PHT MARKET, UPPAL DG WORKS

TENDER FOR EXTERNAL ELECTRICAL WORKS

1. SPECIAL CONDITIONS

2. SI TE S A FE T Y R E Q UI R E M E NT S

3. TECHNICAL SPECIFICATIONS

Chapter 1 DG SETS

Chapter 2 RECOMMENDED MAKES OF MATERIALS

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1. SPECIAL CONDITIONS

1. General:

1.1 These special conditions shall be read in conjunction with the description of the item of
work in the Bill(s) of Quantities, the particular Specifications, Local Statutory Regulations,
Indian Standards Specifications/Codes and the drawings. All the above quoted documents
shall be considered supplementary to each other. However, in the case of conflict amongst
the various provisions, the owner's and the consultant’s opinion will be final and shall be
adopted.

1.2 The tender is advised to inspect the site to ascertain the nature of site, access thereto,
local facilities for procurement of materials and working labour rates prevalent in the area,
in fact all matters affecting his prices and execution of the work. The tender shall be
deemed to have full knowledge of the site and drawings whether or not he actually inspects
them.

2. Rates

2.1 The rates quoted shall be deemed to allow for all minor extras and constructional
details which are not specifically shown on drawings or given on the specifications but are
essential in the opinion of the Engineer-in-charge to the execution of works to confirm to
good workmanship and sound engineering practice. The Consultant/Employer reserves the
right to make any minor changes during the execution without any extra payment.

2.2 The Consultants decision to clarify any item under minor changes, minor extras and
constructional details shall be final, conclusive and binding on the Contractor.

2.3 The rates quoted by the Contractor shall be net so as to include all requirements
described in the contract agreement and no claim whatsoever due to fluctuations in the
price of material and labour will be entertained.

2.4 The rates quoted by the Contractor shall include for supplying materials and labour
necessary for completing the work in the best and most workmanship like manner to the
satisfaction of the Consultant/Employer and which in the opinion of the Consultant cannot

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be made better, and for maintaining the same. The rates shall be complete in all respects
also including cost of materials, erection, fabrication, labour, supervision, tools and plant,
transport, sales and other taxes royalties, duties and materials, contingencies, breakage,
wastage, sundries, scaffoldings, etc., on the basis of works contract. The rates quoted
shall include all taxes, duties, transport, insurances, octroi, or any other levies applicable
under the statute.

3.0 Materials:

3.1 The Contractor shall ensure to the satisfaction of the Consultant/Employer that
the materials are packed in original sealed containers/packing bearing manufacturer’s
markings and brands etc., except where the gross quantity required is a fraction of the
smallest packing. Materials not complying with this requirement shall be rejected.

3.2 Testing of Materials:

a) When required by the Consultant, the Contractor shall provide all facilities at site or at
manufacturer's works or in an approved laboratory for testing the materials and/or
workmanship. All the expenditure in respect of this shall be borne by the Contractor unless
specified otherwise in the Contract. The Contractor shall, when required to do so by the
Consultant shall submit at his own cost, manufacturer's certificate of tests, proof sheets,
mill sheets etc., showing that the materials have been tested in accordance with
requirements of these specifications.

b) Neither the omission by the Consultant to test the materials nor the production of
manufacturer(s) certificate etc., as aforesaid shall affect the right of the Consultant to
reject, after delivery the materials found unsuitable or not in accordance with the
specifications.

4 Drawings:

4.1 Clarifications required or discrepancies, if any, noted by the Contractor in the various
drawings supplied by the Consultant must be obtained well before tendering, failing which
the decision of the Consultant shall be final and binding on the Contractor with regard to
detailing and general acceptance of the Contract.

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5.0 Rectification of Defects:

5.1 Any defect in the work done or materials used in the works pointed out by the
Consultant shall be rectified within a week or such extended time as may be allowed in this
failing which the Consultant at the risk and cost of the Contractors shall be rectified the said
defect.

6.0 Cables Layout:

6.1 All these drawings shall be issued by us and the Bidder shall execute strictly as per our
drawings. The Contractor shall study the drawings thoroughly before execution and bring
out any discrepancies in the drawings

7.0 Regulations & Standards:

7.1 The installation shall conform in all respects to Indian Standard Code of Practice for
Electrical Wiring Installation IS: 732 and IS: 2274. It shall also be in conformity with the
current Indian Electricity Rules and Regulations and requirements of the local Electric
Supply Authority in so far as these become applicable to the installation. However, in the
case of conflict amongst the various provisions the owner's and the consultant’s opinion will
be final and shall be adopted.

8.0 Shop Drawings:

8.1 The Contractor shall prepare and submit to the Consultant for the approval of
detailed fabrication drawings for Distribution Board, switch board, special any
other equipment to be fabricated by Contractor within 60 days of signing of the
contract.

9.0 Completion Drawings:

9.1 At the completion of the work and before issuance of certificate of virtual completion
the contractor shall submit to the consultant/Employer layout drawings drawn at

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approved scale indicating the complete system "As Installed". These drawings shall in
particular, give the following information.

(a) Run and size of Cables/ Busduct/trays.

(b) Location of panels/ Dg set.

(c) Size of Dg sets/ acoustic enclosures

(d) Locations of all earthing stations, routes and size of all earthing conductors, manholes
etc.

Five Sets of Prints and One set of Drawings on RTF & Soft copy shall be submitted after
completion of work.

10.0 Manufacturer's Instructions:

10.1 Where manufacturers have furnished specific instructions, relating to the

materials used in this job, covering points not specifically mentioned in the
documents, these instructions shall be followed in all cases.

11.0 Completion Certificate:

11.1 On completion of the Electrical Installation a certificate shall be furnished by the

Contractor counter signed by a licensed supervisor, under whose direct supervision the
installation was carried out.

This certificate shall be in the prescribed form as required by the local supply authority.
The Contractor shall be responsible for getting the drawings and Electrical Installation
inspected and approved by the local Authority concerned. Only Statutory Fees, if any
applicable, only will be paid and Incidental expenses will not be paid.

12.0 Qualified Competent Supervision:

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12.1 The Contractor shall employ competent fully licensed, qualified full time Engineer to
direct the work of Electrical installation in accordance with drawings and specifications.
The Engineer shall be available at all times on the site to receive instructions from
Consultant in the day to day activities, through out the duration of the contract. The
foremen shall co-relate the progress of the work in conjunction with all relevant
requirements of the supply authorities.

13.0 Sub Contractor :

13.1 If the Main Contractor proposes to subcontract the part/ whole of the Electrical/
Communication systems Work, the sub contractor’s credentials shall be submitted and get
the same approved before employment. The Sub contractor shall be licensed to execute
works unto 33KV or the class of Voltage as applicable.

14.0 Approvals from Electrical Inspectorate

14.1 The Contractor shall liaison with CEIG and PCB and obtain approval for Drawings and
Final installation.

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2. SI T E S A F ET Y REQ UI R E M E NTS

The Contractor, his Sub-Contractors and nominated sub-contractors, shall comply with the
safety precautions, protective measures, house keeping requirements, etc. The Client with
due intimation shall have the right to stop the work at site, if in his opinion proceeding with
the work will lead to an unsafe and dangerous condition. The contractor shall get the
unsafe condition removed or provide protective equipment. The contractor shall ensure
that all workmen are aware about the nature of risk involved in their work and have
adequate knowledge for carrying out their work safely.

The instructions issued herein are indicative and not exhaustive. Therefore the contractor
shall be responsible to ensure that adequate safety measures have been adopted in the
course of execution of the contract in accordance with safety standards / statutory
regulations, as applicable.

The contractor shall be held responsible for non-compliance if any of the safety measures
and delays, implications, injuries, fatalities and compensation arising out of such situations
or incidents.

1. TRAFFIC

1.1The contractor shall organize operations by taking approval to use the existing
roads, if any, from Client.
1.2The contractor shall exercise full care to ensure that no damage is caused by him
or workmen, during the operation, to the existing water supply, sewerage, power or
telecommunication lines or any other services or works. The contractor shall
provide and erect before construction, substantial barricades, guardrails, and
warning signs. He shall furnish, place and maintain adequate warning lights, signals,
etc., as required by Client.

2 . SAFE MEANS OF ACCESS

2.1 Adequate and safe means of access and exit shall be provided for all work
places, at all elevations.

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2.2 Suitable scaffolds shall be provided for workmen for all works that cannot safely
be done from the ground, or from solid construction except such short duration work as
can be done safely from ladders. Ladder shall be of rigid construction having sufficient
strength for the intended loads and made of metal and all ladders shall be maintained well
for safe working condition. Suitable footholds and handholds shall be provided on
the ladder. The ladder shall be given an inclination not steeper than 1 in 4 (1 horizontal and
4 vertical).

2.3 Scaffolding or staging more than 3.5m above the ground or floor, swung or
suspended from an overhead support or erected with stationary support shall have a
standard guard-rail properly attached, bolted, braced or otherwise secured at least 1m high
above the floor or platform of such scaffolding or staging. The guardrail shall extend along
the entire exposed length of the scaffolding with only such opening as may be necessary for
the delivery of materials. Standard railing shall have posts not more than 2m apart and an
intermediate rail half way between the floor and platform of the scaffolding and the top rail.
Such scaffolding or staging shall be so fastened as to prevent it from swaying from the
building or structure. Scaffolding and ladder shall conform to relevant IS specification (IS
3696-1966). TIMBER/BAMBOO SCAFFOLDING SHALL NOT BE USED.

2.4 Working platforms of scaffolds shall have toe boards at least 15cm in ht. to
prevent materials from falling down.

2.5 A sketch of the scaffolding proposed to be used shall be prepared prior to start
of erection of scaffolding. Safety engineer shall examine all scaffolds before using.

2.6 Safe means of access shall be provided to all working platforms and other
elevated working places. Every ladder shall be securely fixed. No single portable
ladder shall be over 9m in length. For ladders, up to 3m in length the width between
side rails in the ladders shall in no case be less than 300mm. For longer ladders, this width
shall be increased by at least 20mm for each additional meter of length. Step spacing
shall be uniform and shall not exceed 300mm.

2.7 Adequate precautions shall be taken to prevent danger from electrical lines and
equipment. No scaffolding, ladder, working platform, gangway runs, etc. shall exist

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within 3 meters of any un-insulated electric wire. Whenever electric power and
lighting cables are required to run through (pass on) the scaffolding or electrical
equipment are used, such scaffolding structures shall have minimum two earth
connections with earth continuity conforming to IS code of practice.

3. DEMOLITION

• Before any demolition work is commenced and also during the progress of the work
the contractor shall ensure that the power on all electric service lines is shut off and
the lines cut or disconnected at or outside the demolition site.

• If it is necessary to maintain electric power during demolition operation, the

required service lines shall be adequately protected against damage.

• Persons handling heavy materials/equipment shall wear safety shoes.

4. PERSONAL PROTECTIVE EQUIPMENT

All necessary personal protective equipment shall be kept available for the use of the
persons employed on the site and maintained in a condition suitable for immediate use.
Also the contractor shall take adequate steps to ensure proper use of equipment by those
concerned. The personal protective equipment to be provided by the contractor are:

a) All persons employed at the construction site shall use safety helmets.

b) Persons engaged in welding and gas-cutting works shall use suitable aprons,
leather gloves and welding face shields. The persons who assist the welders shall
use suitable goggles. Protective goggles shall be worn while chipping and grinding.

c) All persons working at heights more than 4.5m above ground or floor and
exposed to risk of falling down shall use safety belts, unless otherwise protected by
cages, guard railings, etc. In places where the use of safety belts is impractical,
suitable net of adequate strength fastened to substantial supports shall be
employed.

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5. LIFTING MACHINES AND TACKLES

5.1Use of lifting machines and tackles including their attachments, anchorage and supports
shall conform to the following standards or conditions:

Lifting machines and tackles shall be of good mechanical construction, sound material
and adequate strength and free from any defects and shall be kept in good repair and in
good working order.

Every rope used in hoisting or lowering materials or as a means of suspension shall be of

good quality and adequate strength and free from any defect.

Every crane operator or lifting appliance operator shall be properly qualified. No person
under the age of 21 years shall be in charge of any hoisting machine or give signal to
operator of such machine.

In case of every lifting machine (and of every chain, ring, hook, shackle, swivel and pulley
block used in hoisting or as means of suspension) the safe working load shall be ascertained
and clearly marked. In case of a lifting machine having a variable safe working load, each
safe working load and the conditions under which it is applicable shall be clearly indicated.
No part of any machine or any gear referred to above in this paragraph shall be loaded
beyond the safe working load except for the purpose of testing. The safety engineer shall
approve this.

The safety engineer shall note the safe working load. Regarding other machines, the
contractor shall notify the safe working load of the machine to the safety engineer,
whenever he brings any machinery to site of work and gets it verified by the safety
engineer.

Thorough inspection and load testing of lifting machines and tackles shall be done by a
competent person at least once every 2 months and records of such inspection and testing
shall be maintained.

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5.2 Motors, gearing transmission, couplings, belts, chain drives and other moving parts
of hoisting appliances shall be provided with adequate safeguards. Hoisting appliances shall
be provided with such means as will reduce to the minimum the risk of any part of a
suspended load becoming accidentally displaced or lowered. Barricades shall be erected
around the place of hoisting the equipment(s).

6. WELDING AND GAS CUTTING

6.1Welding and gas cutting operations shall be done by qualified and authorized persons
and as per IS specifications and code of practice.

6.2 Welding and gas cutting shall not be carried out in places where flammable or
combustible materials are kept and where there is danger of explosion due to presence of
gaseous mixtures.

6.3 Welding and gas cutting equipment including hoses and cables shall be maintained
in good condition.

6.4 Barriers shall be erected to protect other persons from harmful rays from the work.
When welding or gas cutting is done in elevated positions, precautions shall be taken to
prevent sparks or hot metal falling on persons or flammable materials.

6.5 Suitable type of protective clothing consisting of fire resistant gauntlet gloves,
leggings, boots and aprons shall be provided to workers as protection from heat and hot
metal splashes. Welding shields with filter glasses of appropriate shade shall be worn as
face protection.

6.6 Adequate ventilation shall be provided while welding in confined space or while
brazing, cutting or welding zinc, brass, bronze, galvanized or lead coated materials.

6.7 Welding and gas cutting shall not be done on drums, barrels, tanks or other
containers unless they have been emptied cleaned thoroughly and it is made certain that no
flammable material is present.

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6.8 Fire extinguishers shall be available near the location of welding operations. Fire safety
permit shall be obtained for working at vulnerable areas and operating areas before flame
cutting/welding is taken up.

6.9For electric (Arc) welding the following additional safety precautions shall be taken:

When electrical welding is undertaken near pipelines carrying flammables, such pipelines
shall not be used as part of earth conductor but a separate earth conductor shall be
connected to the machine directly from the job.

Personnel contact with the electrode or other live parts of electric welding equipment shall
be avoided.

Extreme caution shall be exercised to prevent accidental contact of electrodes with ground.

The welding cable shall not be allowed to get entangled with power cables. It shall be
ensured that movement of materials does not damage the cables.

7. GRINDING

7.1 All portable grinders shall be used only with their wheel guards in position to reduce
the danger from flying fragments should the wheel break during the use.

7.2 Grinding wheels of specified diameter only shall be used on a grinder – portable or
pedestal - in order not to exceed the prescribed peripheral speed.

7.3 Goggles shall be used during grinding operation.

8. HOUSE KEEPING

8.1 The contractor shall at all times keep his work site, site office and surroundings clean
and tidy from rubbish, scrap, surplus materials and unwanted tools and equipment.

8.2 Welding and other electrical cables shall be so routed as to allow safe traffic by all
concerned.

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8.3 No materials on any of the sites of work shall be so stacked or placed as to cause
danger or inconvenience to any person or the public.

8.4 At the completion of the work, the contractor shall ensure removal from the work
premises all scaffoldings, surplus materials, rubbish and all huts and sanitary arrangements
used/installed for workmen on the site.

9. FIRE SAFETY

All necessary precautions shall be taken to prevent outbreak of fires at the construction site.
Adequate provisions shall be made to extinguish fires, should they still break out.

a) Quantities of combustible materials like timber, bamboo, coal, paints, etc. shall be the
minimum required in order to avoid unnecessary accumulation of combustibles at site.

b) Containers of paints, thinners and allied materials shall be stored in a separate room,
which shall be well ventilated, and free from excessive heat, sparks, flame or direct rays
of the sun. The containers of paint shall be kept covered and properly fitted with lid and
shall not be kept open except while using.

c) Fire extinguishers shall be located at the construction site at appropriate places.

d) Adequate number of workmen shall be given education and training in fire fighting and
extinguishing methods

10. WORK IN RADIATION AREA

The contractor shall follow the stipulated procedure regarding work in the radiation area
and other works related with radiography.

11. MEDICAL FACILITIES

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11.1 The contractor shall arrange for medical aid and treatment for his staff and workers
engaged on the work site including the first-aid facilities if they are not available at the
project site.

11.2 First-aid appliance including sterilized dressing, cotton wool and antiseptic cream shall
be made available at readily accessible places at every work site. These shall be
maintained in good order under the charge of a responsible person.

11.3 At large work places, where hospital facilities are not available within easy reach of
the work first-aid posts shall be established. Ambulance availability shall be identified during
the entire period of work for attending to injury cases.

12. SAFETY COORDINATOR

The contractor shall have a Safety Office or a Supervisor to be designated as a Safety

Coordinator in order to specifically look into the implementation of different safety
requirements of the site work. The person thus designated will in general co-ordinate on
matters of safety and in particular ensure that the Safety Manual is complied with. His
name shall be displayed on the Notice Board at a prominent place at the work site.

13. REPORTING OF ACCIDENT

13.1 All accident leading to property damage and/or personnel injuries shall be reported to
the concerned authorities viz. Insurance Co. Police, Head Office, Regional Office, etc.

13.2 The contractor shall also submit a monthly statement of accidents to the Client by 4th
of every month showing details of accident, nature of injury including disability, days lost,
treatment provided, etc., and the extent of property damage.

14. PUBLIC PROTECTION

The contractor shall make all necessary provisions to protect the public. He shall be held
responsible for defense of every action of other proceedings at law that may be brought by
any person for injury sustained owing to neglect of any precaution required to taken to
protect the public.

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15.OTHER STATUTORY PROVISIONS

All operations involving the transport, handling, storage and use of explosive shall be as per
the standing instructions and conform with the latest Indian Explosives Act and the
explosives Rules. Handling, transport, storage and use of compressed gas cylinders and
pressure vessels shall conform to the latest Gas Cylinder Rules and Static and Mobile
Pressure Vessels (Unfired) Rules. In addition, The Indian Electricity Act and Indian
Electricity Rules - latest, the Atomic Energy Act, the Radiation Protection Rules - latest,
Radiation Protection Manual of Nuclear Facilities and the Atomic Energy (Factories) Rules –
latest, and various latest rules and Act related to mining shall also be strictly complied with.

16. GUIDELINES AND GENERAL PROCEDURES FOR SUPPLY AND USE OF

ELECTRICITY AT SITE

16.1 Following safety requirements shall be complied with before the contractor uses the power
supply.

16.1.1 The contractor shall submit a list of licensed electrical staff to be posted at Site.

16.1.2 It shall be the responsibility of the contractor to provide and maintain complete
installation on the load side of the supply point with regard to the safety
requirements at Site. All cabling and installation shall comply with the appropriate
latest statutory requirements given below and shall be subject to approval of the
Project Manager:

Indian Electricity Act.

Electricity (Supply) Act.

Indian Electricity Rules.

National Electricity Code.

Other relevant rules of Local Bodies and Electricity Boards.

The power supply shall be regulated as per the terms and conditions of the supply of

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the respective electricity boards.

16.1.3 Where distribution boards are located at different places the contractor shall submit
schematic drawing indicating all details like size of wires, Overhead and Cable
feeders, earthling etc. The position and location of all equipment and switches shall
be given.

16.1.4 The contractor shall make his own arrangement for main earth electrode and
tapings thereof. The existing earth points available at site can be used at the
discretion of Client with prior permission. Method of earthling, installation and earth
testing results shall conform to relevant I.S. Specifications (IS-3043).

16.1.5 All three phases’ equipment shall be provided with double earthling. All light fixtures
and portable equipment shall be effectively earthed to main earthling.

16.1.6 All earth terminals shall be visible. No gas pipes and water pipes shall be used for
earth connection. Neutral conductor shall not be treated as earth wire.

16.1.7 The contractor shall not connect any additional load without prior permission of
Client.

16.1.8 Joints in earthling conductors shall be avoided. Loop earthling of equipment shall
not be allowed. However, tapings from an earth bus may be done.

16.1.9 The entire installation shall be subjected to the following tests before energisation of
installation including portable equipment: -
• Insulation resistance test.
• Polarity test of switches.
• Earth continuity test.
• Earth electrode resistance.

The test procedures and their results shall conform to relevant standards.

16.2 Following guidelines are provided for general observations: -

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16.2.1 INSTALLATION
a. Only persons having valid wireman’s license/competency certificate shall be
employed for carrying out electrical work and repair of electrical equipment,
installation and maintenance at site. A qualified licensed Supervisor shall supervise
the job.

b. Electrical equipment and installations shall be installed and maintained as to prevent

danger from contact with live conductors and to prevent fires originating from
electrical causes like short circuits, overheating etc. Installation shall not cause any
hindrance to movement of men and materials.

c. Materials for all electrical equipment shall be selected with regard to working
voltage, load and working environment. Such equipment shall conform to the
relevant standards.

d. The minimum clearance to be maintained for all overhead lines along roads and
across roads shall be as per the statutory requirements.

e. Grounding conductor of wiring system shall be of copper or other corrosion-resistant

material. An extra grounding connection shall be made in appliances/equipment
where chances of electric shock are high.

f. Electric fuses and/or circuit breakers installed in equipment circuits for short circuit
protection shall be of proper rating. It is also recommended that high rupturing
capacity (HRC) fuses are used in all circuits. For load of 5 kW or more earth leakage
circuit breaker shall be provided in the circuits.

g. Wherever cables or wires are laid on poles, a guard wire of adequate size shall be
run along the cables/wires and earthen effectively. Metallic poles as a general rule,
shall be avoided and if used shall be earthen individually. Anti climbing guards and
danger notices shall be provided on poles. Each equipment shall have an isolating
switch.

h. Wires and cables shall be properly supported and an approved method of fixing shall
be adopted. Loose hanging of wires and cables shall be avoided. Lighting

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and power circuits shall be kept distinct and separate.

i. Reinforcement rods or any metallic part of structure shall not be used for supporting
wires and cables, fixtures, equipment, earthing etc.

j. All cables and wires shall be adequately protected mechanically against damages.
In case the cable is required to be laid under ground, it shall be adequately
protected by covering the same with bricks, Plain Cement Concrete (PCC) tile or
any other approved means.

k. Using suitable cable glands shall properly terminate all armoured cables. Using
cable lugs/sockets shall connect multi-stranded conductor cables. Cable lugs shall
preferably be crimped. They shall be of proper size and shall correspond to the
current rating and size of the cable. Twisted connections will not be allowed.

l. All cable glands, armoring and sheathing of electric cable, metal circuits and their
fittings, metallic fittings and other non-current carrying parts of electrical equipment
and apparatus shall be effectively grounded.

m. All the Distribution Boards, Switch Fuse Units, Bus bar chambers, ducts, cubicles
etc. shall have MS enclosures and shall be dust, vermin and waterproof. The
Distribution Boards, switches etc. shall be so fixed that they shall be easily
accessible. Changes shall be done only after the approval of the Project Manager.

n. The contractor shall provide proper enclosures/covers for protection of the entire
switchboard, equipment etc. against rain. Exposed live parts of all electrical circuits
and equipment shall be enclosed permanently. Crane trolley wires and other
conductor, which cannot be completely insulated, shall be placed such that they are
inaccessible under normal working conditions.

o. Ironclad industrial type plug outlets are preferred for additional safety.

p. Open type distribution boards shall be placed only in dry and ventilated rooms; they
shall not be placed in the vicinity of storage batteries or otherwise exposed to
chemical fumes.

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q Isolating switches shall be provided close to equipment for easy disconnection of

electrical equipment or conductors from the source of supply when repair or
maintenance work has to be done on them.

r. In front of distribution boards a clear space of 90 cm shall be maintained in order to

have easy access during an emergency.

s. Adequate working space shall be provided around electrical equipment, which

requires adjustment or examination during operation.

t. As far as possible electrical switches shall be excluded from a place where there is
danger of explosion. All electrical equipment such as motors; switches and lighting
fittings installed in workroom where there is possibility of explosion hazard shall be
explosion proof.

u. All connections to lighting fixtures, starters or other power supplies shall be provided
with PVC insulate, PVC sheathed twin/three/four core wires to have better
mechanical protection for preventing possible damage to equipment or injury to
personnel. Taped joints shall not be allowed and the connections may be made in
looping system. Electric starter of motors, Switches shall not be mounted on
wooden boards. Only sheet steel mounting or iron framework shall be used.

v. All the lighting fixtures and lap holders shall be of good quality and in good
condition. Badly repaired or broken holders, etc. shall not be used.

w. Only PVC insulated and PVC sheathed wires or armoured PVC insulated and
sheathed cables shall be used for external power supply connections of temporary
nature. Weatherproof rubber wires shall not be used for any temporary
power supply connections. Taped joints in the wires shall not be used.

y. The bulbs/lamps used for illumination and testing purpose shall have cover or guard
to protect them from accidental breakage. Only 24 V supply system shall be used
for hand lamps etc. while working inside metallic tanks or conducting vessels.

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16.3 OPERATION & MAINTENANCE

a. All persons, who work with electrical installation/equipment, shall be aware of the
electrical hazards, use to protective devices and safe operational procedures. They
shall be given training in fire fighting, first aid and artificial resuscitation techniques.

b. The contractor shall instruct the workers in the proper procedure, specify and
enforce the use of necessary protective equipment such as adequately insulated
pliers, screw drivers, fuse pulleys, testing lamps and similar hand tools. Only
wooden ladders shall be used to reach the heights in electrical work.

c. No material or earthwork shall be allowed to be dumped below or in the vicinity of

the bare overhead line conductors.

d. Before any maintenance work is commenced on electrical installations/

equipment,the circuits shall be de-energised and ascertained to be dead by positive
test with an approved voltage-testing device. Switches shall be tagged or the fuse
holders withdrawn before starting the work. Adequate precautions shall be taken in
two important aspects viz.

e. That there shall be no danger from any adjacent live parts and

f. That there shall be no chances of re-energisation of the equipment on which the

persons are working.

g. While working on or near a circuit, whenever possible the use of one hand may be
practiced even though the circuit is supposed to be dead. The other hand may
preferably be kept in pocket.

h. When it is necessary to touch electrical equipment (for example when checking for
overload of motors) back of the hand may be used. Thus, if accidental shock were
tocause muscular contractions, one would not ‘freeze’ to the conductor.

I. Operations of electrical equipment shall be avoided which standing on wet floor or

when hands are wet.

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j. Before blown fuses are replaced, the circuit shall be locked out and an investigation
shall be made for the cause of the short circuit or overload.

k. When two persons are working within reach of each other, they shall never work on
difference phases of the supply.

l. When structural repairs, modification or painting work are to be undertaken,

appropriate measures shall be taken for the protection of persons whose work may
bring them into the priority of live equipment/circuit.

m. It shall be ensured that the insulation and wire size of extension cords are adequate
for the voltage and current to be carried.

n. While tapping electricity from the socket, plug top must be used. It shall be ensured
that no extension boards are over loaded while tapping. Only standard three pin
plugs shall be used for tapping electricity. Broken sockets/plugs shall be replaced
immediately with good ones. Only joints free cables shall be used for connecting
equipment/ apparatus.

o. Floors shall be kept free from tailing electrical cables to avoid tripping hazard.

P. Power supply to the entire machines and lighting fixture shall be switched off when
not in use.

q. Temporary electrical connections shall be removed as soon as the stipulated work is

over. After completion of the works, the contractor shall dismantle the distribution
boards and the other facilities erected at site.

r. Unauthorized tapping of power by others from distribution boards shall be prohibited

at all circumstances.

s. No flammable materials shall be stored in any working area near the switchboards.

“MEN ON LINE” “DO NOT SWITCH ON” “DANGER” OR “CAUTION” boards as

applicable shall be used during maintenance works on the electrical equipment.

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16.4 PORTABLE ELECTRICAL EQUIPMENT

a) Portable electrical equipment shall be regularly examined, tested and

maintained to ensure that the equipment and its leads are in good order.
Register shall be maintained for inspection recording the testing dates
and results of the equipment.

b) All portable appliances shall be provided with tree core cable and three-pin
plug. The third pin of the plug shall invariably be earthen. It shall be ensured that
the metal part of the equipment shall be effectively earthen.

c) All connections to portable equipment or machines from the

panel/distribution board/extension board shall be taken using 3 core double
insulated PVC flexible copper wire in one length. No joints shall be allowed in this
flexible wire. In case single length of wire is not sufficient for a particular location
then the supply can be tapped by providing another extension board comprising of
switch and socket.

d) Flexible cables for portable lamps, tools and apparatus shall be regularly
examined, tested periodically and maintained to ensure safety.

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TECHNICAL SPECIFICATIONS
CHAPTER – 1
DG SETS

1 SCOPE

1.1 This specification defines the minimum requirements for the supply of self excited
Internal Combustion Engine driven 2No.of 250KVA emergency generator complete
with Radiator cooled, Acoustic enclosure, automatic voltage regulator, control panel,
generator breaker, and other accessories as required.

1.2 Unless otherwise specified the emergency generator shall be supplied complete with

a) Brush less excitation system complete with AVR.

a) Local control panel with AMF Relay including control cubicle and associated
auxiliary devices, generator breaker, battery and charger.
c) Any other part / accessories not specifically mentioned above but considered
necessary for safe and reliable operation.

2 CODES AND STANDARDS

Unless they are in variance with the clause of this specification the Internal Combustion
Engine driven generator system and its components shall comply with the latest edition of
the applicable standards listed below. For imported electrical equipment corresponding
local codes and standards shall apply.

IS - 2253 Designation for type of construction and mounting arrangement of rotating

electrical machines.

IS - 4691 Degree of protection provided by enclosures of Rotating Electrical Machinery

IS - 4722 Rotating electrical machines.

IS - 4728 Terminal marking and direction of rotation for rotating electrical machinery.

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IS - 4889 Methods of determination of efficiency of rotating electrical machine.

IS - 6362 Designation of Methods of Cooling of Rotating Electrical Machines.

IS - 7132 Guide for testing synchronous machines.

IS - 7306 Methods of determining synchronous machines quantities from tests.

IS - 7816 Guide for testing of insulation of rotating machines.

IS - 12065 Permissible limits of noise level for rotating electrical machines.

IS - 12075 Mechanical vibration of rotating electrical machines with shaft heights 56 mm

and higher –
measurements, evaluation and limits of vibration severity.

IS - 12802 Temperature rise measurement of rotating electrical machines.

IS - 13364 AC Generators driven by reciprocating internal combustion engines.

IS - 13947 Low voltage Switchgear and Control gear: General Rules.

IEC - 34 Rotating Electrical Machines.

The equipment shall also confirm to the provisions of Indian Electricity rules and other
statutory requirements currently in force.

In case of any contradiction between the standards listed above and this specification, the
requirement laid down in this specification shall prevail.

3. PERFORMANCE REQUIREMENTS

3.1 Site Conditions

Generator shall be suitable for operating satisfactorily in Hyderabad, Telangana conditions.

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Generator rating indicated in the Schedule shall be the net output of the set at specified site
conditions after accounting for all auxiliaries for the prime mover and generator.

3.2 Voltage Regulation

The voltage regulation of the machine shall be within ±2 % of the nominal

Voltage under following conditions:

- Between no load and nominal load with p.f . of 0.8 lag to unity.

- With the machine cold or warm.

- At a speed drops of approximately 3% of the nominal speed.

3.4 Voltage setting range

The generator terminal voltage shall be adjustable with a continuously variable

potentiometer. The adjustment range shall be ± 10% of the nominal voltage.

3.5 Unbalanced Load

The generator shall be capable of withstanding without injury the effects of a continuous
current unbalance corresponding to a negative - phase sequence current of 8 % of the
rated current for cylindrical rotor machines and 10% for salient pole machines provided
none of the phase current exceeds rated current.

3.6 Frequency Limits

The generator shall be suitable for continuous operation at rated load for a frequency
variation of ± 3 % of rated value. In addition the vendor shall furnish the short time under-
frequency operating limits.

3.7 Over Current Requirement

The generator shall be capable of withstanding without injury stator current of

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1.5 pu for 30 seconds and 1.1 p.u. for one hour.

3.8 Short circuit conditions

The generator shall be capable of withstanding with out damage, three phase or a line to
line or line to earth or two line to earth short circuit for a period of 3 seconds when
operating at rated speed and rated load and with an excitation corresponding to 5 % over
voltage.

3.9 Parallel Operation

The Generator sets shall be suitable for parallel operation with other generating sets at
operating voltage and under load conditions up to rated value.

3.10 Excitation support system

Excitation system shall be provided with short-circuit support equipment (series

compounding) to maintain three times the rated current for three seconds in case of short-
circuit to ensure proper fault clearance in outgoing feeders.

4 DESIGN AND CONSTRUCTION

4.1 The generator design shall meet the ambient conditions of Hyderabad.

4.2 The generator shall be mounted on a common base frame together with prime mover
unless otherwise agreed. The generator shall be provided with necessary lifting
hooks and two earth terminals on opposite sides for connection to main earth grid.

1. The generator winding shall be of class ‘H’ insulation with temperature limitation
for class ‘ H’. The windings and overhangs shall be braced to withstand the short
circuit forces.

2. The stator winding shall be star connected and all windings shall be brought out
to six insulated terminals in a terminal box. The stator neutral side connection shall
be brought in neutral cubicle having protection CT s. The terminal boxes for the line
terminals and neutral shall have sufficient space for the terminals of cable size

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specified in Schedule. The terminal boxes shall be complete with lugs and Single
compression cable glands. Current transformers shall be as specified in Schedule

4.5 All parts and accessories shall be suitable to withstand stresses due to over
speed/overload/short circuit conditions specified.

3. Bearings shall be antifriction, shielded and pre lubricated. Grease in the bearing
enclosure shall provide additional lubrication to bearing as well as provide sealing
against dust and moisture.

4. The generator shall be air cooled unless otherwise specified. Generator enclosure
shall be as specified in data sheet.

5. The direction of rotation of the rotor of the machine shall be compatible with that of
the prime mover. A clear indication of the direction of rotation shall be given on either
end of the machine.

4.8 Field winding shall have class’H’ insulation. The field winding shall be capable of
operating at a field voltage of 125 % of field voltage at rated load for at least one
minute starting from stabilized temperatures at rated conditions.

4.9 All cabling on the generator set skid shall be in GI perforated cable trays/ conduits.
All cables shall be identified close to their termination point. Single compression type
cable glands shall be used for cable termination.

4.10 A rating plate of stainless steel shall be fixed on the generator frame and shall give
the information as per IS : 4722.

b) EXCITATION SYSTEM

The generator shall be provided with brush less type solid state self-excitation system with
automatic voltage regulator. The excitation system shall include the automatic voltage
regulator, AC exciter and rotary rectifier.
All components shall be mounted considering the effects of the centrifugal forces.
Automatic solid state voltage regulator shall be provided with the following features as a

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minimum.
- Short circuit protection.

- Manual voltage control

- Voltage build up circuitry

- Test mode

6.1.1 Automatic mains failure scheme

This shall be effective in Auto position of Auto / Manual selector switch located in local
control panel. The generator set shall normally be at rest. Upon failure of normal supply,
an impulse shall be extended from purchaser’s equipment. Upon receipt of this impulse,
generator set shall start automatically and rated speed and voltage shall be built up. All
accessories required for starting and completion of various sequence of operation for the
above purpose shall be provided as part of DG set. Immediately after this, voltage
monitoring relay located in control panel shall extend an impulse for closing generator
breaker. The relay shall also be controllable from PLC and hence necessary control wiring
shall be brought out

6.1.2 Manual Start in service mode

This shall be effective in manual position of Auto / Manual switch and service position of
service / test selector switch located in control panel. The scheme of operation shall be
same as of auto mode as per clause 6.1.1 above except that starting impulse shall be
extended manually through the push button either in local control panel or purchaser’s
control panel.

6.1.3 Test mode

This shall be effective in test position of service / test selector switch. The scheme of
operation shall be same as that of manual start in service mode as clause 6.1.2 above
except that the closing impulse for generator breaker shall not be extended automatically.

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6.2 Shut-down
Unless otherwise specified, stopping the generator set in all cases for a normal shut down
shall only be done manually by means of push button in either local control panel or
purchaser’s remote panel.

6.3 Starting time

The total time from the receipt of the starting impulse for the generator set till reaches
rated speed and generator reaches rated voltage shall not be more than 30 seconds. If this
time is exceeded, an annunciation in the local control panel shall be provided with a facility
for repeat annunciation in purchaser’s panel.

7 GENERATOR CONTROL PANEL

7.1 The local generator control panel for the generator set shall comprise of the
following unless otherwise specified in the attached data sheet.

a)Battery charger suitable to charge 2 sets of Batteries.

Any other accessory required to make the generator set operational as a package
shall be included in scope of supply. If required the generator control panel shall be split
into various functional sections viz. metering, control, and regulation etc.
The generator breaker shall also be part of the control panel unless otherwise
specified. The breaker rating shall be as specified in the Schedule/SLD. This
breaker shall serve the purpose of local isolation. The breaker shall be in draw out
execution. In case of 415 V generators, breaker shall have four poles for isolation of phases
and neutral.

All motor starters for DG set auxiliaries if required shall be DOL type in fixed
execution with compartmentalized construction having sheet steel enclosed vertical panels
along with horizontal and vertical bus bars. All busbars shall be PVC sleeved. Each panel
shall have a separate cable alley.

Unless otherwise specified, the DC control supply required for AMF/local control

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panel and for any other purpose shall be met by DC system consisting of battery
and battery charger of suitable capacity to be supplied by the generator set manufacturer.

The battery shall be Sealed Maintenance Free lead acid, high discharge
automotive type suitable for engine starting duty and conforming to relevant IS. The
battery shall be placed on battery stands made of steel with suitable PVC coating. The
battery capacity shall be adequate for three consecutive starts of the engine under cold
engine condition, without recharging, with additional 10 % spare capacity.

The battery charger shall have 3 phase full wave controlled rectifier bridge with their
protective devices. The charger shall be of solid state design, constant voltage type with
current limiting feature suitable for automatic and manual, normal and quick charging of
batteries. The output voltage shall be stabilised to±1 % for mains variation of ± 10 % and
load variation of 0 to 100 % . Taps shall be provided on the primary side of the
transformer at ± 5% and ± 10 % rated voltage. A suitable filter circuit shall be provided at
the rectifier output to obtain a smooth Dc output voltage. The maximum ripple
content in the charger output voltage shall be lower than the safe value recommended by
battery manufacturer and in any case shall not exceed 5 % with battery disconnected. The
charger shall be sized for boost charging the battery within 10 -14 hours.

The charger shall have auto as well as manual control facility through a lockable
selector switch. In auto mode, the charger shall automatically control the battery
charging current/voltage to ensure optimum boost charging of the battery. After
completion of boost charging, the charger shall switch to float charging mode without any
manual intervention.

In the manual mode, it shall be possible to charge the battery at any desired current
which is safe for the battery. Fine control of the output voltage/current shall be possible.
In both auto and manual modes the battery charging current shall be limited to a safe value
by means of adjustable potentiometric control. A backup timer of 0-24 hours range shall
be provided for switching the charger from boost to float mode after the set time,
under any mode of operation.

The charger shall be complete with all interconnections within the panel. All
connections shall be made using 660 V grade PVC insulated wires/ cables with adequately

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sized copper conductors for power connections and copper conductor of size 1.5 mm size
for control connections.

All main and control transformers shall be class B insulated. All semi conductor
devices shall be natural air cooled with absolute case temperature limited to 75 ۬ ۬C
at highest load and ambient temperature. PCB shall be tropicalised to render them
immune to dust, moisture and fungal growth. Auto / Manual selector switch.
ON/OFF switch for incoming power supply, float/boost selector switch, potentiometer for
coarse and fine control of output voltage and backup timer shall be provided on the front of
the panel in addition to AC incoming voltmeter and ammeter with selector switch and DC
output voltmeter and ammeter. Indication lamps for AC power on (3 lamps) charger in
float, charger in boost, charge failure shall also be provided.

7.2 The generator control panel shall be free standing, metal enclosed fabricated with
cold rolled sheet steel of 2mm thickness, dust and vermin proof type with a hinged
door and having a degree of protection IP 51 unless otherwise specified. Power and
control equipment shall be segregated inside the panel as far as practicable. The
maximum height shall not be more than 2275mm. All hardware shall be corrosion
resistant and bolts, nuts and washers shall be made of galvanised, zinc passivated
or cadmium plated high qualitysteel. Unless otherwise specified the panel shall be
suitable for bottom cable entry. The Panel shall be powder coated with Siemens
grey after seven tank treatment for sheet

Necessary removable type un drilled gland plate, single compression cable glands
and cable lugs shall be provided with the panel.

All auxiliary devices for control, indication, measurement and alarm such as push
button, control / selector switches, indicating lamps, metering instruments,
annunciations etc. shall be mounted on the front door of the panel. Adequate
number of potential free contacts shall be provided in the control panel for any
remote control, monitoring of the generator set.

7.3 All switches shall be load-break, heavy duty type. All fuses shall be non deteriorating
HRC

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cartridge pressure fitted, link type. The contactors for auxiliary motor starters shall
be of air-break type having AC-3 duty rating. Thermal overload relays shall be three
element, positive acting, ambient temperature compensated type with adjustable
setting range and built in protection feature against single phasing. All indicating
instruments shall be moving iron, flush mounting type and of 72 mm x 72
mm.square pattern. As an option, vendor may offer digital meters. All
control/selector switches shall be rotary back connected type having a cam-operated
contact mechanism with knob type handle ‘Stop’ push buttons shall having a cam-
operated contact mechanism with knob type handle. ‘Stop’ push buttons shall be
stay put type.

7.4 Wiring for power, control and signaling circuits shall be done with PVC insulated
copper conductors having 660 V insulation grade. Minimum size of control
wires shall be 1.5 mm Clamp type terminals shall be acceptable for wires up to 10
mm size and for conductors larger than 10 mm bolted type terminals with crimping
lugs shall be provided. A minimum of 10 % spare terminals shall be provided on
each terminal block.

7.5 50 x 6 mm Aluminum or equivalent copper earth bus shall be provided in the panel
for connection to the main earth grid. All non current carrying metallic parts of the
mounted equipments shall be earthed. Doors and movable parts shall be earthed
using flexible copper connections.

7.6 Engraved nameplates shall be provided for all devices mounted on the front of
the panel. Nameplate or polyester adhesive stickers shall be provided for each
equipment mounted inside the panel.

8 Diesel Engine:

Diesel Engine shall be suitable for generating set application developing suitable BHP at
1500 RPM, powered by multi cylinder. The engine shall be of heavy duty type suitable for
cold starting and equipped with a minimum of the following accessories.

a) Fly wheel to suit flexible couplings with guard

b) Air cleaner

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c) Heat Exchanger with Air Cooled fluid cooler, Pipe lines, Water pumps
d) Fan with guard
e) Water pump-centrifugal type, engine mounted
f) Fuel pump
g) Fuel filter
h) Governor-Electronic type
i) Fuel injection equipment
j) Exhaust silencer (Residential Silencer)
k) Electric starting equipment comprising of starting motor on 24V DC supply
l) Lubricant oil cooler
m) Lubricant oil pump-gear type, engine mounted
n) Lubricant oil filter
o) Turbo charger (exhaust gas driven)
p) Battery charging generator with voltage regulator-24V DC
q) 24V Battery of suitable AH capacity

8.1.1 Instrument panel shall consist of:

a) Starting switch with key

b) Lubricating oil temperature gauge
c) Lubricating oil pressure gauge
d) Water temperature gauge
e) Battery charging ammeter
f) Circuit breaker
g) Safety control for low lubricating oil pressure
h) Safety control for high water temperature
I) Hour meter (mech.) and RPM indicator

The Instruments a to d & I can be mounted on the Engine itself

8.2 Base frame:

The engine alternator shall be perfectly aligned and assembled on a sturdily fabricated
adequately machined base frame, made out of high quality MS channels. The base frame
should be provided with lifting facilities and pre-drilled foundation holes suitable for
installation either on concrete foundation or with anti-vibration mountings.

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8.3 Fuel tank:

Fuel tank capacity for each set with inlet-outlet pipe connections, filling cap, drain plug level
indicator as per manufacturer’s standards

9. ACCOUSTIC ENCLOSURE:

The Enclosure shall be completely as per CPCB norms and generally consist of a self
supporting frame work built with tubular section and plain or corrugated metallic sheets and
its base shall be built of standard channel section, M.C 100x50, to support the frame work
on its own weight. The base shall be placed on the ground around the DG set without any
foundation or anchor to the ground

The panels, framework, doors and all other surfaces are finished with a rust preventing
primer. The outer surface shall be painted matt finish paint.

The enclosure shall be completely weather proof and is suitable for both indoor and outdoor
application. The DG set Control panel, Fuel tanks shall be mounted within the enclosure

Performance: The average Noise level at 1mtr from the outer surface of the enclosure shall
be maintained as per CPCB norms The Sound level shall be measured at site using a
calibrated Noise level measuring device, with all noise making loads switched off, in the
presence of Engineer-in-charge.
The Temperature rise inside the enclosure shall not be more than 5Deg.C. Over ambient
temperature. The enclosure shall be supplied by the Agencies with approval from ARI
Pune.

10 TESTS AND INSPECTION

10.1 The purchaser or his authorized Representative may visit the works during
manufacture of equipment to assess the progress of work as well as to ascertain
that only quality raw materials are used for the same. He shall be given all assistance to
carry out the inspection.

10.2 Detailed test procedures along with the facilities available at vendor’s works shall be

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furnished by the vendor.

10.3 Minimum Acceptance tests:

On completion and before handing over of the work, the following tests shall be
carried out by the contractor to the entire satisfaction of the Engineer-in-Charge.

A) Phase-I Test:

i) Insulation resistance test - Sectional and overall

ii) Continuity resistance test-sectional and overall

iii) Earth resistance test

iv) All instruments and relays shall be tested under normal operating conditions.

v) Visual examination to ensure that the plant equipment and accessories are
provided and the finish and general appearance of the work are as per contract
specification.

vi) A no load test for a period of 3 hours continuously to see that the engine,
alternator and other accessories are functioning normally.

The duration of the test may be increased if necessary and as directed by the authorized
representative of the accepting officer.

B) Phase-II Test:
On completion of the Phase-I tests to the entire satisfaction of the authorized
representative of the accepting officer. A load test shall be carried out at factory dispatch
as given below.

25% Load : 1 hour,

50% Load : 1 hour,
75% Load : 1 hour,

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100% Load : 1 hour

110% Load : 10 minutes

Similar tests to be carried out at site after erection as part of commissioning.

C) Tests on Alternator

i) Routine tests for alternator as per IS : 4722.

ii) Phase sequence test

11. PAINTING, PACKING AND DESPATCH

11.1 All metal surfaces shall be thoroughly cleaned of scale, rust, and grease etc. Prior to
painting. Cleaned surfaces shall be given two coats of primer and prepared for final
painting. Final finish shall be free from all sorts of blemishes.

11.2 The equipment shall be shipped to site suitably packed to prevent any damage
During transit. Each package shall have labels to show purchaser’s name, purchase order
and equipment no.& Suitable lifting lugs etc. Shall be provided and lifting points shall be
clearly marked on the package. Packing shall be suitable for storage at site for a minimum
period of 6 months.

11.3 Dg Set supplier should quote for Comprehensive AMC Charges for next 5years
after Defective Liability period of 12 Months/ or as per OEM Standards.

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CHAPTER 2
RECOMMENDED MAKES OF MATERIALS

MAKES OF MATERIALS FOR DG SETS

1. Alternator : Kirloskar/Stamford/ Leroy Somer / Mutsubishi

2. Engine : Cummins/ Cater Pillar/Mitsubishi/Kirloskar

3. ACB/MCCBs : Schneider/L&T/Siemens/ABB

4. LED Indications : Binay/Siemens/Vaishno/Technique

5. Digital Meters : Conzerv/ Meco/ HPL/Prok DVs

6. GCU/Relays : Cummins/ Cater Pillar/Woodward/DIEF

7. MV Cables : Asian/ Gloster/ Nicco/Unistar/Havells

8. Control Cables : Lapp/RRKable/Finolex

9. Batteries : Amaron/Nife/Exide

10. Control panel/BusDuct : CPRI ceritified

11. Current Transformer : AE/Kappa/Poweronics/Kalpa

12. Voltage Transformer : AE/Kappa/Poweronics/Kalpa

13. Push Buttons : L&T/Seimens/BCH

14. Timer : L&T/Seimens

15. Cable end Terminations : Dowells/3D

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16. Cable Gland : HMI/Comet/Braco

17. M.S/G.I Pipes : Tata/Jindal

18. Welding Electrodes : Advani/Eqvt

19. Valves : Audco/C&R/Advance/Hawa

Note : Before use of any of the above brands for the Project, Prior Written permission
shall be taken from client/Consultant. The Client shall have choice to select any of the
above approved brands.

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