adapter Should be

provided along with the mount.
13. Camera should be Compatible with all Operating Systems, (Windows’TM

Windows 2008, Linux and Mac)
14. Dynamic Range of the camera should be of 55 dB or better.
15. The Light Sensitivity of the camera should be of the range of 0.5 lux at F 1.0
approximately.
16. Camera should have Auto Exposure and Manual exposure facility
17. Camera should have the features of both Automatic / Manual White Balance
facility.
18. Power Consumption of the camera shall be in the range of 6 W
19. Operating Temperature of the camera should be of the range of 0°C to +50°C
(environmental enclosure should be provided for extended temperatures with

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fan / heater) as applicable if necessary.
20. Non-condensing Operating Humidity of the camera should be of the range of

5%-95%,
21. Interface Connector of the camera should be with RJ45 10/100 baseT
Ethernet compatible
22. Lens Mount should be Adjustable CS-Mount
23. Extended Memory Option should be an added feature to the camera
24. Camera must have the feature of Intelligent camera offering real-time video
analytics at the camera head
25. Camera having the capability of Detailed monitoring of a scene — alerting

when suspicious activity is occurring should be an added feature.
26. Camera must have the feature of enabling surveillance operators to make
more proactive decisions as and when necessary.
27. The camera should have I/O connector and must have the feature to provide
an interface to an external alarm sensor or control of peripheral equipment
such as IR lights and E-mail or UDP alarm notification providing the date and
time stamping.
28. The camera IP address and On-board memory buffers must have the feature
to supply still images via FTP that precede and follow with alarm events.
29. The camera must also have True day/night module providing automatic sliding
IR cut filter, providing outstanding night time performance.
30. Alarm setting & trigger of alarm under configurable options such as detection
of motion, loss of video & tempering of camera. Communication & visualization
of alarms with on/off/mute configuration on client stations.
31. Outdoor Fixed Box camera Housings, 18” aluminum outdoor housing, 1P66
rated with sunshield &heater, 12-24VAC
32. For hazardous area installations - Outdoor Fixed box camera Flame proof
Housings as per 1S 2148 group I, IIA, IIB /IEC and Weather proof As per IS
13947 and general design as per IS 13346 for Flame proof housing.
33. POWER TRANSFORMER MODULE ASSEMBLY
34. Voltage Input
Fuse 24 VAC or 24 VDC

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Lightening Protection 1.25A
Surge Protection Required
The offered Still CCTV Built-in

camera shall have FCC,
Class B, CE,ClassB, UL/cUL
Listed, C-Tick, NEMA Type
4X, IP 66.types of
certifications and
approvals
5.4.2 CCTV Camera Specifications —Weatherproof & Flameproof PTZ Camera
The weatherproof CCTV camera pan and tilt drive system shall be a totally integrated system
consisting of an integral receiver/driver, environmentally sealed enclosure components, variable
speed/high speed pan and tilt drive unit with continuous 3600 rotation, and on-screen
programmable auto-focus camera optics package. It shall be designed for weatherproof areas,
and it shall be designed to mount horizontally.
The outdoor CCTV camera pan and tilt drive system shall meet or exceed the following
specifications, defined by pan and tilt drive unit, camera, lens, and operation.
Sl. Features Parameters

No.
A PAN AND TILT DRIVE UNIT SPECIFICATIONS
1. Construction Aluminum Weatherproof IP 66
Patterns: Four user-defined programmable patterns

including
pan, tilt, zoom, and preset functions; pattern
programming through control keyboard or
through dome system on- screen menu.
2. Pan Movement: 360° continuous pan rotation.
3. Tilt range -5° to 185° unobstructed.
4. Manual Pan Speed 0.10 to 80°/sec manual operation, 150°/sec

Turbo.
5. Manual lilt Speed 0.10 to 40°/sec manual operation.

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6. Preset Pan Speed 400°/sec.
7. Preset Tilt Speed 200°/sec
8. Preset accuracy 0.45°
9. Presets: 128 minimum
10. Zones 16 zones
11. Tours 4
12. Remote Reset Required
13. Password Protection: Programmable settings with optional

password protection
B HIGH RESOLUTION COLOR IP BASED CAMERA/OPTICS
1. Image Sensor ¼” inch progressive scan CCD OR ¼” inch

CMOS, colour
Signal Format NTSC /PAL
2. Scanning System 2:1 interlace / Progressive.
3. Effective Pixels 752(H) x 582(V) for PAL & 768(H) x 494(V) for
NTSC
4. Horizontal Resolution 540 TVL I 450 TVL
5. Focal length 3.4 -119 mm
6. Zoom 35 X optical zoom, 12X digital zoom
7. Zoom focus accuracy +/- 0.45%
8. Focus Automatic with manual override
9. Sensitivity (PAL) 0.025 lux at 1/1.5 sec (Colour)
10. Sync System Internal / AC line lock, phase adjustable

through remote control, V-sync
11. White Balance: Automatic with manual override
12. Iris Control Automatic with manual override
13. Gain Control Automatic/off
14. Video Output: 1 Vp-p, 75 ohms

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15. Video Signal to Noise: >50 Db
16. Day & Night Operation Required
17. Auto Image Stabilizer On/Off
18. Scene Change On/off
19. Auto Tracing On/Off
20. Cooling Fan Shall be available
21. View Material Polycarbonate / Or as per OEM
22. Mounting Shall be mounted on Pole with suitable

bracket s & FRP canopy
C CERTIFICATIONS
1. Weather Proof Cameras FCC, Class B, CE, Class B, UL/cUL Listed, C-

Tick, NEMA Type 4X, IP 66
2. For Flameproof Cameras CCOE certified for Zone -2, Group IIA/IIB
5.4.3 Networking Video Recorder
Network Video Recorder shall receive live video data from any/all camera sources, store live video
in the storage hard disk, playback and control. NVR shall be ONVIF compliant.
* Main Processor High performance

* Functions Live, recording, playback, backup
* Control Mode USB mouse, Keyboard, Network
* IP Camera Input 16 Channel Intelligent Analysis Process
16ch 720P@3M / 16ch 1080P@4M
* Output HDMI, VGA. Resolution upto full HD
* Recording Encoding: H.264 CBR VBR, Bit rate: 8Mbps or better
Frame rate: 25fps/30fps, Resolution: upto full HD
* Playback Sync Playback, Time/Date/Alarm Search Mode,
Complete playback functions with camera selection
and zoom.
* Network RJ-45 port, Ethernet TCP/IP
* Storage 4TB HDD, supports to expand upto 8TB.
Support for backup on USB device.
* Support • Privacy masking, camera title, motion detection, time
function, recording, video loss, camera lock, alarm,
scheduling.
• Viewing Live Video: Single Camera, multi camera
view
• Camera self-diagnostics and failure reporing.
* Video Display Two nos. of 24” HD LED LCD video monitor displays
for monitoring purpose and connected to the NVR with

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required cabling.
* Certification UL, CE
5.4.4 LCD Display Screen

No.
1. Monitor Minimum 32” TFT LED-LCD Colour Flat

screen Monitor
2. Resolution 1,920 x 1,080 pixels
3. Display Colours (approx.) 1,064 million colours
4. Pixel Pitch (H x V) 0.485 x 0.485 mm
5. Brightness 700 cd/m2
6. Contrast Ratio 3000:1
7. Active Screen Area 9302 x 523.3 mm (36 5/8” x 205/8”)

(WxH)
8. Response Time 8 ms (gray to gray, avg.)
9. Computer Input Video / Analogue RGB (0.7 Vp-p) [750],

Digital (conforms to DVI 1.0 standards)
10. Synchronization Horizontal/vertical separation

TTL: positive/negative), Sync
on green, composite sync
(TTL: positive/negative)
11. Plug & Play VESA DDC2B
.12. Power Management VESA DPMS, DVI DMPM
13. Video Colour System NTSC (3.58 MHz, 4.43 MHz), PAL, PAL60,
SECAM
14. Input Terminals PC/AV Video / DVI-D 24-pin (HDCP

compatible), Analogue mini D-sub 15-pin,
Analogue BNC
15. PC/AV Audio 3.5 mm-diameter mini stereo jack x1
16. Video BNC x 1

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17. S-Video Component BNC (Y, Cb/Pb, Cr/Pr) x 1
18. HDMI (HDCP compatible)
19. Audio RCA pin (L/R) x 2
20. Output Terminals Computer Signal / DVI-D 24-pin(HDCP

compatible, PC/AV signal)
21. Audio RCA pin (L/R)
22. Speakers 10W + 10W (60)
23. Input/output Terminals LAN Port
24. RS-232C sub 9-pin (input x 1, output x 1)
25. Speaker Output 10W + 10W
26. Mounting VESA (6 points), 200 nn (77/8”) pitch, M6

screw or VESA (4 points), 200 mm (7 7/8”)
pitch, M6 screw
27. Power Supply 100V to 240 V AC, 50/60 Hz
28. Main Accessories required Power cord (3pin*5, approx. 3 m), remote
controller and batteries (AAA size x 2), CD-
ROM, operation manual, stand hole
protection cover x 2, vertical sticker
(operation panel) x 1, vertical sticker (logo)
x 1,blankstickerx 1, cable clamp x 2
29. Remote Control Infra Red Remote with Control Function

Required
30. Mounting Shall be suitable for rigid support mounting

from Wall.
5.4.5 Video Encoder
Sl. Features
No.
1. MPEG 4/ H.264 Advanced Simple Profile Video encoder capable of dual

encoding of real time image at maximum resolution.
2. The video encoder shall have Microsoft Windows Operating system or

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embedded Linux on the encoder itself.
3. Encoder must have a built in firewall. It must support IP filtering
4. The video encoder must incorporate a separate host processor and video
processor to provide best quality video even at maximum processor loads.
5. The host processor will be responsible for MPEG4 / H.264 audio, Video
Analytics, Activity Controlled Frame rate, Alarms, Serial (PTZ) and Network
communication. The host processor must not perform any video Operations
to ensure that video is unaffected during maximum processor load.
6. The offered Encoder, control centre software and Analytics software shall
be of same make only.
7. The Video Frame rate shall be 25 /21 FPS per channel at all resolutions
Configurable to 1.3 mega pixel & 4 CIF based on cameras & under high
motion for clear video images
8. Shall support and configure following resolution
9. 704 X 576 (4 CIF)
10. 704 X 288 (2 CIF)
11. 352 X 288 (CIF)
12. 1280x960 (1.3 mega pixels)
13. Each stream must allow independent configuration of bit rate, frame rate, I
frame interval, rate control mode and motion data. All streams must still
guarantee full frame rate under high motion.
14. The video encoder must support full frame rate video and adjusts the quality
dependant on the level of motion in the scene.
15. Shall have Activity Controlled Frame Rate (ACF) or other advanced
mechanism Control to minimize the storage and bandwidth utilization. With
ACF or Other advance mechanism, during periods of very low motion, the
frame rate will drop to 1 fps (approximately 20kbps) and when motion
occurs the frame rate will return to full frame rate (25fps/21fps) within
100ms. It must be Configurable using a Region of Interest editor (ROl) that
can select regions of he scene where the motion will be ignored.
16. Support network protocol 802.3 and IETF Standards,

10/100 Base-T Ethernet, RTP/RTCP,TCP, UDP, ICMP, SNMP, HTTP, FTP,
TELNET, MULTICAST, ARP and IGMP

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17. Each stream Bit-rate shall be user configurable from 32 to 4096 Kbps
18. Shall have 4-Alarm inputs- opto Isolated, and 2-Relay Outputs
19. Type of licenses - Dongle / Hardware lock I Paper
5.4.6 Managed Ethernet Switch-16 Port
All cameras and the NVR shall be connected to the L2+ Switch, which shall be managed 16-port
switch.
* Fully managed 16port switch
* Layer 2 and 3 switching capabilities
* 16no. RJ-45 autosensing 10/100/1000/10000 port, Full & / Half Duplex
* 1no. RJ-45 10/100/1000/10000 port (uplink)
* IEEE 802.3af compliant device.
* Power budget available to all ports to suite 16 cameras.
* MAC address table size 10000 entries
* Switching capacity 10 Gbps
* Rack-mountable
* LEDs: Power, Fault, Per-port LEDs to view of status, activity
* Physical security – Front-panel buttons to disable reset and clear buttons on front
panel for added security
* Certification: CE & UL
* Temperature: 10° to 35° C; Relative Humidity: 20% to 80% (non-condensing);

Voltage: 110V~230V AC
5.4.7 15 U Rack

No.
1. 15U height with basic steel 15U height with basic steel frame
frame
2. Construction, should be welded, Top& Bottom cover to

the frame with cable entry cut out facility

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and should be DIN std. 10mm Sq Slots.
Front Door Should Lockable toughened

glass door
3. 19” Mounting angle should be provided with

steel- powder coated
6.0 CCTV Installation, Testing and Commissioning.
6.1 Scope of Installation Work
6.1.1 The scope of installation work includes, but not limited to, installation of CCTV system as per the
specifications and Scheduled of Quantity (SOQ) attached in this tender document.
6.1.2 Installation of all instruments along with necessary stanchions/supports that are in the Bidder’s
scope of supply as well as laying, dressing, glanding and termination of all signal, control and
power cables.
6.1.3 Minor civil works like chipping of pavement and grouting on the pavements the instrument panels /
supports / stanchions and chipping, refilling and finishing of the pavement for conduits.
6.1.4 Painting of all structural supports for trays, pipes, junction boxes, instruments, ducts, trays etc., as
per painting specification.
6.1.5 Grounding of shield of all shielded cables to respective instrument earth bus provided in the control
room / JB’s.
6.1.6 Laying and termination at both ends between instrument earth buses provided in control room to
instrument earth pit provided by others.
6.1.7 Supply free of cost of all types of consumables required for the execution of the job.
6.1.8 The GGL/MECON representative shall have free access to Bidders facility and those of all major
Supplier/Vendors facility at all times.
6.1.9 Inspection and testing shall be carried out at the Supplier/Vendor’s work place and shall be
witnessed by GGL/MECON representative.
6.1.10 Based on this document, Bidder shall submit full testing procedure for factory testing, site testing
and acceptance procedure for GGL/MECON approval. For hardware, the procedures shall
include purpose of test, test definition of input, procedure, result expected, and acceptance
criteria. For software, it shall include details of the method, list of tests, sequence of execution,
result expected, and acceptance criteria.
6.1.11 The testing and acceptance of the system shall be carried out on the mutually agreed procedures
and criteria based on this specification and Supplier/Vendors standard procedures.

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6.1.12 Complete cabling for CCTV system inside the buildings shall be concealed. Supply & installation of
conduits & wall finishing is by bidder.
6.1.13 Supply of all necessary cable laying accessories including GI conduits, PVC pipes/channels, cable
trays, supporting structures, clamps, identification tags, ferrules etc required for laying of cables.
The Bidder shall include in scope, any excavation work required for lying of cables.
6.1.14 Civil works such as chipping / cutting of floors/wall for making grooves, making holes/opening
through walls, ceiling or floors, drilling of holes through steel structures and frames, grouting of
frames, hooks on walls/ceiling etc for concealed cabling as would required/necessary for
execution of work. After erection, surface shall be made good by plastering / painting to their
original shape and finish. Road cutting, if any, shall also be resurfaced and brought to their
original shape and finish for complete CCTV systems.
6.1.15 Testing and configuration of network equipment as per finalized and approved scheme.
6.1.16 The testing shall involve end-to-end testing.
6.1.17 The bidder would carry out the work of re-dressing, re-laying and commissioning under the
supervision of MECON/GGL.
6.1.18 The bidder would ensure and take care not to damage any false ceilings (if any) while laying the
cables and other electrical cables passing through the ceilings.
6.1.19 All the civil work & other related jobs for installation of the cabinet would be carried out by the
successful bidder. The required materials would be provided by bidder only.
6.1.20 The bidder should provide all the service support and components/ replacement during the warranty
period.
6.2 CCTV Cable
6.2.1 All CCTV distribution cables shall be fire retardant. This requirement is for all cables associated with
the CCTV system including the power feed cables, fibre optic video cables and data cable for
controlling camera.
6.2.2 All multi-core CCTV cables shall include 20% of spare pairs for future expansion.
6.2.3 Bidder shall lay cables for various items as defined in the scope of this tender document outside
control room in field for various instruments/systems as well as inside control room.
6.2.4 Conduits shall be sealed on both sides with anti-rodent sealant. All cables shall be rodent resistant
and fire retardant type.
6.2.5 All Ethernet cables outside the buildings shall be CAT6 armoured, rodent resistant and fire retardant
type.

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6.2.6 All cables lay in duct/ tray shall be properly dressed and tied with aluminum clamp. Suitable cable
clamps shall be provided at every 500 mm interval on vertical trays and 2 meters on horizontal
trays. Clamp shall consist of formed Aluminum flat.
6.2.7 All cables (including system cables) shall be tagged at both the ends i.e. at origination and
destination end. Cable tags shall be used for identification and shall be securely fastened to the
cables. All wiring termination shall have proper ferrules and full direct, cross ferruling shall be
used. Ferrules shall be printed with white sleeves and black text.
6.3 CCTV cabling, conceal conducting
6.3.1 Cabling for All CCTV system & monitors installed shall be concealed. Supply, installation & finishing
of concealed area are by CCTV bidder. Other cabling & accessories required to make complete
functional system is also by CCTV Bidder. Bidder is responsible to supply the hardware and shall
interface with other system & Bidder to verify the requirements.
6.3.2 A minimum of 20% installed spare terminals shall be provided in panel and spare cable entries shall
be provided.
6.4 The signal and power cables should be segregated. No cable shall be left on the floor.
6.5 No electrical power cables except UPS and DC shall be routed through the CCTV Equipment room.
6.6 All the cables should be brought to the cabinets and terminated with a proper clamping and with
weatherproof double compression type cable glands. No seal fittings shall be used.
6.7 All cables shall have sufficient mechanical strength and shall be guarded against electrostatic,
electromagnetic and radio-frequency interference. Each cable shall be properly tagged prior its
entry in the cabinet.
7.0 Acceptance Test
7.1 Factory Acceptance Test (FAT)
7.1.1 The FAT shall be a thorough and complete functional test of the hardware and software of the entire
CCTV Surveillance system.
7.1.2 Bidder shall conduct inspection after completion of all work, including equipment burn-in and pre-
FAT test performed as appropriate. Pre-FAT test report shall be submitted to the Owner prior to
FAT. Bidder shall give Owner advance notice of at least fifteen (15) working days before the FAT
is conducted.
7.1.3 Bidder shall demonstrate the functional integrity of the system hardware and software.
7.1.4 No material or equipment shall be transported until all required tests are successfully completed and
certified ‘Ready for Delivery’ by the GGL/MECON. Or waived by the GGL/MECON in written
confirmation.

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7.1.5 GGL/MECON reserves the right to be involved and satisfy himself at every stage of inspection.
7.1.6 GGL/MECON shall be free to request any specific test on any equipment considered necessary by
him although not listed in this specification.
7.1.7 Bidder shall note that acceptance of any equipment or the exemption of inspection or testing shall in
no way absolve Bidder of the responsibility for delivering the equipment, which meets all the
requirements specified in the specification.
7.1.8 The FAT shall be conducted at Bidders/Contractors manufacturing facility. Bidder shall provide a
place, complete with acceptable office facilities for the GGL/MECON representative(s) for the
duration of the FAT.
7.1.9 All tests shall be conducted utilizing only equipment that will eventually be shipped to the Owner.
Use of “replacement” units during any part of the FAT will not be allowed.
7.1.10 Any defects found during the FAT shall be rectified in the presence of the GGL/MECON In the event
this is not possible, a checklist shall be prepared stating all outstanding items for approval by the
Owners Inspector.
7.1.11 It shall be Bidders responsibility to modify and/or replace any hardware and modify the software if
the specified functions are not satisfactorily achieved during testing and factory acceptance.
7.1.12 The equipment shall not be shipped until all discovered defects have been rectified and
satisfactorily re-tested. The following test shall be included into the FAT as a minimum:
a. Power Supply tests
b. Processor tests
c. Functional and signal tests
d. All communication interfaces
e. Electrical noise immunity
f. Radio Frequency Interference
g. Dimensional checks
7.1.13 The factory inspection shall be carried out as follows:

a. Bidder shall perform in-house testing prior to GGLMECON witnessed FAT to assure smooth
testing during the FAT.
b. Bidder shall then systematically, fully, and functionally test all the hardware and software in
the presence of GGL/MECON representative/inspector. All systems shall be interconnected
to simulate, as close as possible, the total integrated Telecommunications system.
c. All hardware must be inspected for physically damaged components and general
workmanship standards. Particular note should be made of:
 Wiring loops and terminations
 Quality of earth and power connections
 Ease of access for maintenance work.
 Door seals and paint finish with reference to the final site environmental conditions.
 Printed circuit board connections to backplanes in card cages
 Plug and socket connections.
 Robustness of supports, frames, and circuit boards

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7.1.14 A number of tests must be carried out on the completed system. The following tests are a minimum
requirement and shall be carried out on the total deliverable system hardware and software,
including commissioning spares. The system shall be fully configured to provide all functions as
detailed in the Specification. Any external system interfaces must be adequately simulated by
Bidder equipment.
7.1.15 Shock Test and Vibration Test During this inspection, a simple shock vibration test shall be carried
out on a number of lugs, sockets, terminal blocks, and printed circuit board backplane
connections to ensure that a reliable and secure connection is provided. The shock test shall be
performed on an operational system by tapping the aforementioned components with an
insulated device. Care shall be exercised so as not to damage the equipment. Any abnormal
effect of the system shall be investigated and rectified be Bidder
7.1.16 Supply Power Variations This test shall be conducted to verify the ability of the system to
compensate for input power variations without impairment of system performance. The following
power variations shall be applied on an operational system for a minimum of 20 minutes each.
System functional performance shall be monitored for abnormalities at the system displays :
a. Maximum specified voltage and nominal frequency.
b. Minimum specified voltage and nominal frequency.
c. Maximum specified frequency and nominal voltage.
d. Minimum specified frequency and nominal voltage.
e. Input power interruption with nominal voltage and frequency before and after interruption.
7.1.17 Functional Test : Functional testing is largely dependent on individual system requirements. The
system shall be subjected to tests sufficient to determine its compliance with all functional
requirements specified in this Specification. The following tests shall be performed, where
applicable:
7.1.18 Operator Interfaces

a. All specified operator commands & display requests shall be exercised. The response to all
commands shall be verified to be correct and within the specified response times.
b. Particular attention should be paid to commands under restricted access by means of key
locks or passwords. The specified security access level shall be verified for all commands.
c. All operator and system displays shall be demanded and examined for compliance with the
Specification. Where displays are accessible be various routes, all such routes shall be tested
and display cross references and indices shall be checked.
7.1.19 Maintenance
Procedures specified by SUPPLIER/VENDOR in the maintenance manual(s) for maintenance of

equipment shall be carried out to ensure that all specified adjustments and other maintenance
work could be conducted in a safe and reliable manner.
7.1.20 Electrical Test
The following test shall be performed on all electrical and electronic modules and systems:
Functional test of all electronic modules, test for short circuits, and test for ground faults.
Verification that terminal and wiring coding is in accordance with the panel drawings.
7.1.21 System Failures

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Tests shall be carried out in order to verify that redundant systems operate as specified, i.e.
changeover to back-up occurs correctly and is annunciated to the operator. Operator displays
and diagnostics identifying the particular failed sub-system shall be checked as sufficient. The
following redundant sub-systems are typical.
a. Redundant Equipment
Where applicable, failures of main equipment in turn shall be simulated. Failures should be
simulated:
- By interruption of the equipment power supply for sufficient duration to cause the equipment
reset condition.
- By manual reset of the equipment
- Check the auto activation of the back-up equipment.
b. Redundant Power Supplies
Failures on each power supply in turn, within a redundant system shall be simulated by
isolating the supply. Functional performance of the system shall be verified as satisfactory
with the minimum number of redundant power supplies in operation. Where battery back-up
supplies are employed, the primary supply shall be completely isolated and correct operation
of the battery supply shall be verified. This test shall be carried out on both system battery
supplies and memory retention batteries.
c. Degraded Operations
The capability of systems providing reduced operations following particular sub-system

failures shall be tested.
Degraded system operations shall be verified as meeting project requirements.
d. System Diagnostics
All standard system diagnostics provided by Bidder shall be performed including both
resident and non-resident diagnostic software.
e. Typical diagnostics include:
Memory tests
Communications tests
Printout tests
Display character tests
Where practicable, faults shall be simulated to verify correct diagnosis and monitoring by
system diagnostic routines.
7.2 Test Documentation
7.2.1 Bidder shall supply a full set of deliverable documentation before the start of FAT. As a minimum,
the following shall be supplied:
a. The Specification and relevant drawings
b. Draft set of operator and maintenance manuals
c. Test Plan and Test Specification for factory acceptance tests

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d. Summaries of all previous testing including Supplier/Vendor tests
The usefulness and purpose of documents shall be major consideration. For example, the
operating manual must include clear and concise instructions for the typical operations, while
technical manuals shall be detailed, complete, and accurate. Modifications carried out during the
test period shall be detailed appropriately in the documentation.
7.3 Coverage Area Design and Testing
During detail engineering, Bidder shall perform coverage prediction calculation for the proposed
locations and to design the CCTV systems according to the coverage area requirement
stipulated in this document. The coverage prediction calculation shall be verified and tested
during actual installation. Blind spots and intermittent areas shall be identified and tested against
prior to proceeding with Operation Field Trail.
7.4 Operation Field Trail
Operation Field Trail shall be a test for a continuous operation of the system. This test shall
demonstrate the availability of the service for a period of twenty (20) days on a 24 hours per day
basis, in accordance to the Availability Criteria specified herein.
7.5 Test Equipment
7.5.1 Bidder shall provide all test equipment required to complete the works. All test equipment shall be
ensured to work properly under the environmental and other external conditions of the site works.
7.5.2 Bidder shall provide all test equipment, required for timely and uninterrupted start-up and
performance testing/acceptance, and for warranty period of the system. Test equipment list,
description, quantity and type shall be submitted for review and approval.
7.5.3 All test equipment shall be calibrated in accordance to manufacturers’ recommendation and
applicable industry standards prior to the start of the test. All test certificates shall be submitted
for review.
7.6 Site Acceptance Test (SAT)
7.6.1 SAT shall be performed at site during hook-up and commissioning.
7.6.2 Bidder shall be responsible for and shall provide the technical work force necessary for the
supervision of the tie-in connections of the power cables for the system equipment, serial link
cables, and the telecommunications cables to the cabinets. However, Bidder shall be responsible
for the supply of special tools and all wiring (i.e. supply, install and terminate) within the CCTV
System equipment.
7.6.3 Bidder shall provide test kit to allow complete testing of system per module.
7.6.4 Bidder shall be responsible for the correct installation and hook-up of the complete equipment.
Bidder shall then load the system and application software and shall demonstrate the system
functionality to verify system conformance with the requirements to the satisfaction of Owner.

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7.6.5 Owner shall reserve the right to instruct Bidder to carry out a repeat of any or all of the tests
performed during FAT.
8.0 Project Execution Plan and Schedule
Bidder shall submit complete project plan and schedule with activity break-up, supply schedule
and manpower deployment schedule. Schedule shall be complete on all respect and shall be
based on minimum 10 hrs /per day and 6 days/week. However, based on work front availability
and schedule requirement, bidder shall arrange to work for 24 hrs a day. Detailed schedule shall
be submitted for approval of owner/consultant after award of contract.
9.0 Spares
9.1 For cabinets, there shall be 20% spare wired up to the terminals of field cable. Additionally, 20%
spare space shall be provided for installation, in future.
9.2 The installed CCTV system, including all the nodes required to interface to the required systems
shall have 25 percent node expansion capability for future development, and still be capable of
meeting the requirements of this specification.
9.3 Consumable spares shall be supplied along with system required for minimum three months
duration after Site acceptance test.
10.0 Commissioning Spares
Commissioning spares shall be supplied as required for commissioning the complete system and
the same shall be included in Bidder’s offer. The commissioning spares shall be as per
recommendation of sub vendors/suppliers and these shall be available at the time of
commissioning.
11.0 Engineering Activities
11.1 Preparation and furnishing of all drawings and documents as per the requirement and approved
drawing list for further approvals from GGL/MECON.
11.2 Documentation, training, preparation and submission of as built drawings.
12.0 Availability criteria/Performance Guarantee
12.1 System Availability
12.1.1 The CCTV Systems shall provide 24 hours a day service on a year round basis. Bidder shall design
and service the system to accomplish these requirements, including as necessary: redundant
equipment, on site spares, level of spares, service locations and special test procedures or any
other suitable mechanism.
12.1.2 Bidder shall provide a minimum “average monthly availability” of 99% with an average service
restore time of 12 hours and a maximum no greater than 24 hours.
12.2 Performance guarantee

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All supplies and installations shall be covered under guarantee for satisfactory performance for a
period of 2 years. During the guarantee period, all system & equipment level defect diagnosis,
replacement of defective parts, modification to hardware & software and rectification of defects
shall be within the Contractor’s agreed contract price and no extra payment towards replacement
shall be allowed. The Contractor, at his own expense shall provide all materials / services
necessary for diagnosis/ rectification / repairs of equipment & systems which are under
guarantee period of this contract.
13.0 Maintenance tools & Equipments
Bidder shall provide maintenance tools and equipment as recommended by the

Manufacturer/Supplier to provide field maintenance on the equipment and for making field repairs
of the Radio Systems. The maintenance tools shall be supplied with a proper toolbox.
14.0 Spare parts
14.1 Bidder shall supply the spare parts for the Commissioning and Start-up Spares for the complete
CCTV System.
14.2 Bidder shall include in the proposal, separate and individually priced the following categories of
spare parts and tools.
a. Start-up and Commissioning spares
b. Two-year operational spares
c. Capital spares
d. Special tools and equipments
14.3 Start-up spares shall include all items required during start-up and commissioning period.
14.4 Operational spares shall take into account related factors of equipment reliability, effect of
equipment downtime on production and safety, cost of parts, and availability of service facilities.
14.5 Owner shall be continuously informed of the new upgrades/versions of software, hardware, and
firmware.
14.6 Bidder shall guarantee that spare parts for the system shall be available for a minimum of fifteen
years. After this period, if Supplier/Vendor discontinues the production of spare parts,
Supplier/Vendor shall give at least twenty-four months notice prior to such discontinuation so that
Owner may order his requirements of spares in one lot.
14.7 All spare parts furnished by Bidder shall be wrapped and packaged so that they will be preserved in
original, as-new condition under normal conditions of storage and shall be properly tagged and
coded so that later identification as to intended equipment usage will be facilitated.
14.8 They shall be packaged separately, clearly marked as “Spare Parts.” Packing lists shall be furnished
so that the parts can be handled without un crating if desired.
14.9 The operational spares shall be categorized into the following:

a. Consumable Items
Normal wear and tear items required for routine preventive maintenance. Delivery to
commence on receipt of order and completed within 15 days.

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b. Critical Items
These items are critical to the operation of the equipment. Failure will cause the unit to be out
of commission. Delivery to commence in five (5) days and completed in fifteen (15) days on
receipt of order.
c. Non-Critical Items
The failure of these items reduces some function or eliminates a safety system, but they will
not cause the entire unit to be out of service. Delivery will commence in five (5) days and
completed in thirty (30) days on receipt of order.
d. Non-Stock/Long Lead Items
These items are available at full factory lead-time only.
e. Repair Kits/Replacement Components
Items listed are repair kits or replacement components for item (c) and (d). Delivery to
commence in five (5) days and completed in thirty (30) days on receipt of order.
15.0 Training
15.1 Bidder shall provide maintenance training and operation program for the CCTV System for the
Owners personnel. The training shall be both on-the job and classroom sessions. The training
shall be designed to familiarize the operators and the users on the operation of the Systems
services being provided.
Training shall as minimum shall cover the followings:
a. Theory and functional design of the System.
b. In depth understanding of the System components
c. The operation of the System
d. Start-up and Shut-down of the System
e. Maintenance of the System.
f. Data Backup on media, retrieval of specific data based on date or event from backup.
The training shall be of sufficient detail to allow Owners personnel to perform the operation and
maintenance of the CCTV system.
16.0 Documentation
All documentation for a complete system shall comply with the project requirements. Bidder shall
submit technical documents particularly drawings and specifications in a grouped, orderly fashion
for review, acceptance, and installation. Groups of drawings shall be submitted together. English
language
shall be used exclusively. Multilingual markings, instructions, inscriptions etc., are NOT
acceptable.
17.0 Safety
17.1 Bidder to strictly follow the safety work procedures and safety regulations of GGL/MECON and as
mentioned else where in the bid document.

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17.2 Entire Bidder work force team shall be well aware of job safety requirements and they must have
under gone the safety training and refresher training periodically.
17.3 Bidder shall provide complete range of PPE (Personal Protective Equipment) to his workforce team
and all PPEs shall be as per IS code.
17.4 The Bidder shall be responsible for all arrangements with respect to work men’s compensation
insurance and any other local regulations covering the labour employed.
17.5 The Bidder shall also make available all sort of medical aid, first aid facilities and all personal
protective equipments for his workers at site.
17.6 Particular attention is drawn to the following:

 In case of accident, the MECON/GGL shall be informed in writing forthwith. The Bidder shall
strictly follow regulations laid down by Factory Inspector, government and Local Authorities
in this regard. The Bidder shall report immediately in triplicate to the owner/consultant any
accident at site involving loss of life. Each such report shall include the information as
required by the regulations.
 Compliance with statutory requirements for inspection and testing of all lifting appliance such
as cranes, gantries, etc. and auxiliary lifting gear.
18.0 Quality Assurance
18.1 The Bidder shall maintain an effective quality system. A concise description of the Bidders system
and its proposed application to the scope of work, including references where applicable to a
quality manual or similar authorised company document, is required with the quotation.
18.2 A List of documents, in dossier form, shall be retained as evidence or proof that the product or
service supplied complies with specific requirements.
18.3 A quality plan, indicating the verification activities that will be applied in order to achieve the required
quality will be required to be submitted for approval.
19.0 Preservation and Storage
19.1 These instructions are applicable for complete project cycle from engineering, design, test, supply,
installation, commissioning and giving satisfactory acceptance test. Hence all the equipments
and materials covered in this tender, shall be carefully preserved, stored and handled by the
Bidder at his works, during transportation as well as at Owner site till the successful completion
of project.
19.2 At site, Bidder shall arrange by own, the facility for proper storage of all equipments and material
supplied as part of the system. Manual and mechanised handling shall be also carried out by
Bidder.
19.3 The equipment shall only be packed for shipment, once major deficiencies, if any, have been
corrected. Bidder shall be solely responsible for the adequacy of the preparation for shipment
provisions with respect to materials and application, and to provide equipment at the destination
in ex-works condition when handled by commercial carriers.

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19.4 Separate, loose, and spare parts shall be completely boxed. Pieces of equipment and spare parts
shall be identified by item number and service, marked with Bidder's order number, tag number,
and weight, both inside and outside of each individual package or container. A bill of material
shall be enclosed in each package or container of parts.
19.5 One complete set of the installation, operation, and maintenance instructions shall be packed in the
boxes or crates with equipment. Packing list with all details shall be pasted on each crate or box.
20.0 Site Management
20.1 The Bidder shall keep on site during all working hours a responsible person, thoroughly familiar with
the class and nature of the work to be performed as per tender. This responsible person will be
deemed to have full authority to receive and to pass onto the Bidder's other employees all
instructions relating to the work under the terms of the contract.
20.2 The Bidder shall arrange skilled, semi-skilled and unskilled labour, Supervisory staff, Engineer,
Stores personnel and other clerical staff required to complete all the work as specified in this
tender. All technical personnel assigned to the site by the Bidder shall be fully conversant with
the supplied system and software package. Their qualification and experience detail shall be
submitted along with offer and for approval by owner/consultant after award of tender.
20.3 Any instructions given by the "Engineer In-charge" (owner/consultant representative) to the
responsible person shall be deemed to have been given to the Bidder.
20.4 The Bidder shall carry out the work in accordance with the standards listed herein and in
accordance with any local statutory regulations.
20.5 All tools and tackles including welding sets, gas cutting sets, ladders, scaffolding etc. in required
quantities for carrying out the work uninterrupted shall be provided by the Bidder, to meet the
target completion date. Also consumables as necessary and listed below but not limited to, shall
be provided by Bidder
a. All industrial gases like oxygen, acetylene or inert gases, compressed air and all types of
electrodes, brazing rods, flux etc. for welding purposes, with necessary facilities for testing
the welded joints.
b. Teflon tape, insulation tapes and other pipe jointing compounds for threads and material for
sealing of cable entries to control room, local panels, insulation tapes, sealing compounds for
explosion proof conduit fittings.
c. Structural steel, MS plates, GI plates, Flats, pipe etc., required for fabrication of supports
(instruments, tray etc.)
d. Bolts and nuts for supports, U-bolts with nuts, clamps for SS tubes, expansion bolts (pinch
anchor / Rawl bolts) for various sizes for fixing to concrete structures.
e. Paints, primers and solvents.
f. All accessories for electrical wiring like cable lugs, ferrules for identification, cable ties,
aluminum clamps with nuts and bolts etc.
g. Spool pieces and blinds for testing, wherever required.
h. All materials for civil works etc.
20.6 The Bidder shall also include for vehicles including automobiles for personnel transportation, pick up
trucks, cranes, welding machines, ropes, winches, ‘D’ shackles etc. at his own cost. Security of
Bidders equipment and materials is his own responsibility.

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20.7 It shall be entirely Bidder's responsibility to also provide all types of erection aids, machines, testing/
checking equipment, cranes, scaffoldings, etc. necessary to perform the work in, safe and
efficient manner and complete the job as per time schedule indicated. The Bidder shall submit
appropriate test and calibration certificates for the above as required by owner/consultant.
20.8 The Bidder shall not allow rubbish and scrap materials from his operations to lay about the site.
Such rubbish and scrap shall be collected daily and be deposited at a place approved by the
"Engineer In-charge".
20.9 Upon completion of the work, the Bidder shall promptly remove his equipment and return to the
relevant place and any unused free issue materials supplied by the "Engineer In-charge".
20.10 In the event of the Bidder is unable to maintain the target completion dates, he shall increase the
strength of any of the above category of personnel, tools, tackles and equipment as advised by
owner/consultant. When asked by owner/consultant / Engineer-In-Charge, Bidder shall work in
shifts
21.0 Approved Vendor List
21.1 Approved vendor list is available with this tender document, for CCTV items and accessories.
Bidder shall adhere to this list.
21.2 Approved vendor list provided in the tender document is for the manufacturer name only, and not for
any specific model.
21.3 The Bidder should submit Authorization letter from the Original Equipment Manufacturer (OEM) for
the offered Cameras devices and Enterprise Level Software.
Sl. Description of the item Approved vendors

No.
1 CCTV CAMERAS PELCO,VIVOTEK,HONEYWELL,INDIGOVISION,DIVIT

EL, BOSCH, SONY, MOBITIX
2 VIDEO MONITORING PELCO,VIVOTEK,HONEYWELL,INDIGOVISION,DIVIT

SOFTWARE EL, BOSCH, SONY, MOBITIX
3 ENCODER PELCO,VIVOTEK,HONEYWELL,INDIGOVISION,DIVIT
EL, BOSCH, SONY, MOBITIX
5 LCD PANASONIC,SONY,SAMSUNG,SHARP,LG
DISPLAYSCREENS-
INDUSTRIAL GRADE,
SUITABLE FOR 24 X 7
OPERATION
6 NETWORK RUGGEDCOM,MOXA,HIRSCHMAN, ENTRON,

SWITCHES,MEDIA PHONIEX
CONVERTERS(OUTD
OOR INDUSTRIAL

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GAIL GAS LIMITED

GRADE)
7 NETWORK NORTEL,CISCO, ALLIED TELSYN,BROCADE

SWITCHES,MEDIA
CONVERTERS(INDOO
R)
8 UPS(ONLINE) DB ELECTRONICS,TATA LIBERT,FUJI,EMERSON

POWER,APC HI-REL ELECTRONICS,APC
9 FIBER OPTIC LUCENT-

CABLES(SINGLE & AT&T,FINOLEX,DLINK,HCLCOMNET(COMMSCOPE),
MULTI MODE) SIMON, TYCO, MOLEX, ADS-KRONE
10 PATCH CORDS(FIBRE/ LUCENT-

UTP) AND PASSIVE AT&T,FINOLEX,DLINK,HCLCOMNET(COMMSCOPE),
COMPONENTS SIMON, TYCO, MOLEX, ADS-KRONE
11 CABLES/POWER ASSOCIATED CABLES PVT.

CABLES LTD.,DELTON,FINOLEX,ASSOCIATED FLEXICABLES
& WIRES,DIAMOND,NICCO,RELIANCE
ENGG.,CORDS CABLES, THERMO CABLES
12 SYSTEM RITTAL,STAHL, SUDHIR SWITCHGEAR, BALIGA,

PANELS/CABINETS & FLAMEPACK
ACCESSORIES
14 TERMINAL BLOCKS PHONIEX,WAGO,WELDMULLER, CONECTWELL
15 MINIATURE CIRCUIT MDS, MERLIN GERIN-SCHNEIDER ELECTRIC,

BREAKERS SIEMENS

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CNG COCO Station Tender

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GAIL GAS LIMITED

BENGALURU, KARNATAKA (INDIA)

CITY GAS DISTRIBUTION PROJECT AT BENGALURU

COMPOSITE WORKS OF CNG COCO STATIONS & CNG STATIONS IN OMC

OPEN DOMESTIC COMPETITIVE BIDDING

Bid Document No.: MEC/23RT/01/51/D2/T51/ER/0016

E-Tender no.: 6000001380

PREPARED AND ISSUED BY

GAIL GAS LIMITED

PART-I : Civil, Structural and Architectural Work

PART-II : Electrical and illumination Work

PART-III : Mechanical Work

PART-IV : Instrumentation Work

PART- V : Typical CNG station

GAIL GAS LIMITED

SPECIFICATION FOR CIVIL & ARCHTECTURAL WORK

1. CIVIL, STRUCTURAL AND ARCHITECTURAL WORKS

GAIL GAS LIMITED

SPECIFICATION FOR CIVIL & ARCHTECTURAL WORK

1.3. SITE WORK

1.4. SCOPE OF WORK

GAIL GAS LIMITED

SPECIFICATION FOR CIVIL & ARCHTECTURAL WORK

2. PREAMBLE TO SCHEDULE OF RATES

GAIL GAS LIMITED

SPECIFICATION FOR CIVIL & ARCHTECTURAL WORK

GAIL GAS LIMITED

SPECIFICATION FOR CIVIL & ARCHTECTURAL WORK

 Consumption of liquor and smoking shall not be permitted on the site.

 The site shall be illuminated at night when there is work in progress.

 Contractor shall keep the Owner and Consultant completely indemnified by

2.1. SITE CLEARANCE

a. Dismantling of all existing structures in brick masonry/stone masonry/

GAIL GAS LIMITED

SPECIFICATION FOR CIVIL & ARCHTECTURAL WORK

d. Provide all assistance/co-ordination/liaison between any and all government/

2.2. EARTHWORK IN SITE GRADING, EXCAVATION & BACKFILLING FOR PLOT

Brief description of major items shall be as follows:

a. Taking pre-work and finished levels.

GAIL GAS LIMITED

SPECIFICATION FOR CIVIL & ARCHTECTURAL WORK

2.3. EARTH WORK IN FILLING

a. Taking pre-work and finished levels.

2.4. SAND FILLING AND STONE SOLING

a. Taking pre-work and finished levels

GAIL GAS LIMITED

SPECIFICATION FOR CIVIL & ARCHTECTURAL WORK

2.5. PCC WORK

Following works shall be inclusive in the rate of PCC item:

2.6. REINFORCED CEMENT CONCRETE - SUB STRUCTURE

Brief description of major items shall be as follows:

GAIL GAS LIMITED

SPECIFICATION FOR CIVIL & ARCHTECTURAL WORK

2.7. REINFORCED CEMENT CONCRETE - SUPER STRUCTURE

Brief description of major items shall be as follows:

a. Providing shuttering and strutting of all types

2.8. REINFORCEMENT STEEL

GAIL GAS LIMITED

SPECIFICATION FOR CIVIL & ARCHTECTURAL WORK