PATRATUWBMSPECIFICATION - BA89015rev03 2022 03 29 01 - 38 - 41

TECHNICAL SPECIFICATION OF WET BALL MILL EQUIPMENT
(SUB ASSEMBLY OF FGD SYSTEM)

SPECIFICATION No.: BA89015
03 18.03.2022 P V S BABU AMAN KHRK

02 02.07.2021 P V S BABU AMAN KHRK
01 20.07.2020 P V S BABU AMAN SG
00 19.02.2020 P V S BABU AMAN SG
REV DATE PREPARED CHECKED APPROVED
Bharat Heavy Electricals Limited

Heavy Power Equipment Plant
Ramachandrapuram, Hyderabad - 502032
Bidder Sign and Seal

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CONTENTS
1. PROJECT INFORMATION ............................................................................................................................3

2. GENERAL DESRIPTION OF LIMESTONE GRINDING SYSTEMS ......................................................................4
3. APPLICABLE CODES & REGULATIONS .........................................................................................................7
4. INTENT OF SPECIFICATION.........................................................................................................................7
5. PROVENNESS CRITERIA: ............................................................................................................................8
6. MEDIA ANALISYS .......................................................................................................................................8
7. SCOPE OF SUPPLY (REFER ENCLOSED P&ID FOR DETAILS — ANNEXURE-4)................................................8
8. GENERAL TECHNICAL REQUIREMENTS..................................................................................................... 13
9. DESIGN AND CONSTRUCTION OF MILL AND ACCESSORIES ...................................................................... 17
10.PACKING AND FORWARDING .................................................................................................................. 30
11.SUPERVISION OF ERECTION, TESTING AND COMMISSIONING ................................................................. 33
12.EXCLUSION .............................................................................................................................................. 33
13.INSPECTION AND TESTING....................................................................................................................... 33
14.PAINTING ................................................................................................................................................ 40
15.SPARES .................................................................................................................................................... 43
16.SPECIAL TOOLS AND TACKLES.................................................................................................................. 53
17.PERFORMANCE GUARANTEES AND SCHEDULE OF GUARANTEES ............................................................ 54
18.GUARANTEED POWER CONSUMPTION ................................................................................................... 57
19.LIQUIDATED DAMAGES FOR POWER CONSUMPTION.............................................................................. 58
20.WARRANTY ............................................................................................................................................. 58
21.FIRST FILL OF CONSUMABLES: ................................................................................................................. 59
22.TRAINING ................................................................................................................................................ 59
23.CONFLICT................................................................................................................................................. 59
24.DOCUMENTATION................................................................................................................................... 60
A. DOCUMENTS TO BE SUBMITTED ALONG WITH THE OFFER: ..................................................................... 60
B. DOCUMENTS TO BE SUBMITTED AFTER CONTRACT:................................................................................ 61
ANNEXURES LIST .......................................................................................................................................... 63

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1. PROJECT INFORMATION
A Memorandum of Agreement (MOA) has been entered on 29.07.2015 amongst Govt. of Jharkhand (GoJ),
Jharkhand Urja Vikash Nigam Limited (JUVNL), Jharkhand UrjaUtpadan Nigam Limited (JUUNL),
Jharkhand BijliVitaran Nigam Limited (JBVNL) and NTPC Limited to form a Joint Venture Company of
NTPC Limted& JBVNL for transfer of Patratu Thermal Power Station (PTPS) located in Ramgarh District
of Jharkhand State to the proposed JV Company for Performance Improvement of existing capacity & 4000
MW Capacity expansion of PTPS. Further to signing of JV agreement on 29.07.2015, a Joint Venture
Company namely Patratu Vidyut Utpadan Nigam Limited (PVUNL) has been incorporated amongst GoJ,
JUVNL, JBVNL and NTPC Ltd. on 15.10.2015. The Performance Improvement of existing capacity and
4000 MW Capacity expansion of Patratu STPS will be implemented by the JV Company (JVC). The
configuration of expansion of 4000 MW shall consist of 5 units of 800 MW to be implemented in two phases;
Phase-I: 3x800 MW and Phase-II: 2x800 MW. The present proposal is for Patratu STPS Phase-I (3x800
MW).
a) Owner Patratu Vidyut Utpadan Nigam Limited (PVUNL)
b) Buyer BHEL, Hyderabad
c) Process/Application Flue Gas Desulphurization
A) SITE CONDITIONS
Site Elevation Basis +335 meters above sea level
Barometric Pressure
Barometric Pressure
Minimum Reference Maximum
Observational Record hPa
Design Value Outdoor hPa 974
Ambient Temperature
Ambient Temperature
Observational Record Deg C
Design Value Outdoor Deg C 27 45
Design Value Indoor Deg C
Relative Humidity
Humidity
Observational Record %
Design Value Outdoor % 60
Design Value Indoor %

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Note:
1) Guarantee point site conditions shall apply for the Guarantee Values as well as for the Guarantee
test/Performance test.
2) Equipment and Material must be suitable for the range of ambient site conditions.
B) PROJECT LOCATION
Patratu Thermal Power station (PTPS) is located just outside the coal belt of South Karanpura in Ramgarh
District of Jharkhand State. The nearest Railway Station is Patratu which is at a distance of about 4 km on
Barkakhana-Barwadih Railway line.
The latitudes and longitudes of the site are as follows:
Airport
The nearest commercial airport is Ranchi at about 45 km by road.
2. GENERAL DESRIPTION OF LIMESTONE GRINDING SYSTEMS

The purpose of this system is to grind lump limestone of Size 25 mm (Max) to powder and for preparation
of limestone slurry. The duct from the limestone silo hopper feeds the limestone to the gravimetric feeder.
The Gravimetric feeder feeds limestone to Wet ball mill system. The Wet Ball Mill system consists of Wet
Ball Mill, Wet Ball Mill Lubrication system, Mill circuit tank with an agitator, Mill circuit Pump, Mill Hydro
cyclone, 3-way distributor and accessories. The Wet Ball Mill is the wet horizontal type. The Process water
is supplied to Wet Ball Mill and Wet Mill circuit Tank. Slurry from the Wet Ball Mill flows by gravity to the
Wet Mill Receiver Tank and then is pumped up to the Mill Hydro cyclone to be classified. The Mill Hydro
cyclone underflow containing the oversized material is re-circulated to the Wet Ball Mill inlet directly, while
the overflow is discharged to the Limestone Slurry storage Tank via the 3 -way distributor as a product of
Wet Ball Mill system.

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S.No. Description Requirement
1 Quantity
Quantity of Limestone Grinding Systems 2 sets (1 working + 1 standby) - common system
2 Parameters
Design Capacity of mill 87.9 TPH
Media to be Handled Limestone
Limestone Analysis Refer Clause No. 6
Type of WBM System Horizontal
Duty Continuous
Location Inside Building
3. Power Supply
The following voltage levels shall apply:
1) Design Ambient Temperature-- 50 Deg C

2) Design Ambient Temperature for equipment installed in A/C Rooms--35 Deg C
Bidder shall design and supply the equipment suitable for satisfactory operation under
above mentioned power supply condition. HT motor is in BHEL scope.

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4. CONTROL & INSTRUMENTATION SYSTEM
BASIC DESIGN CRITERIA:
When more than one device uses the same measurement or control signal, the transmitter and
other components/ module shall be fully equipped to provide all signal requirements. All the
4-20 mA output signals from transmitters/other control system shall be able to drive minimum
500 Ohms load resistance. The system shall be arranged so that the failure of any monitoring
device or control components or spurious intermediate grounding in the signal path shall not
open the signal loop nor cause the loss or malfunction of signal to other devices using the
same signal.
ENVIRONMENTAL CONDITIONS:
Instruments, devices and equipment’s for location in outdoors/indoor/air-conditioned areas

shall be designed to suit the environmental conditions indicated below and shall be suitable
for continuous operation in the operating environment of a coal fired utility station and also
during periods of air conditioning failure without any loss of function, or departure from the
specification requirements covered under this specification.

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5. Cooling water:
All lube oil cooler to be designed for cooling water supply temperature of 38 Deg C and max
temperature drop of 10 Deg C. Refer Annexure-3 for details.
3. APPLICABLE CODES & REGULATIONS
The design and materials shall conform to the requirements of applicable codes and regulations of the latest
edition (as applicable as on date of bid opening). The design, manufacturing, installation and testing of the
Lime stone Grinding System/Wet Ball Mill System shall follow the latest applicable Indian/International
(ISO/ASTM/AISI/ASME/EN/Japanese) Standards. If any other country standard used shall also be accepted
subjected to approval by NTPC, in such case bidder shall furnish adequate information to justify that these
standards are equivalent or superior to the international standard mentioned above. A copy of such standard
duly translated (complete word to word translation) in English shall be furnished by vendor.
4. INTENT OF SPECIFICATION
This specification covers the minimum requirements for the complete design, material, manufacturing, shop
inspection, testing at the manufacturer’s works, supervision of erection & commissioning and performance
guarantee testing of Limestone Grinding System along with accessories.
a. The FGD system will be provided with common limestone grinding system (LGS). 2 numbers of Wet
Ball Mill (1 working + 1 standby) shall be provided. This WBM system shall be located inside the Ball
Mill Building. Building is in BHEL scope. Refer Enclosed General Arrangement drawing –
Annexure-15
b. Bidder shall assume full unit responsibility for the entire equipment assembly and make all possible
efforts to comply strictly with the requirements of this specification and other
specifications/attachments to inquiry/order.
c. In case, deviations are considered essential by the Bidder (after exhausting all possible Efforts), the
same shall be separately listed in the enclosed Annexure-2.
d. No deviation or exception shall be permitted without the written approval of the purchaser.
e. Compliance to this specification shall not relieve the Bidder of the responsibility of furnishing
equipment and accessories/auxiliaries of proper design, materials and workmanship to meet the
specified start up and operating conditions.

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f. In case, the Bidder considers requirement of additional instrumentation, controls, safety devices and
any other accessories/auxiliaries essential for safe and satisfactory operation of the equipment, the
same shall be recommended along with reasons in a separate section and include the same in scope of
supply.
g. All accessories, items of work, though not indicated but required to make the system complete for its
safe, efficient, reliable and trouble free operation and maintenance shall also be in supplier’s scope
unless specifically excluded.
h. Bidder are requested to carefully examine and understand the specification and seek clarification, if
required, to ensure that they have understood the specification. The bidders offer should not carry any
sections like clarifications, interpretations and/or assumptions.
5. PROVENNESS CRITERIA:
The Bidders are required to meet the Qualification Requirement (QR) for Wet Ball Mill system as per
enclosed Annexure-1 & submit the Annexure to qualification requirement (Attachment-3K). Bidder’s
offers will be rejected if they fail to meet the QR.
6. MEDIA ANALISYS
The analysis of limestone, water & instrument air used in limestone grinding system in as per enclosed
Annexure-3.
7.SCOPE OF SUPPLY (Refer Enclosed P&ID for Details — Annexure-4)
Scope for the bidders shall include Design, Engineering, Manufacture, Inspection/testing as per approved
quality plans, Packing, Supply, Supervision of Erection & Commissioning, Performance Guarantee Test and
handing over of final Customer. Refer Enclosed General Arrangement drawing – Annexure-15
Design: Includes basic engineering, detail engineering, preparation and submission of engineering
drawings/calculations/datasheets/quality assurance documents/field quality plans, storage instructions,
commissioning procedures, Erection & assembly Drawings, operation & maintenance manuals, performance
guarantee test procedures and assisting BHEL in obtaining time bound approval from NTPC.

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Test: The scope of the bidder includes all shop tests, type tests, site tests, routine tests etc., fulfilment of
complete quality assurance & inspection requirement and related activities for all the equipment & systems
covered under the scope of the bidder.
Painting: The bidder scope of work includes supply of paints and painting of all equipment’s as per approved
painting schedule from NTPC.
Supervision of Erection & commissioning: Includes supervision of erection & commissioning, supervision
of startup and trial operation of the entire LGS system.
Performance Guarantee Test: the guarantee tests shall be carried out as per approved Performance
guarantee test procedure, all the special equipment, tools and tackles, instruments, measuring devices
required for successful conductance test shall be provided by bidder free of cost.
Each mill system shall be supplied by separate distribution box.
The scope of supply for each Limestone Grinding System (i.e., one set of LGS) shall include but not limited
to the following:
Sl. No. Item Description Quantity UNIT Vendor to

per Mill confirm
1. Chute from lime stone silo hopper bottom to feeder 1 NO
2. Inlet rod gate at gravimetric feeder inlet 1 NO
3. Knife gate valve at gravimetric feeder inlet with electric 1 NO
actuator (with integral starters - non-intrusive type, SIL2
certified)
4. Gravimetric feeder along with its drives and other 1 SET
accessories (complete assembly)
i. All connection chute with proper liner

ii. All connection bolts/nuts/washers for installation
iii. Required instruments and any safety device

iv. Fully closed type with opening door
5. Facility for unloading the limestone silo, through feeder, to 1 SET
a truck at ground level along with all necessary
chutes/diversion chutes and gate valve

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per Mill confirm
6. Knife gate valve (KGV) below the gravimetric feeder outlet 1 NO
chute. (actuator with integral starter; nonintrusive type SIL2
certified)
7. Chute from gravimetric feeder to ball mill inlet 1 NO
8. Wet ball mill complete (with all accessories) 1 SET
i. Horizontal Ball Mill and Speed reducer
ii. Auxiliary motor for inching operation with speed reducer,
Clutch system
iii. All coupling for connecting main motor to reducer,
inching motor to clutch and reducer, and reducer to pinion.
iv. Lubrication system with all piping and piping supports
(Piping Supports and piping design is supplier’s scope of
supply)
v. Mill Shell, Feed Head, Discharge Head
vi. Water cooling for lubrication system and gearbox
vii. Dumpster or Drum (Ball and limestone rejects)
viii. Ball charging device (Tripping Device) &Ball
Charging Hopper. Vendor to supply (Hoist for lifting &
shifting the balls is BHEL’s sope).
ix. All interconnecting extended drain pipe and chutes
x. Support Beam (Inlet chute, Ball charge chute (Piping),
etc.)
xi. Provision for Vibration Monitoring system
xii. Initial Ball charge –Full quantity of each size
xiii. Anchor Bolts and Nuts of all sizes
9. Mill separator tank with all nozzles as per P&ID 1 SET
10. Mill tank agitator with IE3 motor and gear box 1 SET
11. Mill circuit pump with IE3 motor 2 SET
12. Mill hydro cyclone and complete accessories 1 SET
i. Hydro cyclone clusters
ii. Anchor bolts, nuts and washers
iii. Companion flanges for inlet and overflow
iv. A variety size of vortex finders for all the hydro
cyclone
v. Accessory piping within the skid
13. Distribution box with pneumatic actuator 1 SET

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per Mill confirm
14. All coupling for connecting main motor to reducer, inching 1 SET
motor to clutch and reducer, and reducer to pinion.
Bearing lubrication system of 1s SET
a) LP/HP (both pump 2x100%)
b) 3 Heaters & oil tank with 2x100% duplex filter
15 c) Oil cooling system
d) SS pipes & valves to supplied as per vendor design
e) Jet lubrication system to ring gear & pinion
16 Foundation bolts, anchor bolts, nuts for entire system 1 SET
17. Complete base frame including drive motor base frame 1 SET
18. Butterfly valves as per P&ID with Nonintrusive type As per NOS
Electrical actuator -SIL2 certification P&ID
19. Butterfly valves as per P&ID with manual actuator As per NOS
P&ID
20. Each Butterfly valve as per P&ID with pneumatic actuator As per NOS
& limit switch to be terminated in individual Junction Box P&ID
as per enclosed wiring diagram
21. Pneumatic regulating flow control valves as per P&ID As per NOS
P&ID
22. Pressure transmitter(PT)-HART compatible as per P&ID As per NOS
with root valve/diaphragm valve P&ID
23. Pressure indicator (PI) With root valve/diaphragm As per NOS
P&ID
24. Pressure gauge with root valve As per NOS
P&ID
25. Expansion joint at inlet and discharge of the pumps 4 NOS
26. Flow transmitter (FT) As per NOS
P&ID
27. Flow Indicator control (FIC) As per NOS
P&ID
28. Weight indicator (WT) As per NOS
P&ID
29. Weight indicator Control As per NOS
P&ID
30. Level transmitter (LT) As per NOS
P&ID
31. Level Indicator Control Alarm As per NOS
P&ID
32 Vortex flow meter As per NOS
P&ID

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per Mill confirm
33 Temperature Transmitter with HART compatibility for each 4 NOS
mill mill bearing
34 Local control panel with interlock logics 1 SET
Complete piping as per P&ID: 1 SET
a. Water line
b. Slurry line
c. Instrument airline
35
d. Pump flushing line,
e. Tank over flow, & Drain piping valve
f. All drain piping
36 Complete erection and assembly drawing 2 SET
37 Density meter/mass flow meter(Coriolis Meter) 1 NO
38 All instruments/ transmitter shall be provided along with 1 SET
Junction Boxes
39 Mechanical seal flushing globe valve, any other valves not As per SET
covered above P&ID
40 All motors shall be provided with suitable double 1 SET
compression cable gland
41 Temporary strainers for the Mill circuit pump 2 SET
Any other valves/instruments which are required for 1 SET

operation and maintenance of the system, shall considered
by the vendor while submitting the offer
42
(list of items shall be submitted along with offer)
43 Painting and Rust Prevention during shipment and
construction
44. Export packing and Inland Transportation
45. Supervision of Erection & commissioning at site
46. Performance Test and Inspection at site
47. Special tools & tackles as applicable 1 SET

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per Mill confirm
48. Start-up & Commissioning spares as applicable 1 SET
49. Customer Approved Drawings, Installation, operation and

maintenance manuals
a. Customer Approved Drawings—8 prints + 4 No’s of
CD ROMS’/DVDs/Portable Hard disk.
b. Erection Drawings—10 prints + 4 No’s of CD
ROMS’/DVDs/Portable Hard disk.
c. Erection manuals—6 prints + 4 No’s of CD
d. Operation Manual—6 prints + 4 No’s of CD
e. All quality documents, test reports, performance and
functional guarantee reports/procedures —6 prints + 4
No’s of CD ROMS’/DVDs/Portable Hard disk .
50. Bidder to quote for the Mandatory Spares) with breakup
- -
price.
51. (A) Pneumatic piping from the tapping point to filter As
regulator of respective valve is GI. (B) From filter regulator required
SET
to cylinder port is SS-304 for all pneumatic butterfly valves in the
system
52. Any other items required for completeness of the equipment 1 SET
except the items covered in the exclusions.
NOTE:
 Bidder shall refer to the P&ID diagram for details
 All the utility pipes (water pipes, instrument air, etc.,) are provided at single point near to limestone
ball mill building. Bidder has to further take the piping from the point terminated by BHEL.
 All connecting pipes / chutes, pipe supports, trestles, valves, motor (other drives) etc. along with
necessary valves from chute to mill and from hydro-cyclone to common slurry storage tanks and
wherever required within the system shall be in the scope of the supplier.
8. GENERAL TECHNICAL REQUIREMENTS
Sl. Description Vendor to

No confirm
1. Descriptions in the drawings, in the documents, and in the displays shall be in English
2. Bidder shall submit instruction manual for all the equipment’s covered under the scope
of bidder as per agreed engineering schedule. The instruction manuals shall contain full
details required for erection, commissioning, operation and maintenance of each

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No confirm
equipment. The manual shall be specifically complied for this project. The erection
portion of manual shall contain erection strategy, sequence of erection, erection
instructions, critical checks (along with permissible deviations/tolerance), Bill Of
Materials, procedure for erection, general safety procedures to be followed. Procedure
for initial checking after erection, procedure for testing (along with acceptance norms)
check list for commissioning/pre-commissioning activities, List of tools and tackles.
All the manuals shall be two rim PVC bound stiff sided binder able to withstand
constant usage. The cover shall be printed with project name.
3. Suitable guards shall be provided for protection of personnel on all exposed rotating
and /or moving machine parts. All such guards shall be designed for easy installation
and removal for maintenance purpose.
4. Any item not included above but necessary for safe and reliable operation of the milling
system proposed by the supplier shall also be in the suppliers’ scope.
5. The equipment shall be designed to withstand the corrosive and moist environment in
which these are proposed to operate.
6. Noise level produced by any rotating equipment individually or collectively shall not
exceed a) 90 dB(A) for ball mill and b) 85 dB(A) for all other equipment’s like pumps,
feeder, etc., Noise level measured at a distance of 1.0 meters from the source in any
direction and 1.5m above operating floor. Predicted sound pressure levels for the WBM
drive assemblies shall be submitted as part of the proposal data.
7. The overall vibration level shall be as per ISO 10816.
8. Suitable drain connections shall be provided.
9. The equipment shall be suitable for stable operation continuously.
10.
Suppliers shall suitable specify their delivery schedule along with the offer and
Standard code specified shall be strictly adhered.
11.
All instruments such as pressure transmitters, density transmitters (especially at hydro-
cyclone outlet), and other necessary transmitters wherever necessary shall be supplied
by the suppliers
12.
Supplier shall provide the loading of item and other factors which shall be required for
effective civil construction.
13. Tanks, pumps, hydro-cyclone etc. are to be designed by vendor based on their
experience considering the required milling capacity of each Ball Mill System
14. Limit of connection: The buyer (BHEL) has an intention to minimize interface for
utilities as much as possible. The bidder shall consider this requirement in the planning
stage of layout for the equipment. The bidder shall provide the header piping for WBM
and branch piping to each nozzle. Terminal points for all utilities shall be located at

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No confirm
skid edge. The bidder shall specify all terminal points with tie-in number in the P&ID
and submit it in the proposal to confirm the scope of supply.
15. Service life: Entire equipment except wearing parts shall be designed and fabricated
for a minimum service life of 30 years of operation or 200,000 full load operating hours
whichever is longer.
16. Corrosion allowance: Corrosion allowance for entire equipment shall be in accordance
with latest applicable Indian / International standard.
17. Unless otherwise specified , flanges shall be in accordance with ANSI B16.5 Class 150
18. Name plate: All equipment shall be provided with nameplates indicating the item
number and service name. Name plates shall be of 304 Stainless steel plate and placed
at a readily visible location. Nameplate of main equipment shall have enough
information, which will be confirmed during engineering phase. Stainless steel
nameplates for all instruments and valves shall be provided.
19. Rotation arrows shall be cast in or attached with stainless steel plate on each item of
rotation equipment at a readily visible location.
20. Unless otherwise specified, all equipment items where the weight exceeds 15 kg shall
be provided with suitable lifting lugs, ears or ring bolts or tapped holes for lifting rings.
Minimum shock factor for lifting lugs shall be minimum 2.0. The position of lifting
lugs and reference dimension shall be shown on GA and/or outline drawings. NDT
shall be conducted for lifting lugs. When any spreader bars are required for lifting and
laydown, the bidder shall provide spreader bar with equipment.
21. Skid Mount/Transportation: Equipment shall be fabricated as skid mount design as
much as practical to minimize erection at the site.
22. Two pieces of stainless steel earth lugs shall be provided with equipment diagonally.
The position of earth lugs shall be shown on each GA and/or outline drawing.
23. Provide double nuts for anchor bolts
24. Bidder shall provide allowable vibration level on foundation in foundation drawings
and/or general arrangement drawings.
25. If the driver/driven equipment train is in the resonance condition or any vibration
problems occur, the bidder shall solve the problems in a timely manner.
26. Bidder shall provide the mating flanges with the necessary gaskets.
27. All the surfaces of the carbon steel should be rust prevented before shipment for the
period of at least 12 months for storage and construction.
28. Bidder to provide capacity of crane or hoist required for material handling and the
details of heaviest component to be handled.
29. The list of all Bought out items with makes and country of origin to be mentioned along
with offer to be submitted.

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No confirm
30. Quality Plan to be submitted along with the offer.
31. Cost towards the participation in discussions/meetings, providing technical assistance
during technical discussions/meetings with customer for approval of
drawing/documents etc. TA/DA, boarding and lodging to attend these meetings shall
be borne by the bidder and shall be inclusive in supply portion.
32. Material of construction for all equipment/components shall be subject to NTPC/
BHEL approval during detail engineering. Accordingly, bidder shall consider MOC for
all equipment/component as per best engineering practice.
33. Bidder to provide sub vendor list and Bidder shall strictly adhere to NTPC approved
vendor list. In case bidder proposes an additional vendor for an item or vendor approval
is required for any new item, acceptance shall be subject to approval by NTPC/ BHEL
before placing order and bidder shall submit relevant documents as per sub-supplier
questionnaire attached in enclosed Annexure-5 (Sub-Questionnaire).
34. It shall be the complete responsibility of the successful bidders to obtain “Sub Vendor
Approval” from BHEL / NTPC for all equipment’s & components. Any delay in sub
vendor’s approval should not affect the project schedule. If any of the sub vendors does
not have the approval of NTPC/ BHEL, the same may be replaced with another
NTPC/BHEL approved sub-vendor only, without any price implications to BHEL.
35. The modalities of inspection (Stage, Final, In-process) shall be finalized during detail
engineering after submission of quality assurance plan (QAP). It shall be reviewed by
the NTPC/ BHEL. Bidder shall follow the procedures of inspection as per the approved
QAP. Bidder has to submit the following documents along with inspection call and if
any other documents required as per approved QAP.
- Raw material inspection certificate
- Internal test reports
- Statutory certificates as required.
- All inspection & testing shall be carried out based on the following documents:
a. Relevant Standards
b. Specifications
c. Approved drawings
d. Data Sheets
e. Calibration certificate for all the measuring instruments
f. Bidder should also coordinate in getting the MDCC’s (Material Dispatch
clearance certificate) and all types of IC’s (Inspection Certificates) from
the NTPC along with BHEL.
36. Minor Chipping i.e. up to 50 mm thk, micro leveling and providing shim plates for
erection of equipment / item at site shall be in the scope of bidder.

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No confirm
37. During detail engineering, bidder to strictly adhere to BHEL/NTPC drawing formats,
document numbering, quality plan & FQP formats
38. The identification and numbering of equipment, systems, items, etc. of supply, as well
as of all documents and drawings shall be in accordance with reference Designation
System for Power Plants - KKS system.
39. Complete detail engineering drawings, calculations, selection of components etc. shall
be reviewed & subject to approval of BHEL/NTPC during detail engineering
40. Bidder shall furnish necessary inputs & drawings of all equipment in editable Auto
CAD/ MS-Word /Excel format.
41. During detail engineering, successful bidder shall ensure flow of drawings/documents
as per schedule. Any comments from BHEL/NTPC should be addressed timely by the
bidder.
42. Bidder to note that list above is not exhaustive and any work /items required for
completing the smooth operation and ensuring satisfactory running of the machines till
final hand over to the end user (NTPC) shall also be in the scope of the bidder.
43. Bidder shall submit the signed and stamped copy of all the pages which constitutes this
technical enquiry specification signed by authorized signatory and clearly mentioning
each clause under following two categories to avoid any ambiguity in scope
understanding & the scope division along with technical offer.
a. “Accepted without deviation and considered in scope of work”
b. “Not considered in scope of work”
9.DESIGN AND CONSTRUCTION OF MILL AND ACCESSORIES

(Bidder to fill and submit the enclosed technical data sheet along with offer)
9.1 CHUTE
Sl. Vendor
No Description to
confirm
a)
Silo opening size: 24 inch.
b) The minimum valley angle of chutes shall be 60 degrees from horizontal. Transfer chutes
shall be adequately sized and sloped to ensure smooth flow of Lime without any
accumulation anywhere.
c) Chutes shall be made of minimum 20 mm thick TISCRAL / SAILHARD/ LSLAS07 or
equivalent or fined with SS304 material. All chutes should have one inspection door at
every floor and for the ones in between the floors (more than 1.5 meter above the

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operating floor level) suitable access for trouble free maintenance shall be provided. For
sealing of inspection doors labyrinth type arrangement to be provided.
d) Complete chute work in the region of flap gates shall be fabricated from 20 thk
TISCRAL or equivalent. In case of vertical chute (valley angle more than 80 degree)
complete chute, work shall be of 20 mm thick TISCRAL or equivalent material. While
finalizing the chute work inside the building, arrangement for shifting and replacing
chute legs, proper handling arrangement/wall openings, trolleys, hoists shall also be
provided. While fabricating the chute, no welds in between shall be allowed.
e) Ball Mill Chute:
Feed chute shall be corrosion resistant metal lined and designed to prevent overflow.
Inlet chute shall have necessary provisions for loading balls into the ball mills, such as
ball charging hopper.
A discharge chute shall be provided with necessary provisions to collect and separate
balls and tramp metal.
9.2 CHUTE BLOCKAGE SWITCHES
Vendor to
Sl. Description
confirm
No
a. One no. chute blockage switch of proven type (subject to approval of the employer)
shall be provided
b. Chute blockage switch shall trip the feeding conveyor in case of Chute blockage and
protect the feeding conveyor equipment.
9.3 SILO SHUT OFF GATE VALVE

Vendor to
Sl. Description
confirm
No
a. A bunker outlet chute shall be provided for feeding limestone from bunker to the feeder.
The size of the opening chute shall be sufficient to ensure proper flow of the limestone.
There shall be no reduction of section in the bunker outlet chute from bunker to feeder.
The inlet chute shall be provided with suitable poke doors/holes in order to remove
jamming/blockage. A manual and motorized bunker shut-off gate shall be provided at
the inlet to each feeder
b. All parts of the gate in contact with limestone shall be of stainless steel construction.
c. The shut-off gates and its actuator shall ensure 100% closing of the gate even with
‘Bunker full of limestone’.
d. Facility shall be provided to open/close the bunker outlet gate, through actuator,
from remote as well as local (integral starter)

18 | P a g e
e. In addition, a hand wheel with proper access shall also be provided for manual operation
of the gate. The force at the rim of the hand wheel shall not exceed 35 kg with bunker
full of limestone.
f. For each bunker facilities shall be provided for unloading the bunker, through feeder,
to a truck at ground level, along with all necessary chutes and diversion chutes.
9.4 GRAVIMETRIC FEEDER

Vendor to
Sl. Description
confirm
No
a.
Gravimetric feeders (closed type) shall be sized to meet 110% of the maximum mill
capacity.
b. The limestone feeder belt shall be of seamless rubber construction. It should be possible
to adjust the belt tension from outside without opening the feeder body.
c. All parts in contact with limestone except belt shall be of stainless steel construction.
d. The feeder shall have adequate instrumentation to detect 'loss of flow’.
e. The feeder shall have a motor/pneumatic operated gate at the outlet.
f. For each bunker facilities shall be provided for unloading the bunker, through feeder,
to a truck at ground level, along with all necessary chutes and diversion chutes.
9.5 WET BALL MILL

Vendor to
Sl. Description
confirm
No
a. There shall be two numbers wet Ball mills for grinding of limestone, each mill shall be
sized to meet the following conditions, all occurring together.
Capacity 87.9 Tons Per Hour (TPH)

Input Limestone Size 1” (max.) – 25 mm
Output Fineness 30wt% slurry with Output Fineness 90% or higher
through 325 mesh
Mill Wear Part Conditions Near Guaranteed Wear Part Life.
Limestone
13 (min) kWh/ T
bond index

19 | P a g e
Vendor to
Sl. Description
confirm
No
b. The limestone ball mill shall produce ground limestone slurry at the rated tons/hr (dry
basis) with 30wt% slurry with Output Fineness 90% or higher through 325 mesh. The
wet ball mill shall be of the wet horizontal type and shall be furnished complete with
drive system including speed reducer and Inching Drive, gear lubrication system,
bearing lubrication system, all accessories and all required instrumentation to furnish a
complete functioning ball mill.
c. Ball mills shall be designed to accept the following streams concurrently; dry limestone
feed, process water and recycle stream of oversized limestone slurry.
d. Ball mill shall be fabricated of heavy structural quality welded steel plate. All shell
welds shall be full penetration welds.
e. Each mill shall have an outlet spout that is opposite of the inlet chute.
f. Head, trunnion and shells shall be per the Bidder's standards. The main shaft shall be
forged alloy steel and shall be equipped with heavy duty, precision type which are
designed to provide reliable and trouble free operation. The design shall ensure that
thrust is not transmitted through the gear reducer, shaft and coupling to the motor.
g. The mill shell shall include two (2) inspection doors with a minimum size. The
inspection doors shall be sized to admit the largest liner segment or discharge grate.
The openings shall be hinged (if possible) and shall be equipped with watertight seals
and bolted enclosures.
h. The mills shall be designed and constructed with adequate strength and rigidity to
ensure true alignment of the shell and trunnion bearings. Shell shall be bolted to the
shell, using an external flange design. Head and shell shall be drilled for liners prior to
shipment. The discharge shall be provided with a trommel screen.
i. All internal parts that may require replacement shall be designed to be easily dismantled
and replaced without necessity of removing the mill or its drive from the foundations.
j. Water-jacketed inserts shall be included for bearing cooling, if necessary. The pedestal
and cap shall be of welded steel fabrication with inspection doors in the caps. Sole
plates shall be adjustable.
k. Vibration shall be minimized.
l. For each mill bearing 2 nos. of Temperature elements (TE) & Transmitters (TT) with
feature of HART compatibility to be provided. (Per Mill 4 nos. of TT & TE)
m. A local emergency stop switch shall be provided for all motors(Bidder’s Scope) in mill
system
n. The local control station (with emergency stop switch/ local/remote, etc.) shall be
provided for each inching drive.
o. Ball mill shall be completely shop assembled, aligned and operated in so far as possible.
Components shall be match marked after shop assembly to assure proper assembly in
the field.
p. Mill Liners
 All wetted surface except for ball and trommel grate shall be rubber lined.
 All rubber linings shall be done in strict accordance with the rubber Manufacture
is inspection and applicable codes and standards.
 Mill liners shall be attached by through bolts with leak proof washers.

20 | P a g e
Vendor to
Sl. Description
confirm
No
q. Ball Mill Drives
Each ball mill shall be furnished with speed reducing gear driver and inching drive.
Speed reducer shall be provided with a flexible, spacer type, coupling and guard. Mill
gear and pinion shall be of Spur design. Ball Mill Motor is in BHEL Scope of supply.
r. Grinding Balls
 The Bidder shall furnish a complete ball charge for each mill.
 The Bidder shall provide in the data for frequency, procedures and equipment for
ball removal, screening of undersized balls, and ball charging.
 The Bidder shall provide the ball consumption rate versus limestone hardness in
his offer.
 Bidder shall also guarantee ball consumption per ton of limestone throughput.
s. All integral auxiliaries of the mills like hydro-cyclones, separator tank & mill circuit
pumps shall be sized to meet the above conditions (a). A 100% stand-by pump shall be
provided for the mill circuit pump.
t. The mill hydro-cyclone set shall have sufficient redundancy. A minimum 10% spare
Hydro-cyclone shall be provided in each set of hydro-cyclone. Hydro-cyclones shall be
of modular construction. It shall be possible to remove and replace individual hydro-
cyclone with the set in service. Individual isolation valve shall be provided for each
hydro-cyclone for this purpose. The hydro-cyclone shall be of proven design and shall
be provided with replaceable rubber lining. The hydro-cyclone shall be provided with
replaceable rubber lining of Thickness 12 mm for the feed chamber and 12 mm for the
overflow launder. The liners shall have a minimum wear life of not less than 8000 hrs.
u. All parts of the mill including mill body, HP & LP trunnion, hydro-cyclones, integral
pipes, mill circuit pumps and other parts in contact with limestone slurry shall be
provided with replaceable rubber wear liners. The wear liners or wear parts shall have
a minimum guaranteed wear life of not less than 8000 hrs without reversal of the
liners. The guaranteed capacity and fineness of the mill shall not be affected within the
guaranteed life of the mil wear parts.
v. The material of the balls shall be chosen to ensure that the balls do not lose their original
shape and to ensure minimum ball consumption. The supplier shall also guarantee ball
consumption per ton of limestone throughput. The supplier shall furnish the
minimum ball diameter below which the balls shall be replaced.
w. Facility shall be provided for on-load loading of steel balls to the mill.
x. The ball mill shall be driven by a motor through a peripheral gear/ central drive system.
An auxiliary motor shall also be provided for inching of mills after trip and during
maintenance.
y. The lube oil system shall have 100% stand-by arrangement for lube oil pumps and oil
coolers of each circuit with independent pump / cooler and tank. Wherever required
duplex oil filters shall be provided.
z. The mill auxiliaries like separator tanks, mill circuit pump, hydro-cyclones and all
connecting pipes handling limestone slurry shall have replaceable rubber linings.
aa. Piping and wiring within the skid shall be in the vendor’s scope.

21 | P a g e
Vendor to
Sl. Description
confirm
No
bb. Local control panel shall have display on the front panel and necessary electrical parts.
cc. Supplier shall furnish the minimum ball diameter below which the balls shall be
replaced. Each mill shall be sized to meet the following conditions, all occurring
together.
9.6 MILL CIRCUIT TANK

Vendor to
Sl. Description
confirm
No
a. The slurry preparation tank shall be CS construction with replaceable rubber lining.
The storage tanks shall be equipped with sufficient number of agitators, to avoid
settling.
b. All the slurry tanks shall be designed, fabricated, erected and tested in accordance with
the IS:803, latest edition. Additional Corrosion allowance of 1.5mm on the minimum
tank shell thickness as calculated by IS:803, latest edition shall be provided by the
Contractor
c. Tanks shall be made from IS:2062 quality mild steel plates of tested quality. The
tanks shall be of welded construction.
d. Interior surface of the tanks shall lined with replaceable chlorobutyl/bromobutyl rubber
lining of minimum 5 mm thickness and the outside surface shall be coated with paint
as approved by the Employer. The Tanks shall be provided with drain, manholes, over
flow & inlet level control valves etc. Suction screens shall be installed to protect the
pumps.
Bidder shall source rubber lining work from proven supplier.
9.7 MILL CIRCUIT PUMPS

Vendor to
S. No Description
confirm
Quantity: 2 No’s for each limestone grinding system (Total 4 numbers)
a)
Margins: Flow 10% (minimum) Head 15% (minimum)
b)
Solids Concentration Max. 55% by weight or actual as per suppliers practice,
c)
whichever is minimum.
The Contractor shall offer only proven design in successful operation in similar
d)
application at previous installations. The design, manufacture, installation and testing
of the pumps shall follow the latest applicable Indian / International (ASME /EN /
Japanese) Standards.
The pumps shall be designed for continuous operation. The pump shall be single stage
e)
centrifugal type capable of delivering the rated flow at rated head with margins as
specified in the respective clauses.

22 | P a g e
Vendor to
S. No Description
confirm
The slurry concentration in the pump shall not exceed 55% by weight.
f)
All the slurry pumps shall be provided with motorized suction and discharge valves.
g)
In addition, flushing water lines with motorized valves shall be provided for each
pump for automatic flushing of the pump after each shut down. The flushing water
for the pumps shall be taken form the process water supply
In case of pump with rubber lined casing, the casing should be radially split to allow
h)
easy removal of impeller
All the pump wear parts in contact with the slurry shall be provided with replaceable
i)
rubber/elastomer liners suitable for the fluid handled. The Bidder can also offer an hi
chrome alloy line pump if the Bidder has previous experience of the same for similar
applications. The material used by the contractor shall be proven in previous
installations.
The material and thickness of the liners shall ensure a minimum service life of 2 years
j)
before replacement. All the wear parts of the pump shall be guaranteed for a minimum
wear life of not less than 14000 hrs.
The design of the shaft shall ensure that the operating speed is at least 20% above the
k)
critical speed of the shaft.
The pump shall be provided with seals of proven type and seal type shall be flushless
l)
.The shaft shall be supported on heavy duty ball/roller bearings.
Design and construction of various components of the pumps shall conform to the
m)
following general specifications. For material of construction of the components, data
sheets shall be referred to.
a) Pump Casing
Pumps shall be Radial Split Casing, Close/Semi-open, Over-hang, End Suction type
Back Pull-out design, Vertical Discharge type for Horizontal Centrifugal Pump. The
casing shall be designed to withstand the maximum shut-off pressure developed by
the pump at the pumping temperature. Pump casing shall be provided with a vent
connection and piping with fittings & valves. Casing drain as required shall be
provided complete with drain valves, piping and plugs. It shall be provided with a
connection for suction and discharge pressure gauge as standard feature. It shall be
structurally sound to provide housing for the pump assembly and shall be designed
hydraulically to minimum radial load at part load operation.
b) Impeller
Impeller shall be closed, semi-closed or open type as specified elsewhere and
designed in conformance with the detailed analysis of the liquid being handled. The
impeller shall be secured to the shaft, and shall be retained against circumferential
movement by keying, pinning or lock rings. On pumps with overhung shaft, impellers
shall be secured to the shaft by a lockout or cap screw which tightness in the direction
of normal rotation.
c) Impeller/Casing Wearing Rings

23 | P a g e
Vendor to
S. No Description
confirm
Replaceable type wearing rings shall be provided at suitable locations of pumps.
Suitable method of locking the wearing ring shall be used. Wearing rings shall be
provided in pump casing and/or impeller as per manufacturer’s standard practice.
d) Shaft
The critical speed shall be well away from the operating speed and in no case less
than 130% of the rated speed. The shaft shall be ground and polished to final
dimensions and shall be adequately sized to withstand all stresses from rotor weight,
hydraulic loads, vibration and torques coming in during operation.
e) Shaft Sleeves
Renewable type fine finished shaft sleeves shall be provided at mechanical seals.
Shaft sleeves shall be fastened to the shaft to prevent any leakage or loosening. Shaft
and shaft sleeve assembly should ensure concentric rotation.
f) Bearings
Heavy duty bearings, adequately designed for the type of service specified in the
enclosed pump data sheet and for long, trouble free operation shall be furnished. The
bearings offered shall be capable of taking both the radial and axial thrust coming
into play during operation. In case, sleeve bearings are offered additional thrust
bearings shall be provided. Antifriction bearings of standard type, if provided, shall
be selected for a minimum life 20,000 hrs. of continuous operation at maximum axial
and radial loads and rated speed. Proper lubricating arrangement for the bearings shall
be provided. The design shall be such that the bearing lubricating element does not
contaminate the liquid pumped. Where there is a possibility of liquid entering the
bearings suitable arrangement in the form of deflectors or any other suitable
arrangement must be provided ahead of bearings assembly. Bearings shall be easily
accessible without disturbing the pump assembly. A drain plug shall be provided at
the bottom of each bearings housing.
g) Mechanical Seals
Mechanical seals shall be of single type with either sliding gasket or bellows between
the axially moving face and shaft sleeves or any other suitable type. The sealing faces
should be highly lapped surfaces of materials known for their low frictional
coefficient and resistance to corrosion against the liquid being pumped.
The pump supplier shall coordinate with the seal maker in establishing the seal
chamber of circulation rate for maintaining a stable film at the seal face. The seal
piping system shall form an integral part of the pump assembly. For the seals under
vacuum service, the seal design must ensure sealing against atmospheric pressure
even when the pumps are not operating. Seals shall be fleshless type.
h) Pump Shaft Motor Shaft Coupling
The pump and motor shafts shall be connected with an adequately sized flexible
coupling of proven design with a spacer to facilitate dismantling of the pump without
disturbing the motor. Necessary coupling guards shall also be provided.
i) Base Plate

24 | P a g e
Vendor to
S. No Description
confirm
A common base plate mounting both for the pump and motor shall be furnished. The
base plate shall be fabricated steel and of rigid construction, suitably ribbed and
reinforced. Base plate and pump supports shall be so constructed and the piping unit
so mounted as to minimize misalignment caused by mechanical forces such as normal
piping strain, internal differential thermal expansion and hydraulic piping thrust.
Suitable drain troughs and drip lip shall be provided.
9.8 MILL CIRCUIT TANK AGITATOR

Vendor to
S. No Description
confirm
Mill circuit tank agitator shall be of top entry (vertical) type and to be designed for
a)
continuous operation. The design of the agitators shall be of proven type. The shaft
of the agitators shall be of Carbon steel with rubber lining with a minimum life of 2
years. Blades shall be of Alloy 926 or better material.
Agitators shall be supplied in tanks and vessels to prevent caking and settlement of
b)
particles out of the slurry.
Standard type agitators with suitable characteristics shall be used wherever practical.
c)
The agitators shall be complete with motor, gearbox, agitator shaft, coupling, safety
guards, mechanical seal (for side entry agitators), impeller, support legs, agitator
mounting flange including bolts nuts and gasket etc.,
All agitator parts and accessories in contact with the stirred fluid shall be constructed
d)
of materials specifically designed for the conditions and nature of the stirred fluid and
be resistant to erosion and corrosion.
Each agitator and its associated equipment shall be arranged in such a manner as to
e)
permit easy access for operation, maintenance and agitator removal without
interrupting plant operation.
To prevent mechanical blocking load start-up after standstill of pumps, piping and
f)
agitators for slurries shall be applied with C-hose connection.
Lifting lugs and eyes and other special tackle shall be provided as necessary to permit
g)
easy handling of the agitators and their components.
Static and dynamic (as far as applicable) balancing of all agitators shall be carried out
h)
after assembly.
All agitator parts and components shall be designed and calculated for fatigue life,
i)
considering maximum bending loads, induced by fluctuating hydraulic forces and
torsional loads, based on the installed motor power. For side entry agitators the
alternating bending moment resulting from impeller and shaft weight has to be
considered additionally.
All exposed moving parts shall be covered by guards.
j)
Agitator shall be flange mounted.
k)
The shape of the impeller blades of top entry agitators shall be designed to avoid wear
l)
on the impellers which will affect the agitator performance as specified for a
minimum period of 2 years of continuous operation under design conditions for the

25 | P a g e
range of coal & limestone specified in the specification. In order to avoid excessive
wear impeller tip speeds must not exceed 12 m/s.
Belt drives (if applied) shall be properly designed to provide a minimum lifetime of
m)
2 years under design conditions.
9.9 PIPING / VALVES

Vendor to
S. No Description
confirm
The limestone slurry pipes shall be sized to minimize erosion and avoid settling of
a)
the limestone at part load operation. The slurry pipes shall be lined with replaceable
rubber lining of minimum 6 mm thickness. Slurry pipes shall be designed to keep
the velocity above the settling velocity under all operating conditions. The supplier
may provide a recirculation line with motorized isolation valve for the above purpose.
Additional thickness of 2mm shall be provided at bends.
All the pipes handling slurry shall be provided with replaceable rubber lining. The
b)
Supplier can provide slurry pipes of size lower than 3” made up of FRP material
(Silicon carbide coating on slurry exposed surface) if bidder has proven experience
of the same.
For Butterfly Valves refer specification enclosed in Annexure-6. For pneumatic
c)
valves, instrument air is available on corner of the ball mill building. Further piping
to all individual valve shall be bidder’s scope.
All valves shall be ASME B16.34 PN16 (Class 150)Wafer Type with EPDM lining
d)
face to face
For Limestone Slurry Line Valves - BODY:A126-B, DISC:A351-CF8M, STEM:
e)
Duplex 2205
For Water Line – Body: A105/A216-WCB, Disc & Stem :13CR EPDM
f)
For Instrument Air Line- A105 + GI
g)
For Material of construction for pipe refer to P&ID enclosed and as per specification
h)
enclosed in Annexure-6- Pipe & valves spec.
Supplier shall provide all necessary arrangements for purging & flushing of all the
i)
process pipelines, equipment’s etc.
9.10 HYDROCYCLONE
Vendor to
S. No Description
confirm
The hydro cyclone classification system shall be provided to classify the limestone
a)
slurry to the specified size. Overflow from the hydro cyclone shall be gravity fed by
distribution piping to the limestone storage tank. The underflow shall be recycled
back to the ball mill for further grinding
Total no. hydro-cyclone – 2 No’s; 1 no (100%) per grinding system.
b)
Mill hydro cyclone may be of polyurethane. Hydro-cyclone shall be of modular
c)
construction and designed for 100% of inlet feed. It shall be possible to remove and
replace individual hydro-cyclone with the set in service. Individual isolation valve

26 | P a g e
shall be provided for each hydro-cyclone for this purpose. The hydro-cyclone shall
be of proven design and shall be provided with replaceable rubber lining of thickness
12 mm for the feed chamber and 12 mm for the overflow launder. The liner shall have
a minimum wear life of not less than 8000 hours
The mill hydro-cyclone set shall have sufficient redundancy. A minimum 10% spare
d)
hydro-cyclone shall be provided in each set of hydro cyclone.
All parts of the hydro-cyclones, integral pipes, mill circuit pumps and other parts in
e)
contact with limestone slurry shall be provided with replaceable rubber wear liners.
9.11 MOTOR
Vendor to
S. No Description
confirm
 Above 0.2 kW and upto 200 kW: 3 phase 415 V AC-VENDOR SCOPE
a)
 Above 200 kW and upto 1500 kW: 3.3 KV- BHEL SCOPE
 Above 1500 kW: 11 KW-BHEL SCOPE
Bidder to submit the motor datasheet as per format given in the specification.
Motor shall be sourced only from NTPC approved sources and data sheet approval
shall be obtained from BHEL before placing order.
If motor is procured from any new source, acceptance shall be subject to approval
by NTPC/ BHEL before placing order and bidder shall submit relevant documents
as per sub-supplier questionnaire attached in enclosed Annexure (sub-supplier
questionnaire).
Double compression cable gland with lugs to be provided by the vendor, however,
exact size will be informed to vendor after award of contract.
Motors shall be as per the specification given in Annexure-7
9.12 Design Ambient conditions for Electricals

Vendor to
S. No Description
confirm
1) Design Ambient Temperature --- 50 Deg C
2) Design Ambient Temperature for equipment installed in A/C Rooms --- 35 Deg C
9.13 FIELD MOUNTED LOCAL JUNCTION BOXES & CONDUITS

Vendor to
S. No Description
confirm

27 | P a g e
a) JUNCTION BOX shall be Powder coated Junction box with CRCA sheet for IP class
IP65 and the following requirements to be met:
No. of ways ------ 12/24/36/48/64/72/96/128 with 20% spares terminals.
Material and Thickness------ 4mm thick Fiberglass Reinforced Polyester (FRP).
Type--- Screwed at all four corners for door. Door gasket shall be of synthetic rubber.
Mounting clamps and accessories----- Suitable for mounting on walls, columns,
structures etc. The brackets, bolts, nuts, screws, glands required for erection shall be
of SS, included in Bidders scope of supply
Type of terminal blocks--------- Rail mounted cage-clamp type suitable for
conductor size upto 2.5 mm2. A M6 earthing stud shall be provided.
Grounding------- To be provided.
Color ------- RAL 7035.
b) CONDUITS
Conduits shall be generally used for interconnecting cables from field instruments to
Local JB’s. All rigid conduits, couplings and elbows shall be hot dipped galvanised
rigid mild steel in accordance with IS: 9537 Part-I (1980) and Part-II (1981). The
conduit interior and exterior surfaces shall have continuous zinc coating with an
overcoat of transparent enamel lacker or zinc chromate.
Flexible conduits shall be water leak, fire and rust proof flexible GI conduits shall be
provided. The temperature rating of flexible conduit shall be suitable for actual
application.
All rigid conduit fittings shall conform to the requirements of IS: 2667, 1976.
Galvanized steel fitting shall be used with steel conduit. All flexible conduit fittings
shall be liquid tight, galvanized steel. The end fittings shall be compatible with the
flexible conduit supplied.
Conduit sealing, explosion proof, dust proof and other types of special fittings shall
be provided as required by these specifications and shall be consistent with the area
and equipment with which they are installed. Fittings installed outdoors and in damp
locations shall be sealed and gasketed. Hazardous area fittings and conduits sealing
shall conform with NEC requirements for the area classification.
Contractor shall provide double locknuts on all conduit terminations not provided
with threaded hubs and couplings. Water tight conduit unions and rain tight conduit
hubs shall be utilised for all the application which shall be exposed to weather.
Moisture pockets shall be eliminated from conduits.
Conduits shall be securely fastened to all boxes and cabinets.

28 | P a g e
9.14 VFD
Vendor to
S. No Description
confirm
a) VFD’s shall be as per the specification given in Annexure-8
9.15 INSTRUMENTS
Vendor to
S. No Description
confirm
All instruments shall be as per specification enclosed in Annexure-9. Vendor to
a)
supply all the instruments as given in the P&ID.
Primary instruments like microprocessor based transmitters employing HART

protocol, thermocouples & RTD’s along with temperature transmitters, pressure/diff
pressure/temperature/flow*ultrasonic/electromagnetic) transmitter & gauges, flow
sensing elements (orifice plates, flow nozzles etc.,), ultrasonic, radar type level
transmitters and density meter(coriolis type).
Integral to equipment which are not indicated in the tender drawings, but are required
for control, monitoring and operation of the equipment for which no P&ID is attached
shall be provided to meet the actual system requirements and meeting redundancy
and other technical specifications.
For binary and analog inputs required in major equipment’s of FGD system,
protection triple-sensing devices shall be provided. Binary and analog inputs, which
are required for protection of more than one equipment as well as protection signals
for HT drives etc., triple sensing devices shall be provided.
For other critical binary and analog inputs required for protection and interlock
purpose of other equipment (Eg. Those interlocks which may lead to loss if
production, non-availability of major equipment etc.,) triple sensors shall be
provided
Temperature elements, electronic transmitters etc., are to be provided for all the cases.
Use of process actuated switches is acceptable only in case indicated in tender
drawings.

29 | P a g e
9.16 NETWORKING PROTOCOLS AND CONTROL LOGICS:
Vendor to
S. No Description
confirm
All the measuring instruments, process instruments and electrical actuators shall be
a)
through HART protocol.
Each equipment shall be furnished with required instrumentation and electrical
b)
accessory devices mounted and connected to local junction boxes. Bidder shall
provide the control logic for the entire system.
9.17 Actuators
Vendor to
S. No Description
confirm
All Pneumatic and Electrical Actuators shall be in compliance with Annexure-6 and
Annexure-17 respectively.
10. PACKING AND FORWARDING
Vendor to
S. No Description
confirm
Proper packing to be ensured.
a)
Indigenous Supply: WBM & sub system assembly shall be wrapped in polythene
bags & packed in a strong rigid wooden crate. Rain water should not enter into the
WBM internals during storage in the outer yard of power plant.
Imported Supply: All imported supply should be packed as per Sea worthy packing
standards Annexure – 10 (Specification: HY0490569). All imported items should
have Sea worthy packing. Liberal packing materials and struts shall be provided to
arrest rolling and to protect from transit damages.
Equipment and process materials shall be packed and semi-knocked down, to the
b)
extent possible, to facilitate handling and storage and to protect bearings and other
machine surfaces from oxidation. Each container, box, crate or bundle shall be
reinforced with steel strapping in such a manner that breaking of one strap will not
cause complete failure of packaging. The packing shall be of best standard to
withstand rough handling and to provide suitable protection from tropical weather
while in transit and while awaiting erection at the site. All the major equipments shall
be supplied in steel crates. The package shall be supplied in containers and it should
be suitable for storage in the outside yard of the plant for a minimum period of 12
months.
Equipment and materials in wooden cases or crates shall be properly cushioned to
c)
withstand the abuse of handling, transportation and storage. Packing shall include
preservatives suitable to tropical conditions. All machine surfaces and bearings shall
be coated with oxidation preventive compounds. All parts subject to damage when in

30 | P a g e
contact with water shall be coated with suitable grease and wrapped in heavy asphalt
or tar impregnated paper.
Crates and packing material used for shipping will become the property of owner
d)
(NPGCL).
Packaging or shipping units shall be designed within the limitations of the unloading
e)
facilities of the receiving ports and the ship will be used. It shall be the bidder’s
responsibility to investigate these limitations and to provide suitable packaging and
shipping to permit transportation to site.
Packing (tare) shall be part of the equipment cost and shall not be subject to return.
f)
The packing should ensure integrity and cohesiveness of each delivery batch of
equipment during transportation. In case of equipment assemblies and unit’s delivery
in the packing of glass, plastics or paper the specification of packing with the material
and weight characteristics are to be indicated.
Each package should have the following inscriptions and signs stenciled with an
g)
indelible ink legibly and clearly:
a. Destination
b. Package Number
c. Gross and Net Weight
d. Dimensions
e. Lifting places
f. Handling marks and the following delivery marking
Each package or shipping units shall be clearly marked or stenciled on at least
h)
two sides as follows.
Patratu Thermal Power station (PTPS)
Ramgarh District of Jharkhand State, India
EPC CONTRACTOR: “BHARAT HEAVY ELECTRICALS LIMITED,
INDIA”
In addition, each package or shipping unit shall have the symbol painted in red on at
least two sides of the package, covering one fourth of the area of the side.
Each part of the equipment which is to be shipped as a separate piece or smaller parts
i)
packed within the same case shall be legibly marked to show the unit of which it is
part, and match marked to show its relative position in the unit, to facilitate assembly
in the field. Unit marks and match marks shall be made with steel stamps and with
paint.
Each case shall contain a packing list showing the detailed contents of the package.
j)
When any technical documents are supplied together with the shipment of materials
no single package shall contain more than one set of such documents. Shipping papers
shall clearly indicate in which packages the technical documents are contained.
The case number shall be written in the form of a fraction, the numerator of which is
k)
the serial number of the case and the denominator the total number of case in which
a complete unit of equipment is packed.
Wherever necessary besides usual inscriptions the cases shall bear special indication
l)
such as “Top”, “Do not turn over”, “Care” , “Keep Dry” etc. as well as indication of

31 | P a g e
the center of gravity (with red vertical lines) and places for attaching slings (with
chain marks)
Marking for Safe handling: To ensure safe handling, packing case shall be marked to
m)
show the following:
a. Upright position.
b. Sling position and center of Gravity position.
c. Storage category.
d. Fragile components (to be marked properly with a clear warning for safe
handling).
Each crate or package is to contain a packing list in a waterproof envelope. All items
n)
are to be clearly marked for easy identification against the packing List. All cases,
packages etc. are to be clearly marked on the outside to indicate the total weight
where the weight is bearing and the correct position of the slings are to bear an
identification mark relating the to the appropriate shipping documents. All stencil
marks on the outside of cases are either to be made in
waterproof material or protected by shellac or varnish to prevent obliteration in
transit.
The packing slip shall contain the following information:
o)
Customer name, Name of the equipment, Purchase Order number with Date, Address
of the delivery site, Name and Address of the Sender, Serial Number of WBM &
accessories, BHEL item Code, Gross Weight and Net weight of Supplied items.
Prior to transport from manufacturer’s work to destination, components of the unit shall be
p)
completely cleaned to remove any foreign particles. Flange faces and other machined surfaces
shall be protected by an easily removable rust preventive coating followed by suitable
wrapping.
All necessary painting, corrosion protection & preservation measures shall be taken as
q)
specified in painting schedule. Supplier shall consider the coastal environment zone which is
defined as “very severe” during final finishing/shipping.
Successful bidder shall furnish the detail packing /shipment box details with
r)
information like packing box size, type of packing, weight of each consignment,
sequence no. of dispatch, no. of consignment for each deliverable item against each
billing break up units/ billable blocks. Without these details the BBU shall not be
approved during detail engineering.
Also, complete billing break-up with above mentioned details shall be submitted within
10days of LOI.
All items/equipment shall be dispatched in properly packed condition (i.e. no item
s)
shall be dispatched in loose condition such that it becomes difficult to store/identify
its location at site at a later stage).
Cases which cannot be marked as above shall have metal tags with the necessary
t)
markings on them. The metal tags shall be securely attached to the packages with
strong steel binding wire. Each piece, Skid, Case or package shipped separately shall
be labelled or tagged properly.

32 | P a g e
11. SUPERVISION OF ERECTION, TESTING AND COMMISSIONING
Vendor to
S. No Description
confirm
The erection of Limestone Grinding System (LGS) will be done by owner (BHEL)
a)
as per Erection Manual and check List provided by bidder. The bidder has
to supervise for erection, pre-commissioning & post- commissioning check-up,
start-up, trial runs of all the items covered under the scope of supply.
There will be Six visits per grinding system totally there will be 12 visits. The
b)
bidder will be informed well in advance for the visit. Bidder shall consider 60
working days per grinding system.
In case erection and commissioning activities get delayed due to any account,
c)
resulting into overstay of vendor supervisory engineer beyond schedule time, then
BHEL shall pay for additional man-day stay of vendor supervisory engineers. Vendor
to quote Per day cost for deputation along with this offer.
TA/DA, boarding and lodging shall be borne by the bidder and shall be inclusive in
d)
supervision charges portion.
Charges for supervision of Erection & commissioning shall be quoted by the bidder.
e)
Price comparison for evaluating the lowest bid will be considered all main supply,
f)
supervision of E&C charges and mandatory spares price all together.
12. EXCLUSION
Vendor to
S. No Description
confirm
The following work associated with the LGS will be by BHEL:
a. Supply of main drive HT motor
b. Civil foundations
(however vendor to provide foundation drawing & materials like Foundation bolts,
anchor bolts, nuts)
c. Walkways, platforms and ladders
(Vendor to provide GA drawing. However, fabrication & material supply, Erection
by BHEL)
d. Element handling hoists
13. INSPECTION AND TESTING

(As per approved quality plan. However, minimum requirements are as below)
Vendor to
S. No Description
confirm

33 | P a g e
Quality Plan Requirement:
(i) MQP (Manufacturing Quality Plan) shall be submitted in attached format for
BHEL/Customer review & approval. Typical MQP is attached (Annexure-11) for
indicative purposes for guidance & use.
(ii) MQP shall invariably cover w.r.t Inward inspection including on Raw material
Procurement, In process and Final inspection in elaborated way/details.
(iii) Bidder shall also to give specific confirmation that on need basis, their competent
officials shall visit to BHEL/customer for finalization of Quality plan including test
procedure/methodology during pre- award / post award approval / detailed
engineering in the event of an order.
(iv) No deviation on BHEL/Customer approved MQP is acceptable.
(v) Bidder shall agree to submit all cross referred documents other than
codes/standards to BHEL/Customer/Consultant.
1. Important Notes shall be included in MQP:
(a) Latest revision of Standard s & Specification shall apply. Only International
Standards are applicable. Indian & Chinese Standards are not applicable
(b) Materials shall be procured in compliance to Functional Technical Specification.
(c) Inspection shall be in compliance with Approved Quality Control Procedure for
the Product.
(d) NDT shall be carried out by Qualified Personnel with compliance to Approved
NDT Procedures and Acceptance Norms, as per ASME Section V.
(e) Gauges and measuring Instruments, with valid calibration only shall be used.
(f) Cleaning and Painting of products shall be carried out as per Approved Painting
Schedule.
(g) Finished Products shall be packed to comply with Approved Packing Schedule.
(h) Welding shall be carried out by Qualified Personnel with compliance to Approved
NDT Procedures and Acceptance Norms, as per ASME Section V.
2. Domestic / Inland Inspection will be carried out by BHEL/BHEL appointed Third
Party Inspection Agency (TPIA) / Customer/Customer Appointed Inspection
Agency/Consultant. This is applicable for all Stage inspection and Final Inspection
identified as "W" - Witness or "CHP" - Customer Hold Point as per customer
approved Quality Plan/ Technical specification / Approved Drawing/ Approved Data
sheet / Scheme / PID / PFD / SLD (Process Instrumentation Diagram / Process Flow
Diagram / Single Line Diagram) etc. (As applicable).
“The inspection charges at actuals incurred by BHEL will be loaded to compare with
foreign suppliers”.
3. Inspection Agency for Foreign Bidders and also for Indian Bidder but importing
from Foreign Sources:

34 | P a g e
(1) Any one of the following Third Party Inspection Agency (TPIA) shall be
appointed by the bidder and same shall be furnished by the bidder in techno
commercial bid itself.
(2) The details of TPIA with contact details like Name of the official, Phone no, Email
id shall also to be submitted during pre/post award. However cost for such inspection
agency shall be borne by the bidder only. Inspection charges for such inspection
agency shall be indicated separately so that if BHEL/Customer is undertaking the
inspection by on their own, then these charges non claimable by the bidder.
List of TPIA
1) M/s Bureau Veritas
2) M/s TUV-Nord
3) M/s TUV-SUD
4) M/s TUV Rheinland
5) M/s Lloyds Register
6) M/s DNV
4. Stage Inspection during manufacturing Process: Stage Inspection during
manufacturing shall be carried out as per approved quality plan and all necessary
documents shall be provided for review, verification and clearance for further
processing. This inspection call shall be given well in advance (at least 2 weeks
before) to TPI/Bidder's own inspection agency to avoid delay in the manufacturing
processes.
Inspection before dispatch for domestic supplier: Inspection before dispatch at
5.
supplier's works shall be carried out by BHEL/BHEL appointed Inspection agency.
Inspection shall be done as per approved Quality plan/ Technical specification/
Approved Drawing/ Approved Data sheet.
Inspection at Foreign Source/Supplier:
6.
(a) As in Sl. No.: 3. shall be ensured without fail.
(b) No material / items shall be dispatched without getting the written communication
from BHEL / Customer inspection carried out by BHEL/BHEL appointed Third Party
Inspection Agency (TPIA) / Customer/Customer Appointed Inspection
Agency/Consultant. This is applicable for all Stage inspection and Final Inspection
identified as "W" - Witness or "CHP" - Customer Hold Point as per customer
approved Quality Plan/ Technical specification / Approved Drawing/ Approved Data
sheet / Scheme / PID / PFD / SLD (Process Instrumentation Diagram / Process Flow
Diagram / Single Line Diagram) etc. (As applicable).
Inspection before dispatch for Foreign supplier: Inspection before dispatch at
supplier's works shall be carried out by bidder appointed inspection agencies having
international presence at vendors and or vendor's sub vendor works. Inspection shall
be done as per approved Quality plan/ Technical specification/ Approved Drawing/
Approved Data sheet by TPIA mentioned in Sl. no: 03 at supplier's cost.
Painting shall be done strictly as per BHEL/Customer approved painting schedule /
7.
scheme only. Paint Thickness / Paint shade shall be ensured as per BHEL / Customer
approved painting schedule / specification / data sheet etc. No deviation is acceptable
unless otherwise accepted by BHEL/Customer in writing. Any conflict if any among
BHEL / Customer approved painting schedule / Spec / data sheet etc shall be brought

35 | P a g e
to the notice to BHEL well in advance before proceeding including the BOI being
procured for assy / skid like motors etc
Specific conformation for document package in the event of an order (2 Hard copies
8.
& soft copy in PDF file) is to be given containing the following with proper linkages
(i) Index Sheet
(ii) MQP/RQP/Endorsement Sheet (As applicable)
(iii) TCs identified by BHEL/ Customer for record for "CHP" / "W" and Verification
portion ("V") as given in approved QP.
(iv) Final inspection report + TC including Chemical + Mechanical + HT + NDT etc.
(v) Third party Inspection report + TC
(vi) Customer CHP/ MDCC
(vii) Type test / Performance Test reports conducted
(viii) Type test / Performance Test approval/ clearance obtained from
BHEL/Customer
(ix) BOM with As Build Drawings with actual make / rating used with
BHEL/customer approved drawings.
Packing / Seaworthy Packing shall be as per BHEL Packing schedule / approved
9.
drg / sketch. This shall be ensured to take care transit / handling / transshipment in
Road / Sea / Air. Photographs are to be submitted for BHEL review before
dispatching the material as per contract conditions.
Outsourcing of test facilities: Bidder shall ensure all the testing facilities in house.
10.
However If any of the test facilities are not available with successful bidder, then
bidder shall ensure the same at NABL accredited third party lab / Govt. / Govt. Lab
for major testing such as NDT, Electrical & Mechanical testing.
Important Note: No deviation on the above requirement 01 to 10 is acceptable w.r.t
11.
Quality Requirement and those offers not meeting these specific customer
requirement is liable for rejection and hence the bidder shall submit all the required
documentary evidences in the offer itself.
## Necessarily to be filled up by the bidder at the time of offer itself otherwise the
12.
offer may not be considered w.r.t Quality Requirement being customer specific
requirement.
A) Minimum Testing requirements to be considered are as below:
1.
Vibration levels measured on the non-rotating parts shall not exceed the zone limit
“B” as defined in ISO 10816 at steady conditions and shall not exceed the zone limit
“C” as defined in ISO 10816 at transient conditions.
2. List of Non-Destructive test over and above the material test are as follows:
a. Mechanical Seal- Manufacturer’s recommendation.
b. Base Plate- Stress relieving of weld.
c. Replaceable Rubber liner- Shore Hardness, Class and Type certificate.

36 | P a g e
3. Once mounting is finished and operation test will be conducted on each WBM to
determine the characteristic curves to determine the parameters at the design point,
mechanical running & performance testing shall be performed & witnessed.
4. Vibration test and Noise level test shall be witnessed at site.
5. For surfaces with rubber lining Welding shall be visually inspected to verify the
absence of rough area and unacceptable transition between surfaces which prevent
the adequate adherence of rubber. The acceptance criteria shall be as per latest
standard.
6. For surfaces with rubber lining, degree of cleaning shall be visually checked before
the application of the coating. There must be no area with oxidation, dirt or partially
or generalized corrosion defects.
7. Test certificates shall be issued for each lot of raw material used in the coating,
corresponding to specific weight and traction resistance.
8. For surfaces with rubber lining, adherence test shall be conducted on production
samples. Adherence test shall be conducted on the actual surface through hammering.
In order to verify the absence of air packets (or) surface without adherence.
9. For surfaces with rubber lining, Coating thickness shall be checked at 100%.A High
voltage porosity test will be conducted on 100 % of the coated surface.
10. Wear resistant parts shall be UT/RT tested to check soundness after suitable heat
treatment. Check for chemical composition, hardness and microstructure shall be
carried out.
11. Wet ball mill shells shall be statically balanced.
B) General Inspection requirements to be considered are as below:
Bidder shall furnish written copies of shop production, fabrication and quality test
procedures and drawings to be used for review by BHEL / NTPC prior to
1.
manufacture. Inspection of above mentioned tests by BHEL/ NTPC representative at
bidder’s works is envisaged.
Ball Mill
Raw material for shaft, coupling, gears and pinions, Mill Heads, top and bottom races
and other rotating components shall be subjected to UT & Base frame for MPI.
MPI/LPI shall be carried out to check surface soundness.
Rubber wear lining of Mill Shell shall be checked for shore hardness.
For Central driven ball mill shall be run tested (without grinding media) for 30 min
2. at shop to check unusual noise and vibration.
Butt welds in the tube/separator/body casing of the mill shall be tested by RT and
MPI. All other welds in main tube/separator shall be tested by MPI/LPI for
acceptance. The tube shall be statically balanced
All gearboxes shall be run tested for adequate duration to check rise in oil
temperature, noise level and vibration. Check for leak tightness of gear case also shall
be performed.
All WBMs will be inspected at the Bidder’s works before dispatch or where the test
facilities are available.
3. Feeders

37 | P a g e
Any welds in the casing/pulley fabrication shall be checked with MPI.
Routine tests shall be done as per relevant Indian Standards or equivalent
International Standards
All major items like plates for casing, head pulley, tail pulley, pulley shaft and major
castings shall be procured with respective material test certificates
Calibration check shall be carried out on all feeders
PIPING, VALVE
All pipes and fittings shall be tested as per applicable code.
All valves shall be hydraulically/Air tested for body, seat and back-seat (if applicable)
4. as per relevant standard.
NDT on valves shall be as per relevant standard
Valves shall be offered for hydro test in unpainted conditions.
Functional checks of the valves for smooth opening and closing shall also be done.
TANKS
All welds joints shall be DP tested and complete tanks shall be water fill tested.
5.
All atmospheric storage tanks fabricated and erected at site shall be subjected to tests
(water fill test, NDT and Vacuum box test) according to design code as applicable
Rubber lining shall be tested for hardness and spark test, as applicable.
PUMPS
UT on shaft forgings (greater or equal to 40mm) and MPI/DPT shall be done on shafts
and impeller to ensure freedom from defects.
The pump casing shall be hydraulically tested at 200% of pump rated head or at 150%
of shut off head, whichever is higher. The test pressure shall be maintained for at least
6.
half an hour.
The pump rotating parts shall be subjected to static and dynamic balancing.
All pumps shall be tested at shop for capacity, head efficiency and brake horse power
at rated speed as per relevant/applicable standard.
Noise and vibration shall be measured during the performance testing at shop.
Agitators
Rubber lining shall be tested for hardness and spark test
7.
Impellers shall be tested for dimensional and balancing check
Gear Boxes shall be tested for run test as per standard practice
The Bidder shall furnish performance test procedure along with standard. The test
8.
procedure will be reviewed and approved by the BHEL/NTPC.
9. Wet ball mill shell shall be statically balanced.
The Bidder shall conduct performance test for the remaining WBM and submit the
10.
reports.
Acceptance tolerance of actual versus guaranteed performance for capacity, head,
11.
efficiency and power absorbed shall be as per applicable standard.
12. Vibration levels shall be measured during shop running/performance tests.
Contract shaft seals shall be used during shop tests, unless the seal design is
13.
unsuitable for the shop-test condition.
WBM shall not be released for shipment, until shop tests data and performance tests
14.
curves have been approved by Owner.

38 | P a g e
Bidder should furnish performance guarantee as per applicable standard guarantee
15. for the design, manufacture, material and safe & trouble-free operation of the WBM
& all accessories.
BHEL shall witness the test at Bidder's works and a notice of minimum three (3)
16.
weeks shall be given for attending the inspection.
17. Bidder to arrange all calibrated gauges, Instruments during inspection.
Mechanical running and the performance test shall be carried out. Bidder to arrange
18.
Motor of same / higher rating for the shop test and inspection.
Acceptance tests to be carried out as per the procedure defined by the bidder which
19.
shall be submitted for BHEL/ NTPC approval.
C) PURCHASE AND SERVICE
The major items/ equipment’s/ components to be manufactured in the shop of the
contractor i.e. in-house items and those procured from sub-vendors / sub-
1.
manufacturer / sub-contractors i.e. bought out items (BOIs) shall be listed out by the
contractor in their bid proposal.
The list of manufacturers/ sub-vendors for all the BOIs envisaged in contract shall be
included in the bid proposal by the contractor which shall be reviewed by the NTPC
during post bid discussions and the list of proposed manufacturers / sub-vendors for
2. each of the BOIs shall be agreed/ approved. If any item is left out or gets included
during detailed engineering, the contractor shall propose the manufacturer’s / sub
vendor’s details for review / approval of NTPC, prior to initiating the procurement of
such materials.
This specification also contains the Indicative vendor list (with disclaimer) mentioned
against particular item/ equipment/ component/ system etc.
3.
The vendor list are only indicative and not exhaustive. Refer Annexure-16

39 | P a g e
14. PAINTING
Painting scheme given below is tentative. The painting details shall be finalized
during contract stage:
14.1. Limestone Mill- Outside Surfaces:
Vendor to
S. No Description
confirm
SURFACE PREPARATION:
Blast cleaning to Sa 2½
Total DFT
PAINT
(μm min)
Primer: Two coats of Epoxy resin based Epoxy Zinc
100
phosphate primer to IS 13238
PRIMER
DFT- 50μ/coat (Total DFT μm min=100)

Intermediate:
100
One coat of Two component epoxy based intermediate
paint pigmented with MIO/Tio2 DFT- 100μm min)
Finish: One coat of Epoxy based finish paint to IS
FINISH
75
14209, DFT- 75μ/coat
Finish: One coat of acrylic aliphatic polyurethane paint
25
to IS 13213, DFT- 25μ/coat
TOTAL DFT (μm min)
300
14.2. Limestone Mill- Inside Surfaces:
Vendor to
S. No Description
confirm
Blast cleaning to Sa 2½ (Near white metal)
with surface profile 40-60μm conforming to ISO 8501-1
Total DFT
PAINT (μm min)
Primer Coat: One coat of two component moisture
70
curing inorganic Ethyl Zinc Silicate Primer to IS 14946,
PRIMER
(Solid by volume- 60% (min)), (Metallic zinc content

80% (min))
DFT = 70 μm per coat (min.)
Zinc dust composition shall be Type-II as per

ASTMD520-00
FINISH
TOTAL DFT (μm min) 70

40 | P a g e
14.3. Process water pipe accessories
Vendor to
S. No Description
confirm
Power Tool Cleaning to St3 (SSPC-SP3)
Total DFT(μm
PAINT
min)
Primer: Red Oxide Zinc Phosphate Primer to IS: 60
PRIMER
12744 (Two coats)

Intermediate: One coat of Synthetic Enamel 50
intermediate coat to IS 2932; DFT- 50μ
Finish: Two coats of synthetic Enamel to IS 2932,
FINISH
100
DFT-50μm/coat
Shade: Grey white RAL 9002
Identification tag: Sea green shade no: 217 as per IS 5
14.4. Slurry Pipe Accessories
Vendor to
S. No Description
confirm
Total DFT(μm
PAINT
min)
Primer: Red Oxide Zinc Phosphate Primer to IS: 12744
PRIMER
60
(Two coats)
Intermediate: One coat of Synthetic Enamel
50
intermediate coat to IS 2932; DFT- 50μ
Two coats of Synthetic Enamel to IS 2932,
100
FINISH
DFT- 50μ/ coat

Shade: Grey white RAL 9002
Identification Tag: Sea Green Shade no: 217 as per
IS 5

41 | P a g e
14.5. Service Air pipe accessories
Vendor to
S. No Description
confirm
Total DFT
PAINT
(μm min)
100
PRIMER

Intermediate:
100
FINISH
75
25
TOTAL DFT (μm min)
300
14.6. Instrument Air pipe accessories
Vendor to
S. No Description
confirm
Total DFT
PAINT
(μm min)
100
PRIMER

Intermediate:
100
FINISH
75
25
TOTAL DFT (μm min)
300

42 | P a g e
14.7. Valves and fittings
(Temp <95 deg C)
Vendor to
S. No Description
confirm
Total DFT
PAINT (μm min)
Red Oxide Zinc Phosphate Primer to IS: 12744 (Two
PRIMER
60
coats)
Synthetic Enamel to IS 2932 Shade: Grey white RAL

FINISH
60
9002 (Two coats)- 30μ/ coat
15. SPARES
15.1. START UP & COMMISSIONING SPARES

Vendor to
S. No Description
confirm
Start-up & Commissioning Spares shall be part of the main supply of the WBM. Start-
up & commissioning spares are those spares which may be required during the start-
up and commissioning of the equipment/system. All spares required for successful
operation till commissioning of WBM shall come under this category. Bidder shall
provide an adequate stock of such start up and commissioning spares to be brought
by him to the site for the equipment erection and commissioning. The spares must be
available at site before the equipment’s are energized.

43 | P a g e
15.2. MANDATORY SPARES (FOR EACH PROJECT)
Vendor to quote 1 Set per project. List of items with quantities per set is as per below
tables.
PROJECT CONSISTS OF TWO SETS OF LIMESTONE GRINING SYSTEMS.
Vendor to
S. No Description
confirm
a) The list of mandatory spares considered essential by the Employer is indicated in the
list below. The bidder shall indicate the prices for each and every item (except for
items not applicable to the bidders design) in the ‘Schedule of Mandatory Spares’
whether or not he considers it necessary for the Employer to have such spares. If the
bidder fails to comply with the above or fails to quote the price of any spare item, the
cost of such spares shall be deemed to be included in the contract price. The bidder
shall furnish the population per unit of each item in their Bid. Whenever the quantity
is mentioned in “sets” the bidder has to give the item details and prices of each item.
b) Whenever the quantity is indicated as a percentage, it shall mean percentage of total
population of that item in the station (project), unless specified otherwise, and the
fraction will be rounded off to the next higher whole number. Wherever the
requirement has been specified as a ‘set’ (marked by **) it will include the total
requirement of the item for a unit, module or the station as specified. Where it is
specified as ‘set’ (marked by*) it would mean the requirement for the single
equipment / system as the case may be. Also one set for the particular equipment. e.g.
‘set’ of bearings for a pump would include the total number of Bearings in a pump.
Also the ‘set’ would include all components required to replace the item; for example,
a set of bearings shall include all hardware normally required while replacing the
bearings.
c) The assembly / sub assembly which have different orientation (like left hand, right
hand, top or bottom), different direction of rotation or mirror image positioning or
any other regions which result in maintaining two different sets of spares to be used
for subject assembly / sub-assembly shall be considered as different type of
assembly/sub-assembly.

44 | P a g e
d) The prices of mandatory spares indicated by the Bidder in the Bid Proposal sheets
shall be used for bid evaluation purposes.
e) All mandatory spares shall be delivered at site at least two months before scheduled
date of initial operation of the first unit. However, spares shall not be dispatched
before dispatch of corresponding main equipment.
f) The Employer reserves right to buy any or all the mandatory spare parts.
g) Bidder to provide the split up price for mandatory spares during placement of order.
h) Bidder shall indicate the service expectancy period for the spare parts under normal
operating conditions before replacement is necessary.
i) All spares supplied under this contract shall be strictly inter-changeable with the parts
for which they are intended for replacements. The spares shall be treated and packed
for long storage under the climatic conditions prevailing at the site e.g. small items
shall be packed in sealed transparent plastic with desiccators packs as necessary.
j) All the spares shall be manufactured as per same specification quality plan.
k) The bidder shall provide employer with cross-sectional drawings, catalogues,

assembly drawings and other relevant documents so as to enable the employer to
identify and finalize order for recommended spares.
l) Each spare part shall be clearly marked or labelled on the outside of the packing with
its description. When more than one spare part is packed in a single case, a general
description of the content shall be shown on the outside of such case and detailed list
enclosed. All cases, containers and other packages must be suitably marked and
numbered for the purpose of identification.
m) The bidder will provide the employer with all the addresses and particulars of his sub-
suppliers while placing the order on vendors for items/components/equipment’s
covered under the contract and will further ensure with his vendors that the employer,
if so desires, will have the right to place order for spares directly on them on mutually
agreed terms based on offers of such vendors.
n) The bidder shall guarantee long term availability of spares to the employer for the full
life of the equipment covered under this contract. The bidder shall guarantee that
before going out of production of spare parts of the equipment covered under the

45 | P a g e
contract, he shall give the employer at least 2 years advance notice so that the latter
may order his bulk requirement of spares, if he so desires. The same provision will
be applicable to sub-contractors. Further, in case of discontinuance of manufacture of
any spares by the bidder and/or his subcontractors, bidder will provide the employer,
two years in advance, with full manufacturing drawings, material specification and
technical information on alternate equivalent makes required by the employer for the
purpose of manufacture/procurement of such items.
o) Wherever set is mentioned, one set of the spares of that item shall be for complete
replacement of that particular item for one equipment.
p) Any fraction of an item shall mean the next higher integer.
q) Wherever quantity has been specified as percentage (%), the quantity of mandatory
spares to be provided by bidder shall be the specified percentage (%) of the total
population of the plant. In case quantity so calculated happens to be fraction, the same
shall be rounded off to next higher whole number.
r) Where ever quantity has been indicated for each type, size, thickness, material, radius,
range etc., the same shall be furnished in the bid.
s) In case spares indicated in the list are not applicable to the particular design offered
by the bidder, the bidder should offer spares applicable to offered design with
quantities generally in line with the approach followed:
15.2.1. Hydro-cyclone
Vendor to confirm
S. Nos. /Sets for each
Description whether he quoted
No project
or not
10% of each type
1) Hydro-cyclone isolation valve OR 1 no. whichever
is higher
10% of each type
2) Hydro-cyclone OR 1 no. whichever
is higher
10% of each type
Hydro-cyclone rubber lining-Feed chamber and
3) OR 1 no. whichever
overflow chamber
is higher

46 | P a g e
15.2.2. Feeders
Vendor to confirm
Sl. Nos. /Sets for each
No project
or not
1) Belt 4 sets*
2) Belt drive motors 1 no
3) Belt drive reducer 2 nos
4) Speed reducer assembly 1 set*
5) Weighing instruments 1 set*
Feeder weighing roll 1 no

6)
Gravimetric feeder gate actuator assembly 1 no
7)
1 no
8) Counter assembly of feeder complete
Feeder head pulley assembly 1 no

9)
Inlet span roller assembly 6 nos
10)
15.2.3. LIMESTONE MILLS
Vendor to confirm
No project
or not
1) Mill wear parts (liners) & grinding element 1 sets
Note: One set of Mill wear parts (Liners) above is
defined as under:
1 Set = (Grinding elements needed for complete

replacement of one mill) X (8000 x 1)/GWL,
rounded off to nearest highest whole number.
Where:
GWL = Guaranteed wear life of Mill wear parts as
offered by the bidder.
2) Auxiliary motor 1 nos
3) Gear box internals (including bearing and seals) 2 sets*

47 | P a g e
4) Complete gear box 1 set*
5) Lube oil/Grease System for
5.1. Pump assembly 2 no of each type
5.2. Motor 1 no of each type

1 no of each type
5.3. Pressure regulator
2 no of each type
5.4. Filters
1 no of each type
5.5. Pump & motor coupling
15.2.4. SLURRY VALVES
Vendor to confirm
No project
or not
2 no of each type
1. Slurry valves
and size
15.2.5. SLURRY LINE BENDS
Vendor to confirm
No project
or not
2 no of each type
1. Slurry line bends
and size

48 | P a g e
15.2.6. AGITATOR
Vendor to confirm
Nos. /Sets for each
Sl. No Description whether he quoted
project
or not
1. Impeller assembly 1 no of each type
2. Bearing assembly 2 no of each type
3. Motor 1 no of each type
4. Belt and pulley (if applicable) 2 no of each type
5. Gear box assembly (if applicable) 1 no of each type
15.2.7. MILL CIRCUIT PUMPS
Vendor to confirm
No project
or not
1. Impeller Assembly 1 nos. of each type
Casing Liners (where replaceable liners are
2. 2nos. of each type
provided)
3. Seals 4 sets of each type
4. Bearings 2 no. of each type
5. Motor 1 no of each type
6. Motor-Pump Coupling 1 no. of each type

49 | P a g e
15.2.8. CONTROL VALUES, ACTUATORS & ACCESSORIES
Following items shall be provided under this clause for all modulating control values
under this package even if one or more of these items are also specified elsewhere
under mandatory spares
Vendor to confirm
No project
or not
10% or 1 no of each
type, model and
1. Pneumatic and electro-hydraulic actuator assembly
rating, whichever is
more
Diaphragms, O’ rings, seals etc. of all types make
2. 100%
etc.
10% or 2 nos. of each
3. Pressure Gauges of all types
whichever is more
4. Solenoid valves (if applicable)
whichever is more
Positioner units/smart positioners (complete unit)& 10% or 1 no. of each
5.
accessories (link assembly) whichever is more
Pneumatic air-filter/Regulator of each type, make 10% or 2 nos. of each
6.
rating etc. whichever is more
7. Air lock relays
whichever is more
15.2.9. PNEUMATICS ISOLATION / BLOCK VALVES, ACTUATORS &

ACCESSORIES
(For all ON/OFF valves supplied under this package even if one or more of these items
are also specified elsewhere under mandatory spares)
Vendor to confirm
No project
or not
10% or 1 no of each
type, model and
1. Pneumatic and electro-hydraulic actuator assembly
rating, whichever is
more
Diaphragms, O’ rings, seals etc. of all types make
2. 100%
etc.
Limit switches (complete unit) & accessories (link 10% or 2 nos. of each
3.
assembly) whichever is more
Pneumatic air-filter/Regulator of each type, make 10% or 2 nos. of each
4.
rating etc. whichever is more

50 | P a g e
15.2.10. CONTROL AND INSTRUMENTATION
ALL MEASURING INSTRUMENTS
Vendor to confirm
No project
or not
Electronic Transmitters
1.1 Transmitters of all types, ranges and model no. (For
10% or 1 no. of each
measurement of pressure, differential pressure, flow,
type and model
1. level, etc.). This shall include magnetic/
whichever is more
electromagnetic flow meter, mass flow meter also.
50% of each type,
1.2 Level Transmitters(Ultrasonic/radar type) and length including
sensors.
Temp Elements
RTD’s of each type and length (with head assembly,
type and length
terminal block and nipple)
whichever is more
2.
Thermo-couples of each type (with head assembly,
type and length
terminal block and nipple)
whichever is more
10% if each type and
Temperature Transmitters
model
5% or 1 no. of each
make, model and type
whichever is more(to
Local indicators like temperature gauges, pressure
be divided to various
3. gauges, differential pressure gauges, flow gauges,
ranges in proportion
flow meters etc.,
to main of all make,
model, type
population).
Process actuated switch devices includes all types of 5% or 1 no. of each
4. pressure, differential pressure, flow, temperature, type and model
differential temperature, level switch devices whichever is more
1 no. of each type and
5. PD type flow transmitters
model
6. Any other instruments( if applicable) type and model
whichever is more
7. PROCESS CONNECTION PIPING ( For impulse piping/Tubing and air supply piping as applicable)
type, class, size and
1. Valves of all types and models
model whichever is
more

51 | P a g e
type, class, size and
2. 2 way, 3 way, 5 way valve manifolds
model whichever is
more
10% or 1 packet of
each type, class, size
3. Fittings
and model whichever
is more
5% of each model or
4. Purge meters 2 nos. whichever is
more
20% of each model or
5. Filter regulators 2 nos. whichever is
more
15.2.11. ELECTRICAL ACTUATORS

Vendor to confirm
No project
or not
Actuators 1 no. of each type
1.
and
2. Power unit for modulating actuator 2 nos. of each type
3. DC-DC unit / Power Units 2 nos. of each type
4. Electronic cards 2 nos. of each type
5. Position feedback transmitters 2 nos. of each type
6. Control Unit 2 nos. of each type
7. Torque And limit switch assembly of each unit 2 nos. of each type
15.3. RECOMMENDED SPARES

Vendor to
S. No Description
confirm
In Addition to the spare parts mentioned above, the contractor shall provide a list of
1.
recommended spares for 3 years of normal operation of the plant and indicate the list
and total prices. The list shall take into consideration the mandatory spares into
consideration. The employer reserves right to buy any or all the recommended

52 | P a g e
mandatory spares, the recommended spares shall be delivered at project site at least
two months before the schedule date of initial operation.
Prices of recommended spares will not be used for evaluation of the bids. The prices
2.
of these spares will remain valid up to 6 months after placement of Purchase order.
However, bidder shall be liable to provide justification for the quoted prices for these
spares as desired by employer.
16. SPECIAL TOOLS AND TACKLES
Vendor to
S. No Description
confirm
Any special tools & tackles required for the entire equipment to disassemble,
1.
assemble or maintain the units, they shall be included in the quotation and furnished
as part of the initial supply of the machine. List of special tools & tackles shall be
decided by bidder as per his proven practice. When special tools are provided, they
shall be packaged in separate, boxes with lugs and marked as “Special Tools for (tag
/ item number).”Each tool shall be stamped or tagged to indicate its intended usage.
Levers and eye bolts for the removal of parts to be serviced shall be submitted with
special tools.

53 | P a g e
17. PERFORMANCE GUARANTEES AND SCHEDULE OF GUARANTEES
SCHEDULE OF GUARANTEES:
All performance tests shall be carried out in accordance with the relevant latest international codes/standards.
Bidder to confirm the compliance with Sub-Section –VI (Functional Guarantees & Liquidated Damages) of
NTPC Specification, part of Annexure-13 of this specification.
CATEGORY –I GUARANTEES:
Data
S. No Description
Bidder to Provide
1. Guaranteed auxiliary power consumption (equipment’s to be considered for
power consumption is as per 18.1 of this technical specification) at rated
capacity in KW. Bidder shall furnish Break-up among list of equipment’s
considers which is subjected to approval.
CATEGORY –III GUARANTEES:

Data
S. No Description
Rated capacity of Wet Ball Mill (WBM) TPH at rated Limestone output 87.9 TPH @ ≥90%
1.
fineness. through 325mesh.
Contractor shall demonstrate the above capacity with the originally installed
grinding elements in nearly worn-out condition as mutually agreed for the
purpose of ascertaining wear life of any of the wear parts
Life of WBM wear parts
2. ≥ 8,000 hours
Contractor shall demonstrate the life of wet ball Mill wear parts in line with
requirements stipulated in chapter -9(Design and construction of mill and
accessories) of the Technical Specification. The establishment of the above
guarantee shall be based on the operating records available at the Power
station and will be computed for each pulverizer based on actual total hours
of operation.
Guaranteed ball consumption
3. Bidder to Provide
Contractor shall guarantee ball consumption per ton of limestone throughput
in line with requirements stipulated in chapter -9(Design and construction of
mill and accessories) the Technical Specification. Contractor shall furnish
the minimum ball diameter below which the balls shall be replaced.
4. Noise level at a distance of 1.0 meter from the equipment at site and 1.5 m ≤ 90 dB A(for ball mill)
above operating floor ≤85 dB A(for other
equipment’s)
OTHER GUARANTEES
Data
S. No Description
1. Maximum vibration (peak to peak amplitude at site) microns Bidder to Provide
≥ 25,000 hours
2. Scheduled Maintenance (Minor Overhauls): Recommended intervals
between maintenance outages

54 | P a g e
≥ 75,000 hours
3. Scheduled Maintenance (Major Overhauls): Recommended intervals
between maintenance outages
Equipment Availability (%) Continuous for 180 days Bidder to Provide
4.
PERFORMANCE TESTS AND ACCEPATNACE OF GUARANTEE TEST RESULTS
Vendor to
S. No Description
confirm
All performance tests for WBM shall be carried out in accordance with any latest
1.
International codes/standards.
1. Capacity of the WBM to be guaranteed 87.9 TPH (with output fineness of 90%
or higher passing through 325 mesh for the range of Limestone specified
elsewhere).
2. The Bidder shall ensure a design of the equipment to achieve an average target
availability of 98% for 120 days.
3. All the wear parts of the WBM shall be guaranteed for a minimum wear life of
not less than 8000hrs.
4. Bidder to guarantee ball consumption per ton of limestone throughput. Bidder

shall furnish the minimum ball diameter below which the balls shall be replaced.
5. Noise level ≤ 90 dBA( for ball mill excluding motor) and ≤ 85 dBA (for other
equipment’s) at 1m horizontal distance from equipment/enclosures and 1.5m
above operating floor is to be guaranteed excluding motor.
6. Vibration levels measured on the non-rotating parts shall not exceed the zone
limit “B” as defined in ISO 10816 at steady conditions and shall not exceed the
zone limit “C” as defined in ISO 10816 at transient conditions.
7. Acceptance tests to be carried out as per the procedure defined by the bidder
which shall be submitted for BHEL/ NTPC approval.
8. Power consumption for entire wet ball milling system. Bidder to submit
procedure to calculate motor shaft power as per IEC-60034 standard
9. In the event that the performance test is unsuccessful, bidder shall take necessary
remedial action at his cost and the performance test shall be repeated.
10. Product size: 30 wt. % slurry 325 mesh 90% passing limestone.
11. Refer Annexure-13 for functional guarantees and liquidated damages for short
fall in performance, bidder to confirm the compliance accordingly.

55 | P a g e
12. For Category – I guarantees: In case during performance it is found that
equipment/system has failed to meet the guarantees, the contractor shall carry out
all necessary modifications and/or replacements to make the equipment/system
comply with the guaranteed requirement at no extra cost to the employer and re-
conduct the performance guarantees test(s) with Employers consent. In case the
specified performance guarantee(s) is not met Liquidated Damages (LD) shall be
imposed if the demonstrated guarantees are within acceptable Shortfall Limit.
However, if the demonstrated performance guarantees continue beyond the
stipulated Acceptable Shortfall limit even after the above
modifications/replacements within ninety(90) days or a reasonable period
allowed by employer after the test have been completed, the employer will have
the right to either of the following:
Reject the equipment /System / plant and recover from the contractor the payment
already made
OR
Accept the equipment /system/plant after levying LD. The LD for shortfall in
performance indicated in clause 18.0. The LD’s shall be pro-rated for the
fractional parts of the deficiencies.
13. For Category – III & OTHER guarantees: In case during performance it is
found that equipment/system has failed to meet the guarantees, the contractor
shall carry out all necessary modifications and/or replacements to make the
equipment/system comply with the guaranteed requirement at no extra cost to the
employer and re-conduct the performance guarantees test(s) with Employers
consent. In case the specified performance guarantee(s) are still not met even after
the above modifications /replacements within 90 days or reasonable period
allowed by the Employer, after tests have been completed. the employer will have
the right to either of the following:
Reject the equipment /System / plant and recover from the contractor the payment
already made
OR
Accept the equipment /system/plant after assessing the deficiency in respect of
the various ratings, performance parameters and capabilities and recover from the
contract prices an amount equivalent to the damages as determined by NTPC.
Such damages shall, however be limited to the cost of replacement of equipment,
replacement of which shall remove deficiency so as to achieve the guaranteed
performance.

56 | P a g e
18. GUARANTEED POWER CONSUMPTION
Vendor to
S. No Description
confirm
1. GUARANTEED POWER CONSUMPTION
Bidder to specify the guaranteed power consumption of complete limestone grinding
system as well as individual equipment in their offer. While guaranteeing the
auxiliary power consumption the bidder shall necessarily include all continuously
operating packages under scope of supply. The auxiliaries to be considered shall
include but not be limited to the following for Guaranteed Power consumption
calculation (GPC).
a. Gravimetric feeder – 1 No.
b. Wet Ball mill Main Motor (Shaft Power- Bidder to submit procedure
to calculate motor shaft power as per IEC standard.) - 1 No.
c. Mill Circuit Pump- 1 No.
d. Mill circuit Tank Agitator- 1 No.
e. Wet ball mill lubrication – 1 set working pumps(HP Lube Oil Pump &
LP Lube Oil Pumps)
f. Main reducer lubrication system - 1 set of working pumps
The equipment’s listed above for calculating auxiliary power consumption are
indicative. Any other equipment requires for continuous operation of the system shall
be considered for calculation of auxiliary power consumption
BIDDER TO GUARANTEE POWER CONSUMPTION ≤ 2630 KW FOR ENITRE WET BALL
2.
MILLING SYSTEM.
In case power consumption more than 2630 KW bidder shall be loaded 1, 98,198
INR per KW.
Adjustment factor for excess power consumption in INR = (GPC-2630) X PL X 1 No.

of Working WBM.
GPC- Guaranteed Shaft Power Consumption quoted by bidder in KW.
PL- Power Loading @ 1, 98, 198 INR/KW.

57 | P a g e
19. LIQUIDATED DAMAGES FOR POWER CONSUMPTION
Vendor to
S. No Description
confirm
1. If actual shaft Power Consumption during prove out (or) PG Test operating at the
duty point exceeds the value guaranteed by the bidder, liquidated damages for
shortfall in performance shall be deducted from contract price as per the formula
given below
Liquidated damage deductible in INR per WBM = (APC-GPC) X P X 1 No. of
Working WBM
Where,
 GPC- Guaranteed Shaft Power Consumption quoted by bidder in
KW
 APC- Actual Shaft Power Consumption in KW
 P- Penalty @ Rs 1,98,198 per KW
Note:
 In case of shortfall bidder has to carry out necessary modifications and/or
replacements at no extra cost to the employer and re-conduct performance
test with employers consent. In case the specified performance guarantees are
not met and are within the acceptable shortfall limit (+1% of guaranteed
auxiliary power consumption) then penalty shall be imposed.
 If the contract currency is other than US dollars, then the liquidated damages
shall be in equivalent amount in contract currency based on Bill selling
exchange rate of State Bank of India prevailing on the 8th March 2018.
20. WARRANTY
Vendor to
S. No Description
confirm
1. The Bidder warrants that the equipment/ items shall be free from defects in the design,
engineering, materials and workmanship of the Plant and Equipment supplied and of
the work executed. The Defect Liability Period shall be thirty six (36) months from
the date of supply (or any part thereof) or twenty four (24) months from the date of
commissioning (or any part thereof), whichever first occurs. If during the Defect
Liability Period any defect should be found in the design, engineering, materials and
workmanship of the Plant and Equipment supplied or of the work executed by the
Bidder, the Bidder shall promptly, in consultation and agreement with BHEL
regarding appropriate remedying of the defects, and at its cost, repair, replace or
otherwise make good (as the Bidder shall, at its discretion, determine) such defect as
well as any damage to the Facilities caused by such defect.

58 | P a g e
2. In case of failure of the equipment to meet the guarantee, NTPC/BHEL reserves the
right to reject the equipment. However, NTPC/BHEL reserves the right to use the
equipment until new equipment supplied by bidder meets the guaranteed
requirement .
21. FIRST FILL OF CONSUMABLES:
S. No Description Vendor to
confirm
1. Bidder’s scope shall also include supply and filling of all chemicals, reagents, resins,
lubricants, grease, filters and consumable items for operation up to commissioning
including top up requirements. All lubricants proposed for the plant operation shall
be suitable for all operating and environmental conditions that will be met on site
consistent with good maintenance procedures as instructed in the maintenance
manuals.
2. Detailed specifications for the lubricating oil, grease, gases, servo fluids, control
fluids, chemicals including items qualities and quantities required per month of the
plant operation for the NTPC/BHEL’s approval herein shall be furnished within 2
months f placement of Order. On completion of erection complete list of
bearings/equipment giving their location and identification marks shall be furnished
to BHEL along with lubrication requirements. All types of chemicals, consumables,
lubricants and grease shall be readily obtainable locally and the number of different
types shall be kept to a minimum. For each type and grade of lubricant recommended,
bidder shall list at least three equivalent lubricants manufactured by alternative
companies.
22. TRAINING
confirm
Successful bidder shall provide comprehensive training for NTPC/BHEL
Engineering, O&M, Erection & Commissioning staffs at site covering all aspects of
the LGS system - Operation & Maintenance, Troubleshooting etc. and also
Engineering personnel at manufacturer’s works.
23. CONFLICT
confirm
Bidder’s equipment shall be designed for and shall meet the service, performance and
minimum level of quality requirements specified. Bidder shall be solely responsible
for advising NTPC in writing of any conflicts between the specifications and Bidder’s
design, including performance and levels of quality. Bidder agrees that its obligations,

59 | P a g e
liabilities and warranties shall not be diminished or extinguished due to its meeting
the requirements of the Specification.
24. DOCUMENTATION
confirm
Bidder shall submit necessary data, documents , GA drawings (PDF & DWG),
sections, sub-assembly drawings, specifications of main and sub components and
necessary set of operation & maintenance manual as asked by NTPC must be
furnished by bidder in soft copy forms for review. The documents will be in PDF as
well as editable form like DOC, XLS, DWG.
A. DOCUMENTS TO BE SUBMITTED ALONG WITH THE OFFER:

Sl. Required
Description Purpose
No. for Part
Attachment-3K(annexure of Qualification Requirement) of bid Qualification
1. I
Requirement (QR)
Reference plant details of similar or higher capacity mill size
2. supplied I QR
Technical evaluation
3. Sign & Seal of bidder on all pages specification II
of Bid (TEB)
4. Deviation list (if any to be submitted by Bidder) II TEB
General Arrangement(GA) & Cross section drawing of ball
milling system with bill of materials, Material Of
5. Construction(MOC), major assemblies Weights and dimensions II TEB
(also weight & dimensions of heaviest item in every assembly)
for E&C.
6. Ball Mill System foundation plan and loading details. II TEB
7. PFD of Ball mill system with mass balance. II TEB
8. P & ID diagram of ball mill system. II TEB
P & ID diagram of Lube oil system of Support bearing and main
9. II TEB
reducer.
Filled up Data sheet (Annexure-12) of ball mill and other
10. II TEB
accessories.
11. Mill Performance curves. II TEB
12. Operation philosophy and logic of ball mill system. II TEB
2 2
Ball mill Sizing Calculation & Rotor G-D (kg-m ), design basis
13. II TEB
of motor sizing and T-S curve.
14. Instrumentation list II TEB

60 | P a g e
15. Utility list II TEB
16. Electrical Load List II TEB
Schedule of Guaranteed power consumption along with
17. II TEB
breakup.
18. Make of all bought out items & sub vendor list. II TEB
19. Quality Plans. II TEB
List of Start-up & Commissioning to be provided (vendor
20. II TEB
scope).
21. List of Special Tools to be provided (vendor scope). II TEB
Mill handling procedure and handling scheme with hoist crane
22. II TEB
requirement.
23. Overall space & headroom requirement for Ball Mill System II TEB
24. Terminal point details II TEB
25. Catalogue II TEB
B. DOCUMENTS TO BE SUBMITTED AFTER CONTRACT:

Sl. Description Handing Over of Document
No. Documents after required for
Contract in
weeks
1. Wet Ball Mill and Motor Sizing Calculations 1 Customer
Approval
2. Speed Torque Characteristic curve of Mill along 1 Customer
following details for motor selection: Approval
 Max Power Absorbed at Mill Output shaft.
 Motor Rating.
 Mill Speed (RPM).
 Motor Speed (RPM).
 Torque at Max Power Absorbed at Mill Output shaft
referred to motor speed.
 GD2 referred to Mill Shaft.
 Motor Starting torque.
 Maximum axial thrust applied on motor shaft.
 Inching reducer output speed.
 Schematic arrangement of Mill drive train.
3. Utility Consumption & Lubricating Oil List 2 Customer
Approval
4. Foundation plan and loading details(static and dynamic 2 Customer
loads) Drawing, Anchor Bolts, mounting plates static & Approval
dynamic details

61 | P a g e
5. Data sheet (data sheet to be furnished as per Annexure- 2 Customer
13) & General Arrangement of Wet ball Milling system. Approval
Complete filled Datasheet containing performance
curves.
Performance curves should be provided for Mill Thru-put
Vs. Bond Work Index (BWI), Input Limestone Feed size,
Specific Energy and Wear Life.
6. Cross section drawing of ball milling system with bill of 2 Customer
materials, Material Of Construction(MOC), major Approval
assemblies Weights and dimensions (also weight &
dimensions of heaviest item in every assembly) for E&C.
7. P&ID drawing of Ball Mill & Lube Oil System(support 2 Customer
bearing and main reducer) in PDF & AUTOCAD format Approval
and operating procedure.
8. Outline General Arrangement (OGA) of Mill Support 2 Customer
Bearings with lube oil piping arrangement, cross sectional Approval
drawing of lube oil pumps along with data sheet and type
test reports.
All instruments and pumps data sheets.
Wiring Drawings, Equipment sizing report and line &
valve sizing report.
9. Pinion support Bearing, Coupling (all couplings), 4 Customer
Reducer (main and Inching), Clutch and brake Drawings Approval
& Details.
For reducer lube oil system: cross sectional drawing of
lube oil pumps along with data sheet and type test reports.
All instruments and pumps data sheets.
10. Sizing & General Arrangement of Mill circuit Tank 4 Customer
Approval
11. Data Sheet & GA for Mill circuit Pumps for Milling Area 4 Customer
Approval
12. Sizing, data sheet and General arrangement of Hydro- 4 Customer
cyclone Approval
13. Data sheet and drawing of Agitator for Mill Circuit tank. 4 Customer
Data Sheet of agitator motor and type test report. Approval
14. Data Sheet and drawing of gravimetric feeder. 4 Customer
VFD and Motor Data Sheet and type test report(as Approval
applicable)
15. Equipment sizing reports 4 Customer
Approval
16. All piping (Slurry, water and instrument air) lines and 4 Customer
valves sizing report. Approval
17. Measurement list (with interlocks) 4 Customer
Approval
18. All Knife gate valves data sheets and drawings. 4 Customer
Approval

62 | P a g e
19. Quality Plan with Inspection & Performance Test 4 Customer
Procedure at site Approval
20. Sub vendors List 4 Customer
Approval
21. Manufacturing Schedule 4 Review
22. All Piping Arrangement Drawings (Water, Slurry & 8 To verify layout
Instrument Air) out interference
23. Special tools list 8 E&C
24. Start-up & Commissioning Spares 9 E&C
25. Pre Commissioning Check List 10 E&C
26. Installation and assembly procedure 10 E&C
27. Erection drawings and manual 10 E&C
28. Operation and Maintenance Manual with lubrication 10 E&C
schedule
29. Recommended repair procedure 10 E&C
30. List of All Motors with GA & Datasheet 10 For Power

Supply &F
31. Local Panel Control Circuit Diagram 10 For Feeder
arrangement
32. Electrical Load List with Single line Diagram 10 For Feeder
arrangement
33. Control philosophy and Logic Of Ball Mill 10 For DCS
program
34. Complete List of Valves 10 Customer
Approval
35. Complete List of Instruments along with Data Sheets 10 Customer
Approval
36. Catalogue 10 Customer
Submission
37. Pro-forma Packing List 12 Dispatch
ANNEXURES LIST
Annexure Description
Sl. No.
1. Qualification requirement.
2. Deviation list.
3. Media Analysis.
4. P&ID.
5. Sub-questionnaire for suppliers.
6. Piping and valves specification.
7. Motors & JB’s.
8. VFD’s.
9. Instruments.
10. Packing & forwarding.

63 | P a g e
11. Manufacturing Quality plan.
12. Technical Data Sheet.
13. Functional Guarantees and liquidated damages.
14. Cables.
15. General Arrangement & Elevation Details of Limestone grinding system.
16. Indicative vendor list.
17. Electrical Actuators.
VARIANT TABLE
VAR. No. DESCRIPTION MATERIAL CODE Qty /Project

00 WET BALL MILL EQUIPMENT BA9789015003 2 Sets*
(SUB ASSY OF FGD)
01 MANDATORY SPARES FOR BA9789015011 1 Set#
WBM NTPC PATRATU
02 LINERS FOR WBM EQIPMENT BA9789015020 3 Sets
PATRATU PROJECT 2 sets main+1 set
spare.
* Limestone grinding system scope of supply per set is as per Chapter No.: 07.
# Mandatory Spares Lot is as per Chapter No. 15.2.
RECORD OF REVISIONS
REV. DATE REVISION DETAILS REVISED APPROVED

No.
01 20.07.2020 Power consumption revised Uday PVS
02 02.07.2021 Sub-QR clarification added in PVS AMAN
Annexure-1.
03 18.03.2022 Updated Material codes PVS AMAN

64 | P a g e

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TECHNICAL SPECIFICATION OF WET BALL MILL EQUIPMENT

(SUB ASSEMBLY OF FGD SYSTEM)

03 18.03.2022 P V S BABU AMAN KHRK

Bharat Heavy Electricals Limited

Bidder Sign and Seal

1. PROJECT INFORMATION ............................................................................................................................3

Bidder Sign and Seal

Bidder Sign and Seal

2. GENERAL DESRIPTION OF LIMESTONE GRINDING SYSTEMS

Bidder Sign and Seal

1) Design Ambient Temperature-- 50 Deg C

Bidder Sign and Seal

Instruments, devices and equipment’s for location in outdoors/indoor/air-conditioned areas

Bidder Sign and Seal

Bidder Sign and Seal

Bidder Sign and Seal

Each mill system shall be supplied by separate distribution box.

Sl. No. Item Description Quantity UNIT Vendor to

i. All connection chute with proper liner

iii. Required instruments and any safety device

Bidder Sign and Seal

Bidder Sign and Seal

Bidder Sign and Seal

41 Temporary strainers for the Mill circuit pump 2 SET

Any other valves/instruments which are required for 1 SET

45. Supervision of Erection & commissioning at site

46. Performance Test and Inspection at site

47. Special tools & tackles as applicable 1 SET

Bidder Sign and Seal

49. Customer Approved Drawings, Installation, operation and

8. GENERAL TECHNICAL REQUIREMENTS

Sl. Description Vendor to

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Bidder Sign and Seal

Bidder Sign and Seal

Bidder Sign and Seal

9.DESIGN AND CONSTRUCTION OF MILL AND ACCESSORIES

Bidder Sign and Seal

9.3 SILO SHUT OFF GATE VALVE

Bidder Sign and Seal

9.4 GRAVIMETRIC FEEDER

9.5 WET BALL MILL

Capacity 87.9 Tons Per Hour (TPH)

Bidder Sign and Seal

Bidder Sign and Seal

Bidder Sign and Seal

9.6 MILL CIRCUIT TANK

9.7 MILL CIRCUIT PUMPS

Bidder Sign and Seal

Bidder Sign and Seal

Bidder Sign and Seal

9.8 MILL CIRCUIT TANK AGITATOR

Bidder Sign and Seal

9.9 PIPING / VALVES

Bidder Sign and Seal

Motors shall be as per the specification given in Annexure-7

9.12 Design Ambient conditions for Electricals

9.13 FIELD MOUNTED LOCAL JUNCTION BOXES & CONDUITS

Bidder Sign and Seal