TECHNICAL SPECIFICATIONS

FOR
ARCHITECTURAL, CIVIL AND
MEP WORKS

PURCHASER/CLIENT/OWNER : MINISTRY OF MICRO, SMALL AND

MEDIUM ENTERPRISES,
PUDI,VISAKHAPATNAM

PROJECT : MSME TECHNOLOGY CENTER, PUDI

LOCATION : PUDI, VISAKHAPATNAM

CONSULTANT/CMC/PROJECT : TATA CONSULTING ENGINEERS LIMITED

MANAGER

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 Table of Contents
ARCHITECTURE WORKS ....................................................................................... 9
1.1 ARCHITECTURE SCOPE OF WORK .................................................................................................. 9
1.2 SPECIFICATIONS FOR NON-DSR ITEMS ......................................................................................... 9
CIVIL WORKS ........................................................................................................ 36
2.1 RUBBLE SOLING WORK ................................................................................................................... 36
2.2 WATERPRFOOING OF UG WATER TANK...................................................................................... 37
2.3 STEEL CHEQUERED PLATES........................................................................................................... 37
2.4 COLD FORMED SECTIONS ............................................................................................................... 37
2.5 SITE GRADING ................................................................................................................................... 38
2.6 AAC BLOCKS ...................................................................................................................................... 40
2.7 HDPE FILMS ........................................................................................................................................ 41
2.8 LIST OF APPROVED MAKES FOR CIVIL AND ARCHITECTURAL WORKS .............................. 46
PLUMBING WORKS .............................................................................................. 58
3.1 SCOPE .................................................................................................................................................. 58
3.2 SCAFFOLDING ................................................................................................................................... 58
3.3 PROTECTION ...................................................................................................................................... 59
3.4 GUARANTEE ...................................................................................................................................... 59
3.5 APPLICABLE CODES, STANDARDS AND PUBLICATIONS – ..................................................... 59
3.6 QUALITY ASSURANCE AND QUALITY CONTROL ..................................................................... 63
3.7 SANITARY AND OTHER APPLIANCES .......................................................................................... 64
3.8 SOIL, WASTE, VENT AND RAINWATER PIPES ............................................................................. 68
3.9 DRAINAGE ACCESSORIES ............................................................................................................... 71
3.10 MEASUREMENT AND RATES.......................................................................................................... 72
3.11 WATER SUPPLY SYSTEM ................................................................................................................ 74
3.12 VALVES & FITTINGS......................................................................................................................... 77
3.13 TESTING .............................................................................................................................................. 79
3.14 DRAINAGE .......................................................................................................................................... 82
3.15 PUMPS.................................................................................................................................................. 85
3.16 SUBMERSIBLE PUMPS FOR WASTE WATER................................................................................ 92
3.17 PLUMBING SYSTEM-ELECTRICAL REQUIREMENTS ................................................................ 97
3.18 COMMISSIONING & GUARANTEE ............................................................................................... 100
3.19 DATA SHEETS .................................................................................................................................. 105
3.20 LIST OF APPROVED MAKES FOR PLUMBING AND SANITARY WORKS............................... 125
FIRE PROTECTION WORKS ............................................................................... 159
4.1 TECHNICAL SPECIFICATION FIRE PROTECTION SYSTEM..................................................... 159

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 4.2 FIRE PROTECTION SYSTEM-ELECTRICAL REQUIREMENTS ................................................. 167
4.3 FIRE PROTECTION SYSTEM-INSTRUMENTATION AND CONTROL (I&C) SYSTEM
REQUIREMENTS ..................................................................................................................................... 171
4.4 DATASHEETS ................................................................................................................................... 193
4.5 LIST OF APPROVED MAKES .......................................................................................................... 287
HVAC WORKS ..................................................................................................... 292
5.1 SPLIT AIR-CONDITIONERS ............................................................................................................ 292
5.2 AIR-COOLED VARIABLE REFRIGERANT FLOW SYSTEM ....................................................... 299
5.3 MTHERMAL INSULATION FOR COLD SURFACES: ................................................................... 309
5.4 PANEL TYPE AIR FILTERS ............................................................................................................. 320
5.5 AXIAL FANS FOR VENTILATION SYSTEM ................................................................................. 324
5.6 AIR HANDLING UNITS.................................................................................................................... 334
5.7 CONDENSING UNITS FOR AIR-CONDITIONING APPLICATION ............................................. 343
5.8 APPROVED MAKE LIST OF HVAC EQUIPMENTS ...................................................................... 350
COMPRESSOR WORKS ...................................................................................... 357
6.1 SCOPE OF SUPPLY ........................................................................................................................... 357
6.2 CODES AND STANDARDS.............................................................................................................. 360
6.3 SPECIFIC REQUIREMENTS / INSTRUCTION TO CONTRACTOR ............................................. 360
6.4 SPECIFIC ELECTRICAL REQUIREMENT ..................................................................................... 361
6.5 SPECIFIC REQUIREMENT OF I & C SYSTEM............................................................................... 362
6.6 GUARANTEES AND PERFORMANCE REQUIREMENT ............................................................. 366
6.7 ACCEPTANCE TEST ........................................................................................................................ 367
6.8 PAINTING .......................................................................................................................................... 367
6.9 TENDER EVALUATION AND PENALTY FACTOR ...................................................................... 367
6.10 MAINTENANCE REQUIREMENTS ................................................................................................ 368
6.11 SUMMARY OF DATA TO BE FURNISHED ALONG WITH BID AND AFTER ACCEPTANCE
OF PURCHASE ORDER ........................................................................................................................... 368
6.12 SPECIFICATION FOR AIR COMPRESSORS .................................................................................. 377
6.13 SPECIFICATION FOR WELDED UNFIRED PRESSURE VESSEL ............................................... 389
6.14 SPECIFICATION FOR LOW VOLTAGE INDUCTION MOTORS ................................................. 403
ELECTRICAL WORKS ......................................................................................... 419
7.1 INTRODUCTION – ELECTRICAL ................................................................................................... 419
7.2 HIGH VOLTAGE METAL ENCLOSED SWITCHGEAR ................................................................ 419
7.3 LOW VOLTAGE SWITCHGEAR ..................................................................................................... 424
7.4 POWER FACTOR CORRECTION SYSTEM.................................................................................... 433
7.5 TRANSFORMER - OIL TYPE: .......................................................................................................... 436
7.6 BUS DUCTS ....................................................................................................................................... 443

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 7.7 HT CABLE (UE) ................................................................................................................................. 445
7.8 1.1 KV GRADE CABLES AND CABLE TRAYS .............................................................................. 447
7.9 CABLE TRAYS .................................................................................................................................. 453
7.10 LIGHTING SYSTEM ......................................................................................................................... 455
7.11 EARTHING SYSTEM ........................................................................................................................ 470
7.12 LIGHTNING PROTECTION SYSTEM ............................................................................................. 475
7.13 DIESEL GENERATORS .................................................................................................................... 475
7.14 UPS SYSTEM ..................................................................................................................................... 488
7.15 LIST OF ACT / BYE LAWS ............................................................................................................... 498
7.16 SPARES AND MAINTENANCE TOOLS AND TACKLES ............................................................. 499
7.17 APPROVED MAKE OF ELECTRICAL COMPONENT/EQUIPMENT : .............................................................. 500
IBMS & IT WORKS ............................................................................................... 506
8.1. BUILDING MANAGEMENT SYSTEM............................................................................................ 506
8.2. FIRE DETECTION AND ALARM SYSTEM .................................................................................... 521
8.3. PUBLIC ADDRESS SYSTEM ........................................................................................................... 553
8.4. CLOSED CIRCUIT TELEVISION SYSTEMS .................................................................................. 560
8.5. ACCESS CONTROL SYSTEMS ....................................................................................................... 569
8.6. IT & TELEPHONE SYSTEMS........................................................................................................... 585
8.7. APPROVED LIST OF MAKES .......................................................................................................... 596
EOT CRANES....................................................................................................... 599
9.1. EOT CRANES .................................................................................................................................... 599
9.2. APPROVED LIST OF MAKES .......................................................................................................... 599
EXTERNAL SERVICES WORKS ......................................................................... 602
10.1. SCOPE........................................................................................................................................ 602
10.2. SPECIFIC REQUIREMENTS / INSTRUCTION TO BIDDERS............................................... 602
10.3. STP-ELECTRICAL REQUIREMENTS .................................................................................... 615
10.4. LIST OF APPROVED BIDDERS \ MAKES FOR STP ............................................................. 618
10.5. AIR BLOWER............................................................................................................................ 619
10.6. HORIZONTAL CENTRIFUGAL PUMPS ................................................................................ 625
10.7. SUBMERSIBLE PUMPS ........................................................................................................... 627
10.8. VALVES AND SPECIALITIES GENERAL REQUIREMENTS.............................................. 630
LANDSCAPE WORKS ......................................................................................... 638
11.1. SCOPE OF WORK ..................................................................................................................... 638
11.2. GENERAL ITEMS ..................................................................................................................... 638
11.3. EARTH WORKS........................................................................................................................ 639
11.3.1 MAJOR GRADING ........................................................................................................................ 640
11.3.2 EXCAVATION FOR FORMATION LEVELS AND TRENCHES ............................................................. 641

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11.3.3 FINE GRADING AND SHAPING ...................................................................................................... 641
11.4. SOILS: MATERIALS AND PREPARATION ........................................................................... 642
11.4.1 SOILS: SUBSOIL ........................................................................................................................... 642
11.4.2 TOPSOIL MIXES ........................................................................................................................... 642
11.4.3 SOIL MIXES ................................................................................................................................. 643
11.4.4 SOIL PREPARATION AND APPLICATION OF SOIL MIXES ............................................................... 644
11.4.5 FERTILIZERS ................................................................................................................................ 645
11.4.6 MULCHES .................................................................................................................................... 645
11.5. SUBSOIL DRAINAGE .............................................................................................................. 645
11.5.1 SUBSOIL, FIELD DRAINS AND TRENCH DRAINS ........................................................................... 645
11.6. HARDSCAPE FINISHES .......................................................................................................... 646
11.5.2 PAVER BLOCKS / INTERLOCKING CONCRETE BLOCK PAVEMENT: ............................................... 646
11.5.3 BEDDING SAND COURSE :............................................................................................................ 647
11.7. SOFTSCAPE WORKS ............................................................................................................... 648
11.8. SPECIAL CONDITION ............................................................................................................. 648
11.9. GENERAL SPECIFICATIONS ................................................................................................. 651
11.8.1 HOLDING NURSERY ..................................................................................................................... 651
11.8.2 PROVISION OF SITE UTILITIES ..................................................................................................... 651
11.8.3 LANDSCAPE DEVELOPMENT TECHNIQUE .................................................................................... 652
11.8.4 QUALITY OF WORKMANSHIP AND MATERIALS............................................................................ 652
11.8.5 SITE RESPONSIBILITIES ................................................................................................................ 652
11.8.6 PLANT PROTECTION .................................................................................................................... 654
11.8.7 WORK BY MACHINE OR HAND .................................................................................................... 654
11.8.8 NOTICE OF INTENTIONS ............................................................................................................... 654
11.8.9 HEAVY MACHINERY.................................................................................................................... 654
11.8.10 SUBSTITUTIONS ....................................................................................................................... 655
11.8.11 SETTING OUT .......................................................................................................................... 655
11.8.12 TOOLS AND EQUIPMENT .......................................................................................................... 655
11.8.13 FAILURES OF PLANTS (PRE-PRACTICAL COMPLETION) ............................................................ 655
11.8.14 PLANTS DEFECTS LIABILITY AND POST PRACTICAL COMPLETION CARE BY CONTRACTOR .... 655
11.8.15 SUBMITTALS ............................................................................................................................ 656
11.8.16 HANDLING, STORAGE AND DELIVERY .................................................................................... 656
11.8.17 PROTECTION OF WORK ............................................................................................................ 656
11.8.18 REFERENCE STANDARDS ......................................................................................................... 656
11.10. PLANT MATERIALS AND PLANTING OPERATIONS ........................................................ 657
11.9.1 TREES .......................................................................................................................................... 658
11.9.2 PALMS ......................................................................................................................................... 660

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11.9.3 HEDGING PLANTS ........................................................................................................................ 661
11.9.4 CONTAINER GROWN PLANTS ...................................................................................................... 661
11.9.5 CULTIVATION OF PLANT BEDS .................................................................................................... 661
11.11. PLANTING TECHNIQUES AND ACCESSORIES .................................................................. 662
11.10.1 SMALL SHRUBS, HERBACEOUS, GROUND COVER AND ROOT PLANTING IN BEDS ................... 662
11.10.2 SHRUB PITS ............................................................................................................................. 663
11.10.3 TREE PITS ................................................................................................................................ 663
11.10.4 BACKFILLING OF PITS (TREES, SHRUBS AND CLIMBERS) .......................................................... 664
11.10.5 STAKING AND SUPPORTS ......................................................................................................... 664
11.10.6 TURFING .................................................................................................................................. 666
11.10.7 WATERING OF ALL PLANTS ..................................................................................................... 671
11.10.8 MULCHING .............................................................................................................................. 671
11.10.9 FERTILISING ............................................................................................................................ 671
11.10.10 DISEASE CONTROL .................................................................................................................. 671
11.10.11 PLANTING INTO TURF AREAS .................................................................................................. 671
11.10.12 PROTECTION OF PLANTED AREAS ........................................................................................... 671
11.10.13 MAINTENANCE PRIOR TO COMPLETION .................................................................................. 672
11.12. MAINTENANCE WORKS ........................................................................................................ 672
11.11.1 GENERAL................................................................................................................................. 672
11.11.2 MAINTENANCE OF PLANTED AREAS ....................................................................................... 673

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TECHNICAL SPECIFICATION

ARCHITECTURAL WORKS

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 ARCHITECTURE WORKS

1.1 ARCHITECTURE SCOPE OF WORK

The scope includes design, detailing, procurement, supply, construction, furnishing,

testing and execution in accordance with the tender documents.
Items of work include
 Painting
 Door and Windows incl Fire Doors
 Glazing & Facade works
 Stone cladding
 Flooring and finishing
 GRC Works
 Fabrication works
 Dry Partition/Glass partition
 Ceiling Finishes
 Wall Finishes
 Waterproofing and Insulation works
 Gates including automation
 Any other works shown in the drawings but not specifically mentioned above

1.2 SPECIFICATIONS FOR NON-DSR ITEMS

1.2.1 EPOXY FLOORING

1.2.1.1 General

Epoxy coating should be based on carefully selected solvent less Epoxy resin
composition. It should be a 3 component system consisting of base, hardener and hard
wearing quartz fillers. It should be self levelling composition and forms a very smooth,
attractive hygienic, hard wearing and chemical resistant floor topping.
It should provides a joint less flooring making it dust free and is easy to clean because of
smooth surface.
Chemical Resistant – It should have excellent chemical resistance to most chemicals
Wear Resistant – It should provide a tough floor topping to withstand foot and light
vehicular traffic.

1.2.1.2 Surface Preparation

The long term durability of the applied Epoxy topping is dependent upon the adhesive
bond achieved between the flooring material and substrate. It is most important therefore,
that substrate surface is correctly prepared prior to application.
Substrate must be of sufficient strength to support loads applied through the topping.
New concrete or cementitious substrates should have been placed for at least 28 days and
have a moisture content of less than 5% before topping. Before application, the surface to

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be coated should be free from loose particles, rust, oils, grease or earlier coatings and
should be thoroughly dry. After surface is dry, all repair work like sealing of joints,
cracks filling of cavities and crevices should be carried out. 5. The self levelling action is
very localized and does not eradicate irregularities of level present in the original
substrate. It is most important, therefore, that adequate surface preparation and repair is
undertaken prior to application of flooring systems.

1.2.1.3 Priming

To be as per manufacturer‟s specifications.

1.2.1.4 Mixing

To be as per manufacturer‟s specifications.

1.2.1.5 Laying

Spread the mixture on the floor immediately to the required thickness by means of rollers
and serrated trowels. The floor should be rolled by a spike roller to remove trapped air.
The floor shall self level to uniform colour and smoothness.

1.2.1.6 Technical Information

Products Included in this System

Finish: Gloss
Thickness: 1mm
Fire Resistance : BS476: Part 7 Surface spread of flame: Class 2 (indicative)
Slip Resistance Value : Method described in BS 7976-2 Dry 67 (Typical values for 4-S
rubber slider)
Temperature Resistance : Tolerant up to 60 oC
Water Permeability : Nil-Karsten Test (Impermeable)
Vapour Permeability : 4 gms / m2 / mm / 24 hours
Abrasion Resistance : Taber Abrader - 90mg loss per 1000 cycles, (1kg Load using CS17
wheels)
Compressive Strength : >60 N/mm2 (BS6319)
Flexural Strength : >40 N/mm2 (BS6319)
Tensile Strength : >25 N/mm2 (BS6319)
Bond Strength : Greater than cohesive strength of 25N/mm2 concrete. >1.5 MPa.
Toxicity : Taint free to sensitive food stuffs

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 1.2.2 Electro Static Dissipative [ ESD ] FLOORING

1.2.2.1 General Description

a. Finish: Matt
b. Thickness: (4 mm)
c. Colour: Buff / Cream / Mustard / Red / Green / Grey
d. Preparatory work and application in accordance with manufacturer‟s instructions.

1.2.2.2 Description
Flowfresh ESD MF or equivalent to be an antistatic 4 mm heavy duty, chemical resistant
antimicrobial treated polyurethane resin floor finish. Attractive smooth matt coloured
floor finish.

1.2.2.3 Substrate Requirements :

Concrete or screed substrate should be a minimum of 25N/mm2, free from laitance, dust
and other contamination. The substrate should be dry upto 75% RH as per BS 8204 and
free from rising damp and ground water pressure. If no damp proof membrane is present
Hydraseal DPM or equivalent can be incorporated directly beneath the Flowfresh ESD
MF or equivalent system.

1.2.2.4 SUBSTRATE PREPARATION:

By enclosed shot blasting or scarification. Finish edges with hand tools. Cut minimum
4mm x 4mm anchorage grooves at edges, upstands, drains and doorways. Remove all
residues to leave a dry and dust free open textured surface.

1.2.2.5 Products Included in this System

Primer: Equivalent to Flowprime / Scratch Coat @ 0.25kg/m2
Conductive Grid of 10 mm wide copper tape.
Primer: Equivalent to Flowprime / Scratch Coat @ 0.25 kg/m2
Scatter: Conductive Grade 50 @ ~2 kg/m2
Test electrical resistance when primer has cured.
Topping: Equivalent to Flowfresh ESD MF (density 1.9 kg/l) @ 7.6 kg/m2 [ self-sealing
finish ].

1.2.2.6 Conductive Grid

A network of 10 mm wide, self-adhesive, conductive copper tape is always recommended
in combination with any antistatic flooring system. The copper tape must be applied
directly onto the cured Scratch Coat, 150mm in from the perimeter of the application. A
further grid of tape should be applied within this area at 3 m centres. Special attention
should be paid to tape areas passing over expansion or bay joints to ensure permanent
electrical continuity. The applied tape matrix should be secure and fully bonded to a
confirmed earth point.

1.2.2.7 Installation Service

The installation should be carried out by an applicator approved by the manufacturer with
a documented quality assurance scheme.

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1.2.3 VDF FLOORING (‘TREMIX’ OR EQUIVALENT)

Providing & laying in position and compaction as specified machine mixed, plain cement
concrete of grade M20 using maximum 20 mm downgraded coarse aggregate using
Vacuum Dewatering procedure "TREMIX or Equivalent" including all necessary
dewatering, form work, casting in panels of specified size and thickness, wherever
necessary, to shape and depth as specified curing, etc., complete for any specified
thickness, cutting grooves, filling joints etc.
Specification to be inclusive of
 Steel form work with steel channel sections as approved by ER/PMC, mechanical
vibration using needle and screed vibrators.
 Vacuum dewatering and Curing
 Cutting mechanically the dummy joints of 6mm wide and up to 0.33 times depth
within 24hours - 36 hrs after casting the slab. The dummy joints are at approx 4m
x 4m grids.
 Filling the grooves for joints with approved primer and approved joint sealing
compound. The joint sealant will be filed flush with PCC surface.
 The joints will be kept filled with thermocol immediately after cutting and before
filling, the same shall be removed & joints cleaned thoroughly with compressed
air etc as directed.
 The acceptable level difference of VDF shall be only maximum 5mm at entire
length.

1.2.4 METAL FIRE DOORS

1.2.3.1 Scope

This specification covers the design, supply of materials, Manufacture and installation of
factory made special type of approved make steel fire doors of 1 Hour, 2 Hrs. Fire
Rating and General Purpose Doors (FD-1 Hr., FD-2 Hr. & G.D.Series) of approved
makes.

1.2.3.2 General

The Contractor shall furnish all materials, labour, operations, equipment, tools & plant,
scaffolding and incidentals necessary and required for the completion of all metal work in
connection with steel doors, as called for in the drawings, specifications and bill of
quantities which cover the major requirements only. Anything called for in the tender
documents shall be considered as applicable to the items of work concerned. The supply
and installation of additional fastenings, accessory features and other items not
specifically mentioned, but which are necessary to make a complete functioning
installation shall form a part of this contract.
All metal work shall be free from defects, impairing strength, durability and appearance
and shall be of the best quality for purposes specified made with structural proprieties to
withstand safety strains, stresses to which they shall normally be subjected to.

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All fittings shall be of high quality and as specified and as per approval.
The Contractor shall strictly follow, at all stages of work, the stipulations contained in the
Indian Standard Safety Code or its Equivalent British Standard and the provisions of the
safety code and the provision of the safety rules as specified in the General Conditions of
the Contract for ensuring safety of men and materials.
Any approval, instructions, permission, checking, review, etc., whatsoever by the
PMC/AEC, shall not relieve the Contractor of his responsibility and obligation regarding
adequacy, correctness, completeness, safety, strength, quality, workmanship, etc.

1.2.3.3 Codes and Standards

All standards, specifications, acts, and codes of practice referred to herein shall be the
latest editions including all applicable official amendments and revisions.
List of certain important Indian Standards, Acts and Codes applicable to this work is
given below. However, the applicable standards and codes shall be as per but not limited
to the list given below:
IS : 277 Galvanized steel sheet (plain and corrugated)
IS : 3614 Metallic and non-metallic fire check doors – Resistance test and Part – 2
performance criteria.

1.2.5 HOLLOW METAL FIRE DOOR ( 2 Hours Fire Rating) WITH HONEY
COMB CORE

1.2.4.1 GENERAL

Fire door shall be 2 hour fire rated and door quality shall be approved by TAC/CBRI and
tested conformed to IS : 3614 Code or its Equivalent British Standard.
Unless otherwise specified, maximum size of door in this type:
 Single shutter door : 1200 mm x 2200mm
 Double shutter door : 2000 mm x 2400 mm
For doors above 2200 mm height (Single Doors) and 2400 mm height (Double Door) the
options shall be:
 A man operation door of size above 2049 mm height shall be provided with a
removable panel / fixed panel on top.
The construction of above panel shall be designed similar to that of a shutter in
case of flush panel to match the exteriors.

1.2.4.2 Frame

Material
Frame to be manufactured from 1.60 mm (16 gauge) galvanised steel sheets complying
with latest IS 277 Code or its Equivalent British Standard coating class zinc coating mill
phosphatized.

Profile

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Door frame profile to be double rebated of dimensions
143 mm X 57 mm (+ / - 0.3) with bending radius of 1.4 mm.

Manufacture
Frame to be manufactured from 1.60 mm thick galvanised steel sheet to the specified
profiles and dimensions. Frames manufactured at factory shall be knock down form with
butt joints for bolted assembly at site.

Door frame preparations

Frames to be provided with a 3 mm thick back plates on all jambs with provision for
anchor bolt fixing to wall openings. All frames to have reinforcement pads for fixing of
door closer, at appropriate location as per manufacturer‟s details.
Frames to have factory finish-pre-punched cut outs to receive specific hardware and iron
mongery.

Frames to be provided with hinge plates 3 mm thick pre-drilled to receive hinges for
screw mounted fixing. All cut outs including hinge plates, strike plates to have mortar
guard covers from inside to prevent cement, dust ingress into cut outs at the time of
grouting.

Frames to have rubber shutter silencer on strike jambs for single shutter frames and on
the head jambs for double shutter frames.

Finish
Door frames to be suitably cleaned with solvents and etch primered for receiving primer
and top coats. Door frames to be primered in zinc phosphate stoving primer (35 microns
DFT). Door frames to be finished in thermo setting paint (35 microns DFT) of approved
colour and make as specified.

1.2.4.3 Fire Door Shutter

Material
Fire door shutter to be manufactured from 1.25 mm (18 gauge) galvanized sheets
conforming to latest IS : 277 Code or its Equivalent British Standard coating class zinc
coating, mill phosphatized.

Manufacture
Shutters to be press formed to 46 mm thick double skin hollow door with lock seam
joints at stile edges. Shutters to have no visible screws or fasteners on either face.
Internal reinforcement to be provided at top bottom and stile edges for desired fire rating.

Door Shutter Cores

Shutters to be provided with honeycomb kraft paper core to be bounded to the inner faces
of the shutter.

Door shutter preparations

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Shutters to be factory prepared with pre-punched cutouts and reinforcements to receive
iron mongery as per final finish hardware schedule. The shutter should have an
interlocking arrangement at this stile edges for flat surface on either side.
Shutters to have pre-drilled hinge plates with hinge guard covers. Shutters with locks to
have concealed lock box with lock fixing brackets with pre-tapped holes.
For shutter with door closer reinforcement pads to be provided at appropriate location as
per manufacturer‟s design.
All iron mongery preparation to have adequate reinforcement for flushes fixing at site.

Vision panel for Fire rated door

Vision panel to be provided with Borosilicate clear toughened glass of the thickness 6
mm for up to two hours fire rating. Glass to be fixed with clip on frames for square and
rectangular vision panels and with spin turned rings for circular vision panels and
Glazing Tape with one side adhesive. Vision Panels to be fixed with clip-on frames for
square and rectangular Vision Panels with no visible screws. Unless otherwise specified
standard sizes are 200 mm x 300 mm and 360 mm diameter.

Finish
Shutters to be suitably cleaned with solvents and etch primered for receiving primer and
top coats. Shutters to be primered in zinc phosphate stoving primer (35 microns DFT).
Shutters to be finished in thermo setting paint (35 microns DFT) of approved colour and
make as specified.

1.2.4.4 Installation

Door frame fixing

The door frames should be assembled adjacent to the place of installation as the frames
are not designed for transporting in an assembled condition. After assembly it is to be
ensured that all threaded preparations are covered from the back of the frame using self
adhesive strip to prevent penetration of mortar back-fill into screw threads. The head
member of assembled frame shall be positioned against jambs ensuring correct alignment
and secured using M8 x 20 long plated bolts together with nuts spring and flat washers.

The assembled frame shall be kept in position within the opening by means of bracing.
In order to correctly position the frame against finished floor level or equalise on
adjustable floor anchors where specified, shim shall be used under jambs. The frame
shall be checked for squareness, alignment, twist etc. with carpenters bevel and plumb.

A tie rod shall be fixed to the frame during installation to ensure the correct dimensions
between the frame rebated and the same may be removed after installation.

Where a 2nd fix application is required a shim detail is suggested to take up gap between
frame and existing opening.

Existing masonry wall openings – Metal expansion shields

 Brace, position, level etc.
 Mark all positions of fixings on wall.

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  Remove frame and drill wall to appropriate specified size.
 Fit rod anchor shells metal expansion bolts into the wall.
 Fit jamb spacer bracket into back of frame profile.
 Reposition frame back into opening and realign.
 Lightly screw CSK HD machine screws into shells, shim behind frame.
 Slowly tighten screws continually checking plumb, square etc. Finally ensure
frames are not deformed as tightened.
 After fixing the frame shall be grouted with cement mortar 1:3 or Plaster of Paris
or Gypsum powder as approved. Gap between frame and wall to be closed by
cement pointing using cement mortar 1:3.
 Back full the frame through holes provided and insert nylon plugs.

Door shutter fixing

 Fix all the hardware to the door shutter like hinges, flush bolts, bolts, mortise
locks, door closer, door stoppers, handles etc. with the appropriate screws and
bolts supplied.
 The shutter is to be then fixed to the frame which is already installed. Align the
shutter to match the hardware to the cutouts in the frame. Tighten the hinge
screws.
 Application of Fire / Smoke UL 10 C / UL 1784 (2001) classified seal (for smoke
check if specifically required)
 Clean door jamb rebate surfaces of all dust, oil etc. Affix self-adhesive Fire /
Smoke seal on the door frame rebates as indicated by the manufacturer on hinge
jambs, strike jambs, head member and sill.
 2 Hours FIRE RATED DOOR – Hardware Schedule: All hardware to be in line
with door schedule drawing.

1.2.6 HOLLOW METAL FIRE DOOR1 HOUR FIRE RATING) WITH HONEY
COMB CORE

1.2.5.1 General

Unless otherwise specified, maximum size of door in this type:

Single shutter door : 1200 mm x 2200 mm
Double shutter door : 2000 mm x 2200mm
For doors of size above 2200 mm height the options shall be:
A man operation door of size above 2049 mm height shall be provided with a removable
panel / fixed panel on top with glazing or without glazing or without glazing as required.
The construction of above panel shall be designed similar to that of a shutter in case of
flush panel to match the exteriors.

1.2.5.2 Frame

Material

16
Frame to be manufactured from 1.25 mm (18 gauge) glavanised steel sheets complying
with latest IS 277 Code or its Equivalent British Standard coating class zinc coating mill
phosphatized

Profile
Door frame profile to be single rebated of dimensions
100 mm X 57 mm (+ / - 0.3) with bending radius of 1.2 mm

Manufacture
Frame to be manufactured from 1.25 mm thick galvanised steel sheet to the specified
profiles and dimensions. Frames manufactured at factory shall be knock down form with
butt joints for bolted assembly at site.

Door frame preparations

Frames to be provided with a 3 mm thick back plates on all jambs with provision for
anchor bolt fixing to wall openings. All frames to have reinforcement pads for fixing of
door closer, at appropriate location as per manufacturer‟s details.
Frames to have factory finish-pre-punched cut outs to receive specific hardware and
ironmongery.
Frames to be provided with hinge plates 3 mm thick pre-drilled to receive hinges for
screw mounted fixing. All cut outs including hinge plates, strike plates to have mortar
guard covers from inside to prevent cement, dust ingress into cut outs at the time of
grouting.
Frames to have rubber shutter silencer on strike jambs for single shutter frames and on
the head jambs for double shutter frames.

Finish
Door frames to be suitably cleaned with solvents and etch primered for receiving primer
and top coats.
Door frames to be primered in zinc phosphate stoving primer (35 microns DFT).
Door frames to be finished in thermo setting paint (35 microns DFT) of approved colour
and make as specified.

1.2.5.3 Door Shutter

Material
General purpose door shutter to be manufactured from 0.80 mm (22 gauge) glavanised
sheets conforming to latest IS : 277 Code or its Equivalent British Standard coating class
zinc coating, mill phosphatized.

Manufacture
Shutters to be press formed to 46 mm thick double skin hollow door with lock seam
joints at stile edges. Shutters to have no visible screws or fasteners on either face.

Door shutter core

17
Shutters to be provided with honeycomb paper cored to be bounded to the inner faces of
the shutter.

Door shutter preparations

 Shutters to be factory prepared with pre-punched cutouts and reinforcements to
receive iron mongery as per final finish hardware schedule. The shutter should
have an interlocking arrangement at this stile edges for flat surface on either side.
 Shutters to have pre-drilled hinge plates with hinge guard covers. Shutters with
locks to have concealed lock box with lock fixing brackets with pre-tapped holes.
 All iron mongery preparation to have adequate reinforcement for flush fixing at
site.
 For shutter with door closer reinforcement pads to be provided at appropriate
location as per manufacturer‟s design.

Vision panel
Vision panel to be provided with Borosilicate clear toughened glass of the thickness 6
mm for up to two hours fire rating. Glass to be fixed with clip on frames for square and
rectangular vision panels and with spin turned rings for circular vision panels and
Glazing Tape with one side adhesive. Vision Panels to be fixed with clip-on frames for
square and rectangular Vision Panels with no visible screws. Unless otherwise specified
standard sizes are 200 mm x 300 mm and 360 mm diameter.

Finish
Shutters to be suitably cleaned with solvents and etch primered for receiving primer and
top coats. Shutters to be primered in zinc phosphate stoving primer (35 microns DFT).
Shutters to be finished in thermo setting paint (35 microns DFT) of approved colour and
make as specified.
All hardwares to be as per the detail drawing.

1.2.5.4 Installation

Door frame fixing

 The door frames should be assembled adjacent to the place of installation as the
frames are not designed for transporting in an assembled condition. After
assembly it is to be ensured that all threaded preparations are covered from the
back of the frame using self adhesive strip to prevent penetration of mortar back-
fill into screw threads. The head member of assembled frame shall be positioned
against jambs ensuring correct alignment and secured using M8 x 20 long plated
bolts together with nuts spring and flat washers.
 The assembled frame shall be kept in position within the opening by means of
bracing. In order to correctly position the frame against finished floor level or
equalise on adjustable floor anchors where specified, shim shall be used under
jambs. The frame shall be checked for squareness, alignment, twist etc. with
carpenters bevel and plumb.

18
  A tie rod shall be fixed to the frame during installation to ensure the correct
dimensions between the frame rebated and the same may be removed after
installation.
 Where a 2nd fix application is required a shim detail is suggested to take up gap
between frame and existing opening.

Existing masonry wall openings – Metal expansion shields

 Brace, position, level etc.
 Mark all positions of fixings on wall.
 Remove frame and drill wall to appropriate specified size.
 Fit rod anchor shells metal expansion bolts into the wall.
 Fit jamb spacer bracket into back of frame profile.
 Reposition frame back into opening and realign.
 Lightly screw CSK HD machine screws into shells, shim behind frame.
 Slowly tighten screws continually checking plumb, square etc. Finally ensure
frames are not deformed as tightened.
 After fixing the frame shall be grouted with cement mortar 1:3 or Plaster of Paris
or Gypsum powder as approved. Gap between frame and wall to be closed by
cement pointing using cement mortar 1:3.
 Back full the frame through holes provided and insert nylon plugs.

Door shutter fixing

 Fix all the hardware to the door shutter like hinges, flush bolts, bolts, mortise
locks, door closer, door stoppers, handles etc. with the appropriate screws and
bolts supplied.
 The shutter is to be then fixed to the frame which is already installed. Align the
shutter to match the hardware to the cutouts in the frame. Tighten the hinge
screws.
 Application of Fire / Smoke UL 10 C / UL 1784 (2001) classified seal (for smoke
check if specifically required)
 Clean door jamb rebate surfaces of all dust, oil etc. Affix self-adhesive Fire /
Smoke seal on the door frame rebates as indicated by the manufacturer on hinge
jambs, strike jambs, head member and sill.

2 Hours FIRE RATED DOOR – Hardware Schedule

All hardware to be in line with door schedule drawings.

1.2.7 Polycarbonate Roofing

1.2.6.1 Scope
 Solid polycarbonate plastic glazing.
 Multiwall polycarbonate plastic glazing.
 Corrugated polycarbonate plastic glazing.
 Accessories for installation of plastic glazing.
 Skylight Glazing.

19
1.2.6.2 General & Codes

16 CFR 1201 Safety Standard for Architectural Glazing Materials.

ANSI Z97.1 American National Standard for Glazing Materials Used in Buildings.
ASTM D 635 Standard Test Method for Rate of Burning and/or Extent and Time of
Burning of Self-Supporting Plastics in a Horizontal Position.
ASTM D 648 Standard Test Method for Deflection Temperature of Plastics Under
Flexural Load.
ASTM D 696 Standard Test Method for Coefficient of Linear Thermal Expansion.
ASTM D Standard Test Method for Flexural Properties of Unreinforced and
790/ASTM D Reinforced Plastics and Electrical Insulating Materials.
790M
ASTM D 1003 Standard Test Method for Haze and Luminous Transmittance of
Transparent Plastics.
ASTM D 1044 Standard Test Method for Resistance of Transparent Plastic to Surface
Abrasion.
ASTM D 1929 Standard Test Method for Ignition Properties of Plastics.

ASTM D 2843 Standard Test Method for Density of Smoke from the Burning and
Decomposition of Plastics.
ASTM D 3763 Standard Test Method for Impact Resistance of Flat, Rigid Plastic
Specimen by Means of A Striker Impacted by A Falling Weight (40 ft-
lbs).
ASTM G 53 Standard Practice for Operating Light and Exposure Apparatus
(Fluorescent UV-Condensation Type) for Exposure of Non-Metallic
Materials.
QUV 313B Accelerated Weathering Test of Non-Metallic Materials.
ISO-9002 International Standards Organization.

1.2.6.3 POLYCARBONATE SHEETING : Typical Property Values

Property Test Method Unit Value

Physical Density ISO 1183 g/cm³ 1.2
Water absorption, 24 hours ISO 62 mg. 10
Water absorption, saturation /23°C ISO 62 % 0.35
Mould shrinkage ASTM-D955 % 0.6-
0.8
Poison‟s ratio ASTM-D638 - 0.38
Mechanical
Tensile stress at yield 50 mm/min ISO 527 MPa 60
Tensile stress at break 50 mm/min ISO 527 MPa 70
Tensile strain at yield 50 mm/min ISO 527 % 6
Tensile strain at break 50 mm/min ISO 527 % 120
Tensile modulus 1 mm/min ISO 527 MPa 2350
Flexural stress at yield 2 mm/min ISO 178 MPa 90

20
Flexural modulus 2 mm/min ISO 178 MPa 2300
Hardness H358/30 95 ISO 2039/1 MPa 95
Impact
Charpy impact, notched ISO 179/2C kJ/m² 35
Izod impact, unnotched 23°C ISO 180/1U kJ/m² NB
Izod impact, unnotched -30°C ISO 180/1U kJ/m² NB
Izod impact, notched 23°C ISO 180/1A kJ/m² 65
Izod impact, notched -30°C ISO 180/1A kJ/m² 10

PHYSICAL
Specific Gravity ASTM D792 ó 1.20
Sound Transmission, STC Rating (36" x 84") ASTM ó
E9070
@ 0.118" 25
@ 0.177" 29
@ 0.236" 31
@ 0.375" 34
@ 0.500" 34
Light Transmission (Average) ASTM % 88
D1003
Rockwell Hardness ASTM D785 ó M70,
R118
Chemical Resistance ANSI Z26. 1 Passes
MECHANICAL
Tensile Strength, Ultimate ASTM D638 psi 9,500
Tensile Modulus ASTM D638 psi 340,000
Flexural Strength ASTM D790 psi 13,500
Flexural Modulus ASTM D790 psi 340,000
Flexural Endurance @ 1,800 Cycles/Min, 73°F, ASTM D671 psi 1,000
50% RH
Compressive Strength ASTM D695 psi 12,500
Elongation ASTM D638 % 110
Izod Impact Strength, up to 125 mils, Notched ASTM ft-lbs/in 12ñ16
D256A
Drop Dart Impact Strength, 1" dia. dart GE Test ft-lbs
@ 73°F >200
@ 0°F >200
THERMAL
Coefficient of Thermal Expansion ASTM D696 in/in/°F 3.75 x 10-
5
Thermal Shrinkage GE Test % 1
Heat Deflection Temperature ASTM D648 °F
@ 264 psi 270
@ 66 psi 280
Shading Coefficient ASHRAE ó

21
 Clear 1.02
Gray/Bronze 79
FLAMMABILITY
Horizontal Burn (Flame Spread), AEB ASTM D635 in <1
Ignition Temperature ASTM °F
D1929
Flash 873
Self 1,076

1.2.6.4 Accessories

Profile : Aluminium custom profile 60 mm wide

Finish : 15 micron silver anodized
Flashing : Aluminium angle 35x35x1.5 thk
Gasket : EPDM rubber
Fastners : Self drilling and self tapping (SDST) screws
Washer : EPDM
Tapes : Aluminium tape roll
Sealant : Silicon, non stain

1.2.6.5 Preparation
 Glazing channels or recesses shall be cleaned and free of obstructions, soil,
debris, and other materials.
 Seal porous glazing channels or recesses with primer-sealer compatible with
substrate and polycarbonate sheet materials.
 Cut polycarbonate sheet materials to exact sizes required, with clean edges free of
notches; clean contact edges with solvent compatible with polycarbonate sheet
materials, as specified or approved by polycarbonate sheet manufacturer.

1.2.6.6 INSTALLATION
Install plastic glazing in accordance with polycarbonate sheet manufacturer's instructions.
Do not use glazing accessories not specified or approved by polycarbonate sheet
manufacturer.

1.2.6.7 CLEANING
 Immediately after completing construction activities relating to installation of
polycarbonate sheet materials, remove remainder of strippable masking from
surfaces of polycarbonate sheet glazing; do not expose masking to sunlight for an
extended period of time.
 Immediately after removing masking, clean glazing in accordance with
polycarbonate sheet manufacturer's instructions:
 Rinse surface with lukewarm water.
 Wash surface with mild soap and lukewarm water.
 Use soft cloth or sponge gently to loosen dirt and grime; scrubbing glazing
surfaces, or using squeegee on glazing surfaces, is not permitted.

22
  Repeat rinse as above, and wipe surface dry with soft cloth until surfaces are
spotless and dry.

1.2.6.8 PROTECTION OF INSTALLED PRODUCTS

 Immediately after cleaning, cover polycarbonate sheet glazing surfaces with
polyethylene sheeting, or other covering material approved by polycarbonate
sheet manufacturer; secure covering in place by taping to framing members - do
not tape covering to polycarbonate sheet materials.
 Protect installed glazing from damage to function or finish by subsequent
construction activities.
 Repair minor damage to finishes in accordance with polycarbonate sheet
manufacturer's recommendations.
 Replace glazing having damage to function, and glazing having damage to
finishes

1.2.8 GRC [ GLASS REINFORCED CONCRETE ] WORKS

1.2.7.1 Scope
The specifications refer to GRC [Glass Reinforced Concrete] works in the building.

1.2.7.2 Specialist Contractor

The work specified in this section is to be undertaken by a Manufacturer who is a
Member of the National Precast Concrete Association Australia, GRC Industry Group
with experience in the GRC industry, which includes the production of architectural
panels (or other products for which this specification is being used). With his tender, the
contractor shall submit to the construction manager written evidence indicating his
capability of producing panels of a reliable and consistent quality.

1.2.7.3 Standards and Codes

AS 3972 Portland and blended cements.

BS 1 Portland Cement.
BS 3892 Pulverised Fuel Ash for use in Concrete.
BS 476 Test Methods and Criteria for the Fire
Part 8 Resistance of Elements of Building Construction.
GRC Industry Group of National Precast Concrete Association
Australia,
A Recommended Practice – Design, Manufacture and Installation of
Glass Reinforced Concrete (GRC)
AS 3582.1 Supplementary cementitious materials for use with portland and
blended cement - Fly ash.
AS 1130 Code of practice for use of fly ash in concrete.
AS/NZS 1170.1 Structural design actions – Permanent, imposed and other actions.
AS/NZS 1170.2 Structural design actions – Wind actions.
AS 1170.4 Minimum design loads on structures (known as the SAA Loading

23
 Code) – Earthquake loads.
AS 1379 Specification and supply of concrete.
AS 3610 Formwork for concrete.
AS 1478.1 Chemical admixtures for concrete, mortar and grout – Admixtures for
concrete.
BS 1014 Pigments for Portland Cements and Portland Cement Products
BS EN 1169 Precast Concrete Products – General Rules for factory production
control of glass fibre reinforced cement.
BS EN 1170 Precast Concrete Products – Test Methods Parts 1-8 for glass-fibre
reinforced cement.

1.2.7.4 MATERIALS

General & Codes

Materials used for making the GRC unit shall generally comply with relevant British and
Australian Standards and Codes. Any reference to a British Standard shall mean that
current at the time of going to tender.
Where materials are not fully covered by this specification or alternative materials are
offered, the Contractor shall forward to the Construction Manager prior to commencing
the work, details of those he proposes to use together with supporting evidence indicating
that the finished product will be capable of meeting the performance requirements of this
specification.

Alkali-Resistant Glassfibre
Glass fibre shall be an alkali-resistant, continuous filament fibre developed and
formulated specifically to have high strength retention in Ordinary Portland Cement
environments. The glass fibre shall have a minimum ZrO2 content of 16% by weight, in
accordance with internationally-recognised standards, and shall have a minimum strength
retention (determined by Strand In Cement (SIC) testing) of 300 MPa (Test Method:
GRCA SO 104/0184).
The producer shall provide certification from the glassfibre manufacturer to show that the
glass fibre conforms to these requirements, has a history of successful use in similar
matrices, and is manufactured under an internationally-recognised Quality Management
system.
Suitable alkali-resistant glassfibres are “Cem-FIL“, manufactured by Saint-
Gobain/Vetrotex and “NEG ARG Fibre” manufactured by Nippon Electric Glass.

Cement
The cement shall be Ordinary Portland Cement, supplied by a manufacturer of assessed
capability to AS 3972– 1997 and BS 12 or its derivatives, and should be supported by
suitable certification. Cement shall be obtained from one source throughout manufacture.
Cement shall be correctly stored and kept dry to avoid deterioration.

Sand
Sands should be washed and dried to remove soluble matter, and to permit control of the
water/cement ratio. Sand added to the mix shall not exceed 50% by weight of the total

24
mix and sand/cement ratio shall not exceed 1:2. Sand shall be only high silica and
conform to the following specification:
Silica content > 967%
Water content < 2%
Soluble salts < 1%
Grain size < 1.2 mm
< 10% passing a 150 micron sieve
Sands other than silica sands may be used subject to approval of the architect and
engineer, but the producer must be able to show proof of their suitability.

Admixtures
The manufacturer shall ensure that any admixtures used do not have any harmful effects
on the product, and are used in accordance with the manufacturers‟ recommendations.
The use of superplasticisers may be encouraged to keep water content of the composite to
a minimum without loss of suitable working characteristics, especially the ease of
attaining full compaction.
Any admixtures used, shall comply with AS 1478.

Pigments
Any pigments used shall conform to BS 1014. These shall be:
 Harmless to the GRC‟s set and strength.
 Stable at high temperature.
 UV-resistant and alkali-resistant.
The client should recognise that some colour variation may occur, and must agree an
acceptable range of variation with the producer.

Water
Water shall be free from deleterious matter that may interfere with the colour, setting, or
strength of the concrete.

Mix Design
The mix shall have been determined by the manufacturer, and written confirmation of the
mix design shall be submitted so the proportions shall be chosen to achieve the quality-
control requirements specified herein.

Mould-Release Agent
The mould-release agent shall be selected by the manufacturer and approved by the
architect or engineer. This should be compatible with the surface finish required for the
product. Any residue shall be removed from the finished product so that this does not
interfere with any joint sealants or applied finishes which may be used.

Formwork
The design, material and manufacture of the forms shall be consistent with the type and
quality of the surface finish required from the panel, and with the tolerances specified.
The forms shall be constructed such that the finished products conform to the profiles and
dimensions indicated by the contract documents.

25
Support Steelwork and Fixings
 The Manufacturer will be responsible for the design, manufacture and installation
of all support framing, cleats and fixings inserted into and affixed to the GRC
panels, or provided for the support of the GRC panels. Fixing zones are described
on the drawings, together with primary structural concrete and steelwork provided
by others for use by the contractor if required.
 Fixings shall be concealed and cast into panels unless otherwise specified. They
shall be of non-corrosive material and located at suitable spacings to ensure
support of panels without creating undue stresses to the panels under thermal
movements and/or moisture movement.
 The recommendations of the Recommended Practice – Design, Manufacture and
Installation of GRC – NPCAA Publication, August 1999 (herein after called
NPCAA Recomended Practice) shall be incorporated in the design of fixings.
 Steel materials and workmanship shall comply with the relevant codes, and all
steel will be free from rust, loose scale, pitting and other defects.
 Fabricated steel components shall be true to line and free from twists, bends and
open joints.
 All ungalvanised materials shall be thoroughly cleaned prior to fabrication, by grit
blasting to Class 2 in accordance with AS 1627 Part 4 and painted with Red
Oxide Zinc Chromate in two coats to a minimum dry film thickness of 80
microns.
 Fixing cleats to existing steelwork, where indicated on the GRC cladding shop
drawings, shall be site-welded unless otherwise arranged with the construction
manager.
 Any damage to protective coatings on steelwork, supplied as part of this contract
works, shall be repaired.

1.2.7.5 WORKMANSHIP

Weighing and Batching

Dry ingredients shall be batched by weight using calibrated weighing equipment capable
of an accuracy of ± 2% of the stated batch weight. Liquids should be weighed, volume-
batched or automatically dispensed. The producer must demonstrate that the method
employed will give an accuracy of ± 2%.

Mixing
The cement slurry should be mixed in a high-speed shear mixer, or other high-speed
mixer which can achieve a good and even dispersion of all slurry ingredients.

Application
 Application shall be by spraying, using purpose-built equipment which allows the
simultaneous deposition and uniform mixing of the glassfibre and cement matrix.
 The glassfibre and cement slurry shall be metered to the spray head at rates to
achieve the desired mix proportion and glass content. These shall be checked for
each spray pump at least once per day and prior to commencing spray production

26
 after each stoppage. The test shall be conducted in accordance with the method
described in BS EN 1170-3. Distribution of fibre in the mix shall be controlled by
the operator in such a way as to be as uniform as possible.
 Cleanliness of equipment and working areas shall be maintained at all times.

Shape and Finish

 The panels are to be formed of GRC in moulds to achieve the profiles indicated
by the architectural drawings.
 The manufacturer shall provide a means for producing a replacement panel at any
time during the building contract. Moulds shall be adequately cured to eliminate
shrinkage and distortion and shall be properly braced.
 The exposed face of the GRC panels surfaces shall be free of blowholes, cracks,
undulation or similar imperfections.

Manufacture
 The panels shall be manufactured by a spray technique as detailed in the NPCAA
Recommended Practice or as otherwise agreed between the manufacturer and
architect/engineer to an approved method.
 Spray applicators shall be experienced personnel whose proficiency meets
industry standards.
 If an architectural face mix is being used, this will first be sprayed into the mould.
The thickness shall generally be the minimum possible to achieve the desired
finish, which will normally make it at least 20% thicker than the largest sand or
aggregate being used and normally 4 mm minimum and 12 mm maximum
thickness. An acrylic polymer should be used in the face mix to reduce any risk of
this unreinforced layer cracking.
 If no face mix is being used, a mist coat consisting of the basic mortar
composition without fibre may, if necessary, be sprayed onto the moulds to
prevent fibres from being visible on the finished surface of the product. The mist
coat is intended to be just thick enough to cover mould details and surfaces so that
fibres are not visible on the surface, but not so thick that crazing of this
unreinforced layer may occur.
 The normal target thickness of a mist coat for non-polymer GRC is 1 mm, though
the use of acrylic polymer in the mix may allow the thickness to be increased up
to a maximum of 3 mm. However, it should be noted that for design purposes the
thickness of the mist coat should not be considered as contributing to the strength
of the GRC panel.
 Spray-up of GRC backing material shall proceed before any mist coat or face mix
has set.
 The method of spraying the main body of material shall achieve the greatest
possible uniformity of thickness and fibre distribution.
 Consolidation shall be by rolling and such other techniques as are necessary to
achieve complete encapsulation of fibres and full compaction.

27
  Control of thickness shall be achieved by using a pingauge or other acceptable
method. Minimum thickness of panels is recommended as 8 mm (hand-spray) and
6 mm (auto-spray).
 All hand-forming of intricate details, incorporation of formers of infill materials
and over-spraying shall be carried out before the material has achieved its initial
set so as to ensure complete bonding.
 Inserts shall be properly embedded into thickened, homogeneous areas of GRC.
Waste material such as over-spray is not acceptable to encapsulate inserts or for
bonding pads.
 Any rigid embedded items bonded to the GRC shall not create undesirable
restraint to volume changes.

Shop Drawings
 Prior to commencing manufacturing work, the manufacturer shall submit for
approval detailed shop drawings showing the following information:
 layout (sectional plan and elevation) of complete wall panelling;
 full-size section of typical panel and support members;
 method of assembly and supports and fixings to the existing structure and
provision to withstand imposed stresses;
 method of installation, caulking, flashing and provision for vertical and horizontal
expansion;
 junction and trim to adjoining surfaces; and
 fittings and accessories,
 The submission of shop drawings shall be supported by engineering design
computations to show that cladding and supports comply with the design criteria
specified.

Tolerances
The GRC elements shall be manufactured and installed to the tolerances stated in the
NPCAA Recommended Practice (Section 10).

Demoulding and Curing

 Once the initial set has taken place, GRC elements should be covered with
polythene for their protection and to prevent them from drying out fully. They
must not be moved again until they are ready for demoulding.
 The GRC elements must not be demoulded until they have gained sufficient
strength to be removed from the mould and transported within the factory,
without being overstressed.
 If the GRC elements are too large to be demoulded by hand, special demoulding
sockets or loops should be embedded in the panel during manufacture, and
demoulding should be assisted with a lifting frame. This procedure should be
agreed with the engineer.
 During demoulding, the panels shall be uniformly supported in a manner which
avoids undue stresses in the panels.
 If polymers are used in the mix to avoid wet curing, the panels should be stored
under cover for a minimum of 7 days at a temperature of between 5°C and 35°C.

28
  If polymers are not used in the mix, curing shall be continued after demoulding
under conditions which shall provide free water on the surfaces of the panels at a
temperature not exceeding 50°C for a period of not less than 7 days (including the
initial cure in the mould).

Identification of Elements
All panels shall be identified individually to indicate the panel type and date of
manufacture.
At the time of preparation of shop drawings the manufacturer shall indicate his required
order of delivery.

Handling, Transportation and Installation

The products shall be handled, transported and installed using methods which ensure that
no damage or marking of architectural surfaces occurs and so that the panels are not
subject to undue stress.
The safety and protection of GRC units shall be ensured throughout the whole of the
contract works.
Site access and, if necessary, storage space shall be provided by the main contractor.
The main contractor shall also provide true, level and clean support surfaces and shall
provide for the accurate placement and alignment of connection hardware on the
structure.

Test Requirements
The specified glass fibre content shall be 5% by total wet weight of materials.
The GRC from which the panels are made shall have the following properties on
completion of curing:
 Characteristic Modulus of Rupture (MOR) 18 MPa at 28 days.
 Characteristic Limit of Proportionality (LOP) 7 MPa at 28 days.
The value of MOR and LOP design stresses to be used should be determined by the
design engineer for specific service requirements.
The minimum dry density shall exceed 1800 kg/m3.

Tests
The following tests shall be carried out on coupons cut from the test boards in accordance
with BS EN 1170 Parts 2, 4, and 5. If acrylic polymer is used in the mix, presoaking
immediately prior to testing shall not be required for Modulus of Rupture or Limit of
Proportionality.
 Glass Content – BS EN 1170 Part 2
 Modulus of Rupture – BS EN 1170 Part 5 (and simplified method in Part 4)
 Limit of Proportionality. – BS EN 1170 Part 5
Test boards shall be produced alongside each day‟s production (at least one per day for
each production team). The recommended size of these sample boards is 600 x 600 mm.
The test boards shall be produced with the same quality, thickness and curing as the
actual panels.
Those test boards which are not required for testing should be kept for the duration of the
contract, or for a period to be agreed between the manufacturer and engineer.

29
Frequency of Testing
The frequency of testing shall be agreed between the architect, engineer and
manufacturer.
The recommendation of BS EN 1169 is as follows:
 Glass content – tested in accordance with BS EN 1170 Part 2. Once per week for
each spray team. (This is in addition to the calibration test referred to in section
3.3).
 Modulus of Rupture and Limit of Proportionality – tested in accordance with BS
EN 1170 Part 5. Should be tested by the manufacturer or by a qualified laboratory
as the mix design is being set-up and thereafter at least twice per year, or when
the mix design is changed.
 A simplified bending strength test to determine the Modulus of Rupture (MOR)
should be conducted by the manufacturer more frequently The frequency of
testing recommended by BS EN 1169 is for each 10 tonnes of GRC produced, or
at least once per week.
 Water Absorption and Dry Density – tested in accordance with BS EN 1170 Part
6. As the mix design is being set-up, and then for each 10 tonnes of GRC
produced, or at least once per week.

Compliance
Compliance with glass content and the characteristic strength for both LOP and MOR
shall be assumed if the following conditions are met:
 Glass Content : The glass content shall not vary from the specific amount by more
than ± 20%.
 Modulus of Rupture and Limit of Proportionality : The characteristic MOR and
LOP is defined as the value which 95 per cent of all the mean strengths of the
individual test-boards shall exceed.
 Compliance with the characteristic MOR and LOP requirements shall be assumed
if no single test-board mean shall be less than 85 per cent of the characteristic
MOR and LOP, and the average of 4 consecutive test board results shall exceed
21 MPa (MOR), and 8 MPa (LOP).
 If any single test-board fails to meet any of the compliance requirements, the
GRC at risk shall be that produced between the previous complying test board and
the next complying test board.
 Where failure to comply arises from consideration of consecutive groups of four
test-boards, the GRC at risk shall be that represented by the first and fourth
testboards, together with all intervening material.
 Note: If different values for MOR and LOP are required for specific service
requirements, these should be determined by the design engineer for the specific
service requirements. The selection of unnecessarily high strength requirements
may result in cost penalties.
 Dry Density : The dry density of the GRC shall exceed 1800 kg/m3.
 Non-Compliance : In the event of non-compliance, the action to be taken should
be agreed between the manufacturer and the client. Due regard should be paid to
the technical consequences of the non-compliance and the economic

30
 consequences of adopting remedial measures or replacing the rejected products.
Account should also be taken of the safety factors incorporated in the design and
also the thickness of the GRC produced, compared with the design thickness. Re-
testing may be considered appropriate if it is considered that the storage
conditions of the product may result in improved properties because of extended
curing, or if the sampling, testing or calculation may have been at fault.
 The material at risk may be reduced by the testing of additional test boards from
the same, previous, or next manufacturing periods. Testing may also be performed
on GRC samples cut from the actual GRC elements at risk.

Weatherproofing
 Responsibility for the weatherproofing of the whole installation of GRC panels
rests with the GRC manufacturer.
 The joint details shown on the drawings represent the appearance required and
their minimum standard of weatherproofing acceptable.
 Joints shall be weather-sealed with closed-cell polyethylene compressible backing
rods and caulked with 2-part polysulphide sealant or other approved sealant in
selected colours, installed completely in accordance with the sealant
manufacturer‟s recommendations with regard to joint dimension, priming,
substrates, mixing, curing, masking, cleaning and the like.
 The GRC manufacturer shall submit details of the proposed sealant and the
application recommendations for approval by the construction manager prior to
commencement of the contract works.
 Joints located and indicated on the drawings are those required for sealing the
GRC cladding against adjacent materials and those required for architectural
purposes for division of the panels into the design modules. Should the GRC
manufacturer or contractor propose to subdivide the cladding into smaller panels
for ease of casting, handling and erection, additional joints may be introduced in
the design, provided the location proposed is discreet. The GRC manufacturer
shall submit proposed locations and designs of additional panel joints with their
tender submission.

1.2.7.6 Other Issues

Responsibility
The GRC manufacture shall be solely responsible for the design and performance of the
GRC panels and their supports. Information provided on the drawings or this
specification shall not affect this responsibility.

Guarantees
The Manufacturer shall warrant the GRC panels installed, or to be installed, against any
and every defect or failure which may occur during the period of practical completion for
the works arising out of any fault of the GRC cladding system, workmanship, fabrication,
fixing or quality of materials used.

Design Criteria

31
  Glassfibre-reinforced wall cladding shall comply with the following:
 FINISH : Class 1 to the formwork code, smooth face suitable for high paint finish.
 DESIGN LOADS : Cladding and framing shall be designed in accordance with
AS1170.
 DEFLECTIONS OF MAIN FRAME STEEL MEMBERS: The attention of the
contractor is drawn to the allowance made for differential deflections between the
structure at level 2 and the ground. The anticipated allowance is 30 mm. The
detailing of the GRC cladding should take this into account

1.2.9 PARTITION WORKS

1.2.8.1 Scope

This specification covers the general requirements for fabrication and erection of wooden
/ aluminum / gypsum board partitions and other related works forming a part of this job,
which may be required to be carried out though not specifically mentioned above. The
work under this specification shall consist of furnishing of all tools, labour, materials and
everything necessary for carrying out the work.

1.2.8.2 Applicable Codes and Standards

Work shall be carried out as per latest edition of Indian Standards and Code of Practices.
List given here shall not be considered as conclusive and is for reference and guidance
only. Any discrepancies/ conflict noticed shall be brought to the notice of
Architect/Engineer in charge for direction / approval. However, as a general rule more
stringent specification shall take precedence.
IS: 287 Permissible moisture content for timber used for different purposes.
IS: 303 Plywood for general purpose
IS: 710 Marine plywood
IS: 733 Wrought aluminum and aluminum alloys, bars, rods and sections for
general engineering purposes.
IS: 848 Synthetic resin adhesive for plywood
IS: 1200 Method of measurement of building and civil engineering works.
IS: 1328 Veneered decorative plywood
IS: 1868 Anodic coating on aluminum and its alloys.
IS: 1948 Aluminum doors, windows and ventilators
IS: 1949 Aluminum windows for industrial buildings
IS: 2095 Gypsum plaster boards
IS: 2191 Plywood face panels
IS: 2542 Method of test for gypsum plaster
IS: 2835 Flat transparent sheet glass
IS: 3144 Methods of test for mineral wool thermal insulation materials
IS: 3513 Resin treated compressed wood laminates
IS: 3677 Unbonded rock and slag wool for thermal insulation
IS: 4021 Timber door, window and ventilator frames
IS: 5509 Fire retardant plywood
IS: 5523 Methods of testing anodic coatings on aluminum

32
IS: 5437 Figured rolled and wired glass
IS: 8183 Bonded mineral wool
IS: 13871 Powder Coatings
BS: 2972 Methods of test for inorganic thermal insulating materials

1.2.8.3 Aluminium Partitions

Materials
 Aluminium alloy used in the manufacture of extruded sections for the fabrication
of doors, windows, ventilators shall conform to designation 63400 WP of IS:733.
 Transparent sheet glass shall conform to the requirements of IS: 2835. Wired and
figured glass shall be as per IS: 5437.
 Builder's hardware of fittings & fixtures shall be of the best quality from approved
manufacturers.

Workmanship
 All aluminium partitions shall be of the type as specified in the respective items of
work and of sizes as indicated in the drawings.
 All aluminium units shall be supplied with anodized/powder coated finish. The
minimum anodic film thickness shall be 0.015 mm.
 Aluminium partitions shall be as described in the item of work and/or bid
drawings which indicate generally the arrangement along with the overall size of
the various components and weight per running meter of the extruded sections to
be adopted.
 IS:1948 and IS:1949 are referred to incorporate the sizes, shapes, thicknesses and
weight per running meter of extruded sections for the various components of the
units. However, new sizes, shapes, thicknesses with modifications to suit snap-fit
glazing clips etc. are continuously being added by various leading manufacturers
of extruded sections, which are available in the market. As such, the sections of
the various components of the unit proposed by the CONTRACTOR, will be
reviewed by the ENGINEER and will be accepted only if they are equal to or
marginally more than that specified in the codes/ item of works.
 The framework of the partitions with mullions and transoms shall be with
anodized/powder coated aluminium extruded sections of dimensions as per the
item of work. Anodized/powder coated Aluminium extruded sections shall be in-
filled with timber of class 3 (silver oak or any other equivalent) as per IS:4021.
Panels of double/single glazing/plywood shall be fixed as per details indicated in
the drawing. Partitions shall be fixed rigidly between the floor and the structural
columns/beams including provision of necessary shims for wedging etc. Finished
work shall be of rigid construction, erected truly plumb to the lines and levels, at
locations as per the construction drawings.
 Specific provisions as stipulated for steel doors, windows, ventilators shall also be
applicable for this item work. Glazing beads shall be of the snap-fit type suitable
for the thickness of glazing proposed as indicated in the item of work. A layer of
clear transparent lacquer shall be applied on aluminium sections to protect them

33
from damage during installation. This lacquer coating shall be removed after the
installation is completed.

34
TECHNICAL SPECIFICATION

CIVIL WORKS

35
 CIVIL WORKS

2.1 RUBBLE SOLING WORK

2.1.1 Scope

This specification covers general requirements for materials to be used for

carrying out rubble soling including requirements in regard to the quality &
placement of rubble soling. This also covers the compaction of surfaces for level
& profile thereof.

2.1.2 General

Area receiving soling will be excavated and trimmed to the required levels,
profile, gradient, if any, and the same shall be rolled / compacted thoroughly, as
approved by the ENGINEER.

2.1.3 Material Specification

Stone for soling work shall be black stone of good quality of specified size with
minimum size variation. It shall be free from impurities and foreign matter.

2.1.4 Workmanship & Construction

2.5.1 The Soling shall not be constructed on a wet surface.

2.5.2 Unless otherwise specified, the width of the soling stone shall be 230 mm and the
finished soling course thickness shall be 230 mm.
2.5.3 As the laying of rubble advances the soling shall be hand packed by wedging and
packing with 80 mm metal in the joints of the soling and driving them by
hammers in place so as to fill the voids as completely as possible. This operation
of hand packing shall closely follow the rubble laying. The soling shall be laid
and hand packed true to grade and section and these shall be often checked by
boning rods, template boards, fish line, etc. The grades, sections, etc. of soling
shall correspond to those of the surfacing coming thereon. The soling thus laid
shall be finished by knocking out projecting stones and filling depressions by
chips to reach up to the grade and camber
2.5.4 The quality of the 80 mm metal shall be same as that specified for the soling stone
and the longest dimension shall not be more than 100 mm and the shortest
dimension not less than 50 mm.

2.1.5 Payment
Measurements shall be made for the finished work in square metres of the actual
plan area covered with the soling stone. The rate shall include the cost of all
materials, labour, plant and equipment required in all the operations and including
soling stone and gravel.

36
2.2 WATERPRFOOING OF UG WATER TANK

The RCC base slab & wall surface is cleaned by removing dust, dirt etc. by
mechanical means. Ensure that all bolt holes and sleeves, pipe inserts have been
plugged properly by using Polymer Modified Mortar (PMM). Holes are drilled for
fixing of PVC nozzles at 1 mt c/c at construction joints and the same are sealed by
using PMM. Further, cracks are to be opened out by making V groove and filling
the same using PMM.

Thereafter Injection grouting shall be done with providing and injecting non-
shrink cementations grout of flowable consistency, grouting the same under
pressure in pre-drilled holes by grouting pump. 24 hours after grouting is
completed, cut the nipples and seal it with Polymer Modified Mortar.

A layer of about 1 inch IPS in 1:2:4 is provided on the base floor with vata at wall
& floor junctions providing proper slope towards the drain point.

On the side walls provide double coat 20 mm thick plaster in CM 1:3 with
approved waterproofing admixture followed by curing for 7 days. All mortar mix
to be necessarily mixed with approved waterproofing compound.

2.3 STEEL CHEQUERED PLATES

SCOPE: This specification covers general requirements for materials to be used

for steel chequered plates, having raised figures at regular intervals on one surface
of the plate.

SUPPLY OF MATERIAL: General requirements relating to the supply of

chequered plates shall conform to IS 8910.

MATERIAL: Unless specified otherwise the steel (base material) for chequered
plates shall conform to the requirements of Grade E 250A of IS 2062.

2.4 COLD FORMED SECTIONS

Providing, supplying ,designing, detailing, fabricating and fixing erecting GI cold

formed sections (GSM 120 Min), having minimum thickness of 2mm
confirming to the physical specifications of ASTM A-607 (Grade 50) having
minimum yield strength of 345 N/mm2 of any shape (angle, channel, zee,
channel with lips, zee with lips )including fabrication drawings ( approved by
Engineer) for all heights & levels including transportation of the same to site,
provision of necessary erection bolts, fixing bolts, nuts, washers, cleats, and all
necessary operations like straightening, cutting, drilling as specified, welding,

37
 cleaning, grinding and removing the welding burr etc. complete and as directed by
Engineer In Charge.

2.5 SITE GRADING

2.5.1 Scope:-
The work covered shall consist of providing for and executing the site grading
works as shown
in the relevant drawings and in accordance with the specifications.

2.5.2 TECHNICAL REQUIREMENTS

SETTING OUT & LEVELLING

The Contractor shall be responsible for accurate and proper setting out of the
work withregard to lines and levels of reference, and with regard to the
correctness of dimensions, alignments and levels of the work in conformity with
the drawings. The Contractor shall at his own cost, provide all necessary
instruments, labour material and equipment for this purpose should any error be
discovered, at any time, during the progress of work or thereafter, in the
dimensions, alignment or level of part or all of work, the Contractor shall at his
own expense rectify the errors to the satisfaction of the Owner/Consultant. Any
checking of line or level by the Owner/Consultant shall in no way relieve the
Contractor of his responsibilities.

The Contractor shall, prior to start of work, construct one or more permanent
bench marks at a central location from which all levels for the earth work shall be
set. Permanent bench marks shall be accurately referenced to the Owner‟s plant
datum. All labour and materials for setting levels shall be at Contractor‟s cost.
Permanent bench marks shall be made of masonry pillars with a neatly plastered
top and levelled as per the directions of Owner/Consultant. The bench marks shall
be well connected with a triangular grid system or other bench marks and the
entire arrangement approved by the Owner/Consultant.

CLEARING AND STRIPPING

The area where earth work is to be carried out shall be cleared and stripped
completely of all bushes, roots, trees, shrubs and other vegetation, organic matter
and other objectionable materials. All these should be completely uprooted and
not merely scraped at the surface. Trees upto 50 cms girth shall be removed from
the site and those above 50 cm girth shall be handed over to the Owner.

Excess materials including trees, roots etc. shall be removed to the disposal areas
as directed by the Owner/Consultant outside the refinery premises.

EARTHWORK IN FILLING

Description and Testing of Fill Material

38
a) The fill material shall be granular, well graded compactable and possess good
drainage characteristics. It shall be free of vegetation, organic matter and other
impurities. Acceptable classes (as per IS:1498) are GW, GP, GM, SW or a mix of
these. Following limits of grain size distribution are recommended :

1. Maximum size : 100 mm

2. Retained on 20mm sieve : 30%
3. Passing No. 100 sieve : 45%
4. Passing No. 200 sieve : 10%

b) The Contractor shall, at his own cost, conduct tests, to ensure the suitability of
the proposed fill material. He shall submit the test results to the Owner/Consultant
and obtain approval of the same before commencing the site grading operations,
and, if required shall make arrangements for the Owner/Consultant to witness
sample preparation and conducting of the tests.

c) The Contractor shall also carry out on the proposed fill material compaction
tests to determine the optimum moisture content and maximum dry density as per
IS2720-Part 7:1980 and water content test as per IS 2720- Part 2:1973 to
determine the natural moisture content.

d) The Contractor shall repeat the tests described in 3.3.1.b and 3.3.1.c above, as
often as directed by the Owner/Consultant but at least once for every 5000 m3 of
fill. He shall establish an adequately equipped field laboratory for this purpose.
Test results shall be carefully recorded and tagged such that when field control of
moisture during the filling and compaction operation is carried out, based on
them, easy and accurate identification of the test result corresponding to each
stretch of fill is possible.

Filling and Compaction

a) The fill shall be constructed in layers, each layer being compacted to the
required density before the next layer is laid. The compacted thickness shall
be 200 mm for each layer.

b) Compaction shall be carried out using steel wheeled or rubber tyred rollers as
appropriate. The Contractor shall determine the number of passes of the roller
required to achieve the required density by first conducting trials over a test
stretch. Vibrating roller shall be used if it allows faster compaction.
The number of passes shall be reviewed and adjusted in consultation with the
Consultant/Owner, as required during the course of the work.

c) All lumps and clods in the fill material shall be broken before rolling. The top
surface of each layer shall be roughened before placing the subsequent layer to
ensure proper keying in between layers.

39
 d) Prior to rolling, the moisture content of the material shall be brought to within
± 2% of the optimum moisture content as obtained from the tests in 3.3.1.c by
addition or removal of water, accompanied by thorough mixing to ensure a
uniform moisture content. Each layer shall be compacted to at least 95% of the
maximum dry density as obtained from the Standard Proctor Test.

e) Each layer shall be tested by the Sand replacement method to ensure that the
specified density has been achieved. At least one such test shall be carried out for
every 2500 sq. m of graded area of every layer.

If the testing indicates that any part of the fill does not meet the requirements, that
part shall be reworked by the Contractor at his own cost till the specified density
is achieved.

f) The Contractor shall submit daily laboratory and observations report. This shall
provide details of location of sample, time of collection, time it was placed in
oven, the moisture content and density test results.

MICROGRADING
Micrograding shall be carried out by Contractor over graded areas to bring the
finished grade level to level indicated, including provision of required slopes and
finishes. Rolling to be done along with watering using road roller to achieve
proper compaction and level.

2.6 AAC BLOCKS

Scope
This specification covers the construction of load bearing and non-load bearing
walls with autoclaved cellular ( aerated ) concrete blocks conforming to IS : 2185
( Part 3 ) - 1984

Mortar For Masonry

The blocks shall be embedded with a mortar, the strength of which is relatively
lower than that of the mix used for making blocks in order to avoid the formation
of cracks. A 1:6 cement - sand mortar may be used. (Refer IS 6041-1985 Para 3,
3.9.2)

Wetting of Blocks
These blocks need not be wetted before or during the laying in the walls; in case
the climatic condition so required, the top and the sides of the blocks may be
slightly moistened. (Refer IS 6041-1985 Para 6, 6.1)

40
 Coping Beam
Horizontal coping at 0.9 to 1.2 mtr height & Vertical coping in centre if wall
length is more than 3 mtr, with 2nos 8mm reinforcement, M20 concrete. (Refer IS
6041- 1985 Para 4, 4.6.5.1 & 2)

Storage
The blocks shall be stored in such a way as to avoid any contact with moisture on
the site. (Refer IS
6041-1985 Para 5, 5.1)

Mortar Thickness
Keep it limited to 10 to 12 mm in cement sand mortar (Refer IS 6041-1985 Para
7, 7.1) & 3 to 4 mm in ready mix mortar.

Plaster
Plaster thickness required Internal:10 to 12mm, External:15 to 17mm (Refer IS
6041-1985 Para 12)

2.7 HDPE FILMS

2.7.1 Grades

The material (film) shall be classified according to the optical properties, Impact
Strength and Slip. Each grade shall be designated by a set of 3 numerals. The first
one will indicate optical property, the second impact strength and the third slip
property. Whenever numeral '0' (Zero) is used, it shall mean the material has not
been tested for that particular property. For optical properties the numeral 1 shall
mean low clarity, numeral 2 normal clarity and numeral 3 high clarity. For Impact
strength numeral 1 shall indicate low impact strength, numeral 2 normal impact
strength and numeral 3 high impact strength. For slip property numeral 1 shall
denote low slip, numeral 2 medium slip, numeral 3 high slip and numeral 4 mean
extra high slip.

2.7.2 Requirements

Appearance
The film shall be uniform in colour, texture and finish. The material shall be
substantially free from pin-holes and undispersed raw materials, streaks and
particles of foreign matter. There shall be no other visible defects, such as holes,
tears or blisters. The edges shall be free from nicks and cuts visible to unaided
eye. The natural films shall be free from pin-holes.

Film Form
The film shall be furnished in the form of flat sheet or rolls or in the form of flat
tubing or in any other form as agreed to between the supplier and the purchaser.

41
 Odour
The film shall be free from any objectionable odour.

Density
The density of the film, when determined in accordance with A-l of IS : 2508 -
1984 or Method 5 of IS : 8543 ( Part l/Set 2 )-1979 shall be as prescribed in 2.1.2
and 2.2 of IS : 2508 - 1984. However, in case of dispute, the latter shall be the
referee method.

Melt Flow Index

The melt flow index of the film when determined in accordance with 7 of IS :
2530-19637 shall be as prescribed in 2.1.2 of IS : 2508 - 1984.

Black Film
When tested in Bccordance with:
a) 10 of IS : 2530-1963, the percentage of carbon black in material shall be 2.5 ±
0.5 percent by mass; and
b) 16 of IS : 2530-1963, the dispersion of the carbon black shall be satisfactory.

2.7.3 Dimensional Requirements

Nominal Thickness and Nominal Width

a) Nominal thickness is the theoretically desired thickness of a film for a
particular application; and
b) Nominal width is the theoretically desired width of a film for a particular
application.

Tolerance on Thickness
When tested in accordance with A-2 of IS : 2508 - 1984, tolerance on nominal
thickness at any given point and the average thickness of polyethylene film for
various thicknesses shall be as follows:
Nominal Thickness Tolerance, Percent
Up to and including 40 m ± 25
Above 40 m ± 20

Tolerance on Width
The tolerance on width shall be as given below:

Nominal Width Tolerance

mm mm
Up to 500 ±5
Above 500 and up to 1250 ±8
Above 1250 and up to 2500 ± 20
Above 2500 and up to 3000 ± 40
Above 3000 and up to 7500 + 150, - 65
Above 7500 and up to 15000 + 200, - 100

42
2.7.4 Yield Tolerance

The actual yield shall be determined in accordance with the method given in A-3
of IS : 2508 - 1984, and shall be within the following tolerance limits of the
nominal yield:

One roll ± 10 Percent

Lots of 250 kg ± 10 Percent
Lots over 250 kg and up to 1250 kg ± 5 Percent
Lots over 1250 kg ± 3 Percent

2.7.5 Tensile Strength at Break

The tensile strength at break when tested as prescribed in A-4 of IS : 2508 - 1984,
for all thicknesses of polyethylene film shall be not less than 11.77 MN/m2 (120
kgf / cm2) in lengthwise direction and 8.33 MN/m2 (25 kgf / cm2) in crosswise
direction.

2.7.6 Elongation at Break

The elogation at break when tested as prescribed in A-4 of IS : 2508 - 1984, for
various thicknesses of polyethylene film, shall be not less than the value given
below:

Elongation at Break, Min

Thickness of the film Lengthwise Crosswise
Percent Percent
From 12.5m up to but not including 75m 100 350
75 m and above 200 400

2.7.7 Optical Properties

The 450 gloss and haze of the film, when determined in accordance with A-5 of
IS : 2508 - 1984, shall conform to the requirements given below:

Grade 450 Gloss Haze

Low clarity film Below 30 Greater than 15 percent
Normal clarity film 30 to 55 10 to 15 percent
High clarity film Greater than 55 6 to 10 percent

2.7.8 Impact Resistance

The impact resistance of the film shall be as given in 4.7.1 to 4.7.3 of IS : 2508 -
1984.

43
Low Impact Resistance Film

Any LDPE film up to 40 m thickness having impact strength less than 55 gf

when tested by the procedure given in A-6 of IS : 2508 - 1984 using a drop height
of 66 cm would be classified as low impact resistant film.
For such films, when tested in accordance with A-6 of IS : 2508 - 1984 using a
drop height of 22 cm, the impact failure load shall be not less than given below
for appropriate average thicknesses of the film:

Average Thickness of Film Impact Failure Load, Min.

m N (gf)
12.5 0.4 (40)
20 0.6 (60)
25 0.8 (80)
40 1.25 (125)

Normal Impact Resistance Film

When tested by the procedure given in A-6 of IS : 2508 - 1984, the impact failure
load obtained from a drop height of 66 cm shall be not less than that given below
against appropriate average thicknesses of the film:

Average Thickness of Film Impact Failure Load, Min.

m N (gf)
40 0.55 (55)
50 0.70 (70)
75 1.00 (100)
100 1.20 (120)
125 1.60 (160)
150 1.85 (185)
175 2.10 (210)
200 2.35 (235)
225 2.60 (260)
250 3.00 (300)

High Impact Resistance Film

When tested by the procedure given in A-6 of IS : 2508 - 1984, the impact failure
load obtained from a drop height of 152.4 cm shall be not less than that given
below against the appropriate average thicknesses of the film:

44
 Average Thickness of Film Impact Failure Load, Min.
m N (gf)
40 0.50 (50)
50 0.65 (65)
60 0.75 (75)
75 0.90 (90)
100 1.20 (120)
110 1.30 (130)
125 1.55 (155)
150 1.90 (190)
175 2.15 (215)
200 2.50 (250)
225 2.85 (285)
250 3.20 (320)

2.7.9 Slip

The kinetic coefficient of friction for the material when tested in accordance with
A-7 of IS : 2508 - 1984, shall be as follows:

a) Low Slip Film Greater than 0.40

b) Medium Slip Film Greater than 0.30 and up to and including 0.40
c) High Slip Film Greater than 0.20 and up to and including 0.30
d) Extra High Slip Film Up to and including 0.20

2.7.10 Special Requirements

Heavy Duty Film

LOW density polyethylene films for canal lining and other heavy duty
applications like mulching, green houses, post harvest operations, construction
work and allied purposes, shall have an MFI not more than 0.30 g/10 min when
tested by the method given under 7 of IS : 2530-1963. The tensile strength of such
films shall be not less than 140 kgf/cm2 in machine direction and 110 kgf/cm2 in
transverse direction. Films shall also meet the requirement of impact strength as
given in 4.7.3 of IS : 2508 - 1984.

Film Having a Width of Less Than 175 mm (350 mm Slit Open Width in Case of
Tubular Film)

Though films of width less than 175 mm (350 mm slit open width in case of
tubular films ) are not covered by this specification, if one intends to test such
films, used fol general purposes or agricultural operations like nursery bags, it
could be got tested only for tensile strength in machine direction and it should not
be less than 120 kgf/cm2.

45
2.8 LIST OF APPROVED MAKES FOR CIVIL AND ARCHITECTURAL
WORKS
2.8.1 Scope

a) All materials and products shall conform to the relevant standards and shall be
of approved make and design. A list of manufacturers/ vendors is given in
Clause 2.3.2 herein below for guidance. The Engineer shall give the approval
of a manufacturer/ vendor/ only after review of the sample/ specimen. In case
the same is not available in the market or in case of change in trade name,
equivalent makes/ re-designated manufacturer then an equivalent approved
make shall be used with the approval of Employer/ Engineer. The complete
system and installation shall also be in conformity with applicable Codes &
Standards and Tender specifications.

b) Only “First” class quality materials shall be used.

c) Employer reserves the right to choose any of the approved make / vendors as
per this list.

d) In case of products not indicated in this list, bis marked products shall be
preferred.

e) Specification of manufacturer‟s item shall be checked against tender item /

specifications before selecting any product or brand name. In case of any
discrepancy, tender item/ specifications shall prevail, and any such brand of
item shall not be used which is not conforming to tender specifications even if
it is listed in this list.

f) For use of material from a bis listed/ certified manufacturer, the contractor
shall furnish a copy of the valid bis certificate to eil/ Employer before
procuring the material.

g) In case non-availability of any item/ material among approved manufacturers/

brands at a particular site/ region, alternate manufacturers/ brands conforming
to BIS/ BS etc. shall be used subject to approval by Employer.

h) In case of non-availability of any manufacturer among approved

manufacturers at a particular site/ region, alternate manufacturer‟s name shall
be proposed along-with required credentials for Employer‟s approval.

i) In case of any item/ product neither covered in this list nor having A BIS
specifications, the contractor shall submit the proposed item/ product along-
with technical details/ specifications (as per bid), test certificates etc. And
other credentials of the manufacturer for Employers approval.

46
2.8.2 List of Approved Makes For Products And Materials For Civil And
Architectural Works
NOTE:
- All materials and products shall conform to the relevant standards and shall be of
approved make and design. A list of manufacturers/ vendors is given separately
herein below for guidance. The Engineer shall give the approval of a
manufacturer/ vendor/ only after review of the sample/ specimen. In case the
same is not available in the market or in case of change in trade name, equivalent
makes/ re-designated manufacturer then an equivalent approved make shall be
used with the approval of Employer/ Engineer. The complete system and
installation shall also be in conformity with applicable Codes & Standards and
Tender specifications.
- Only “First” class quality materials shall be used.
- Employer reserves the right to choose any of the approved make / vendors as per
this list.
- In case of products not indicated in this list, bis marked products shall be
preferred.
- Specification of manufacturer‟s item shall be checked against tender item /
specifications before selecting any product or brand name. In case of any
discrepancy, tender item/ specifications shall prevail, and any such brand of item
shall not be used which is not conforming to tender specifications even if it is
listed in this list.
- For use of material from a bis listed/ certified manufacturer, the contractor shall
furnish a copy of the BIS certificate to Employer before procuring the material.
- In case non-availability of any item/ material among approved manufacturers/
brands at a particular site/ region, alternate manufacturers/ brands conforming to
BIS/ BS etc. shall be used subject to approval by Employer.
- In case of non-availability of any manufacturer among approved manufacturers at
a particular site/ region, alternate manufacturer‟s name shall be proposed along-
with required credentials for Employer‟s approval.
- In case of any item/ product neither covered in this list nor having A BIS
specifications, the contractor shall submit the proposed item/ product along-with
technical details/ specifications (as per bid), test certificates etc. And other
credentials of the manufacturer for Employers approval.

47
 LIST OF APPROVED MAKES FOR PRODUCTS AND MATERIALS FOR
CIVIL AND FINISHING WORKS ARE INDICATED IN THE TABLE
BELOW. HOWEVER, ANY OTHER MAKE WHICH IS EQUIVALENT AND
MEETING THE TENDER SPECIFICATIONS ARE ALSO
ACCEPTABLEWITH PRIOR APPROVAL OF THE ENGINEER

SR.
DETAILS OF MATERIALS MANUFACTURER’S NAME
NO.
CEMENT ACC / ULTRATECH / JK / C K BIRLA
1. / AMBUJA / BINANI / JSW / SANGHI
/ INDIA CEMENT.
JK / BIRLA WHITE / TRAVANCORE
2. WHITE CEMENT
CEMENT
ULTRATECH / ACC / RMCRIPL / JK
CEMENT / UNITECH / GRASIM /
3. READY MIX CONCRETE
LAFARGE / GODREJ & Boyce /
Madras Cement / RMC Readymix (I) /
4. REINFORCEMENT BARS SAIL/ TISCON/ RINL/ IISCO/ JSW
SAIL/ TISCON/ RINL/ IISCO/ JSW /
5. STRUCTURAL STEEL
CHORUS
TUBULAR STRUCTURAL
6. TATA STRUCTURA
STEEL
CHLOROPYRIPHOUS CHEMICAL
7. ANTI TERMITE TREATMENT PECOPP
DE-NOCIL, CYNAMIDE
DURA-BOARD / KIT PLY / MERINO
BLOCK BOARD / FLUSH
8. PLY ISI MARKED / KUTTY, INDIA
DOORS
PLYWOOD, MYSORE PLYWOOD,
ALL MANUFACTURERS LISTED
BY BIS UNDER IS:2202 (HAVING
OPERATIIVE AND VALID
LICENSE) AT BIS WEB SITE
HTTP://WWW.BIS.ORG.IN/
ALL MANUFACTURERS LISTED
BY BIS UNDER IS:303 (HAVING
9. PLYWOOD OPERATIIVE AND VALID
LICENSE) AT BIS WEB SITE
HTTP://WWW.BIS.ORG.IN/
10. WATERPROOF PLY GREEN PLY, GARNET, CENTURY
GARNET, CENTURY, DONEAR,
11. COMMERCIAL PLY
GREEN PLY

48
SR.
DETAILS OF MATERIALS MANUFACTURER’S NAME
NO.
ALL MANUFACTURERS LISTED
BY BIS UNDER IS:2406 (HAVING
12. LAMINATES OPERATIIVE AND VALID
LICENSE) AT BIS WEB SITE
HTTP://WWW.BIS.ORG.IN/
RAMMICA INDUSTRIES;
THE BOMBAY BURMAH TRADING
CORPN.; GREENLAM, CENTURY,
MERINO
NUCHEM LTD; MANGALAM
TIMBER PRODUCTS LTD;
13. MDF BOARDS WESTERN BIO SYSTEM LTD;
BAJAJ ECO-TEC PRODUCTS
LIMITED
DURO, GREEN, DONEAR,
14. VENEER
CENTURY
ALL MANUFACTURERS LISTED
PARTICLE BOARD (PLAIN / BY BIS UNDER IS:3087 (HAVING
15. VENEERED / PRE- OPERATIIVE AND VALID
LAMINATED) LICENSE) AT BIS WEB SITE
HTTP://WWW.BIS.ORG.IN/
PRE-LAMINATED PARTICLE NOVOPAN/ MERINO/
16.
BOARD ANCHORLAM/ BHUTAN BOARD
ASIAN PAINTS; SHALIMAR
17. WOODWORK POLISHING
PAINTS
NITCO; HINDUSTAN; NEC;
18. TERRAZZO TILES
BHARAT; NIMCO; GK BANSAL;
NAVEEN, MARBO GRANIT,
GRANAMITE, BOSS, NITCO,
ASIAN, RAK, EURO, SOMANY,
19. VITRIFIED TILES BELL CERAMIC, KAJARIA,
REGENCY, ORIENT, JOHNSON;
PELICAN, VARMORA,
PILKINGTON
ORIENT, KAJARIA, NITCO,
SOMANY, BELL, JOHNSON,
20. GLAZED TILES
ASIAN, RAK, EURO, PARSHURAM
POTTERY, PILKINGTON
REGENCY, KAJARIA, ORIENT,
21. CERAMIC TILES BELL, SOMANY, JOHNSAON,
SPARTEK, NAVEEN, BELL,

49
SR.
DETAILS OF MATERIALS MANUFACTURER’S NAME
NO.
VARMORA, PILKINGTON
REGENCY, ENDURA, KOTHARI,
CHORAMANDALAM, RUSTILE,
ACID / ALKALI RESISTANT ARCOY, PERFECT ACID WARES/
22.
TILES MAHAKOSHAL POTTERIES/
CHAMPION CERAMICS,
GOODEARTH MINERALS
ALL MANUFACTURERS LISTED
(HAVING OPERATIIVE AND
VALID LICENSE) BY BIS AT BIS
WEB SITE
23. PVC TILES/ ROLLS HTTP://WWW.BIS.ORG.IN/

EXCELEN BY ARMSTRONG;
MARBLEX BY BHOR INDUSTRIES
SHYAM VINYL
SOLIDLG1 BY ARMSTRONG;
PVC TILES/ ROLLS (ANTI-
24. ANSTAT BY PREMIER POLYFILMS
STATIC)
LTD
ECOFLEX SURFACES PVT. LTD.,
25. RUBBER TILE FLOORING RUDI SPORTS SURFACES, THE
FLOORSMITHS
26. STAINLESS STEEL SECTIONS JINDAL/ SAIL/ GOLDEN
HINDALCO/ JINDAL/ MAHAVIR/
27. ALUMINIUM SECTIONS
LNDAL / AJIT INDIA / ALUMILITE
SKS STEEL IND., DHIMAN STEEL
SUPER STEEL WINDOWS,
RDG ENGINEERING,
ANAND INDUSTRIES,
PRESSED STEEL DOORS AND
28. RAYMUS ENGINEERING,
WINDOWS
NICOMAC, WINDOORS,
SHAKTIMET,
NCL SECOLOR, GODREJ,
SENTINAL, MULTIWIN
ALUMINIUM DOORS AND JINDAL; HINDALCO, AJIT INDIA,
29.
WINDOWS ALUMILITE
SHAKTIMET, SHIRKE POLYNORM,
VIPER BY NAVAIR
30. FIRE PROOF DOORS INTERNATIONAL, RADIANT BY
RDG ENGG., GANDHI
AUTOMATION,

50
SR.
DETAILS OF MATERIALS MANUFACTURER’S NAME
NO.
PROMAT, GODREJ, ADHUNIK,
SIGNUM
INDUSTRIAL DOORS / GATES
GANDHI AUTOMATION;
31. (FOLDING, SLIDING, SWING
NICOMAC; AVIANS;
DOORS)
TECHNO SYSTEMS DOOR
SOLUTIONS; AEGIS; SHAKTIMET;
ROLLING SHUTTERS
GANDHI AUTOMATION;
32. (MANUAL / GEAR OPERATED
DORPLUS; SWASTIK ROLLING
/ MOTORIZED)
SHUTTERS; BENGAL ROLLING
SHUTTERS;
INGERSOL RAND, GEZE, DORMA,
33. DOOR HARDWARE GUARDIAN, DORSET, MAGNUM,
UNION, KITCH
MORTICE LOCKS WITH GODREJ & BOYCE; EVERITE
34.
HANDLES AGENCIES; GOLDEN INDUSTRIES
ALL MANUFACTURERS LISTED
BY BIS UNDER IS:3087 (HAVING
MISC. DOOR HARDWARE /
OPERATIIVE AND VALID
FITTINGS (HINGES, TOWER
35. LICENSE) BY BIS AT BIS WEB
BOLTS, LATCHES, STOPPERS
SITE HTTP://WWW.BIS.ORG.IN/
ETC.
EVERITE; EBCO; ECIE; HARDWYN
36. NUTS BOLTS/ SCREWS KUNDAN/ PUJA/ ATUL
ANODISED ALUMINIUM CROWN/ ALANS/ CLASSIC/
37.
FITTINGS BHARAT/ ARGENT
MILD STEEL BUTT HINGES/
38. JOLLY/ GARG/ AMIT/ASI SUPREME
PIANO HINGES
ALL MANUFACTURERS LISTED BY
BIS UNDER IS:3087 (HAVING
HYDRAULIC DOOR CLOSERS OPERATIVE AND VALID
39. (OVERHEAD AND FLOOR LIECENSE) AT BIS WEBSITE
MOUNTED) HTTP://WWW.BIS.ORG.IN

DOORKING
AIS GLASS/ SAINT GOBAIN/
40. CLEAR FLOAT GLASS
MODIGUARD
SAINT GOBAIN/ MODI FLOAT/
41. GLASS (TOUGHENED)
ASAHI FLOAT

51
SR.
DETAILS OF MATERIALS MANUFACTURER’S NAME
NO.
42. POLYCARBONATE SHEET DANPALON/ ALCOX/ POLYGAL
DURALINE/ ORIPLAST/
43. HDPE WATER SUPPLY PIPES
HALLMARK/ PIONEER / SUPREME
JOTUN, HILTI, AKZONOBEL,
ASIAN PPG, CHEMBOND
44. FIRE RETARDANT PAINT
COATINGS; HITAKSHI SAFETY
SOLUTIONS; AKZO NOBEL
ICI; BERGER; ASIAN PAINTS;
PLASTIC / ACRYLIC SHALIMAR; KANSAI NEROLAC;
45. EMULSION PAINT (INTERNAL JOTUN; ACROPAINTS; GODAVARI
& EXTERNAL), DISTEMPER PAINTS; N E PAINT UDYOG;
SURFA COATS
ICI; BERGER; ASIAN PAINTS;
SHALIMAR; KANSAI NEROLAC;
SYNTHETIC ENAMEL PAINT
46. JOTUN; ACROPAINTS; GODAVARI
FOR BUILDING WORKS
PAINTS; N E PAINT UDYOG;
SURFA COATS
KILLIC NIXON (SNOWCEM);
GODAVATI PAINTS
(SUPREMECEM); ACRO PAINTS
WATER-PROOF CEMENT
47. (ACROCEM); SNOW EHITE
PAINT
INDUSRIAL CORP (SUPERCEM);
RAJDOOT PAINTS (XTRACEM 76
SUPERIOR CEMENT PAINT)
LUXTURE SURFACE COATINGS
PVT LTD (LUXTURE); BAKELITE
HYLAM LTD (HERITAGE); NCL
DECORATIVE TEXTURED ALLTEK & SECCOLOT LTD
48.
PAINT (ALLTEK); ACRO PAINTS LTD
(ACROTEXTURES); UNITILE;
SPECTRUM PAINTS; SURFA
COATS
ANTI CORROSIVE
49. ASIAN PAINTS / BERGER / J&N
BITUMASTIC PAINT
LLYOD INSULATION
PRECOATED PROFILES GI / INTERARCH BUILDING
50. GALVALUME / ZINCALUME PRODUCTS
SHEETS MULTICOLOR STEEL PVT LTD
HARDCASTLE & WAUD MFG CO.

52
SR.
DETAILS OF MATERIALS MANUFACTURER’S NAME
NO.
LTD
JAPAN METAL BUILDING SYSTEM
PVT LTD
TATA BLUESCOPE STEEL LTD
SHREE PRE-COATED STEEL LTD
CRIL
ISPAT INDUSTRIES / SAIL / TATA
51. CGI SHEETS
STEEL /
HINDALCO;
52. ALUMINIUM SHEETS
JINDAL ALUMINIUM LTD
53. FIBRE GLASS SHEET SIMBA FRP PVT LTD
DANPALON, ALCOX, POLYGAL, V.
54. POLYCARBONATE SHEET A. CORPORATION, JOY FAB,
YADAV ENGINEERING
FOSROC (NITOFLOOR SL 2000 /
1000); SIKA; BUILDTECH
PRODUCTS PVT LTD; CICO
TECHNOLOGIES; ASIAN PPG;
BASF; SUNANDA SPECIALITY
55. EPOXY COATINGS
CHEMICALS; CHRYSO; KOTHARI
CORROSION CONTROLLERS;
AKZO NOBEL; BOSTIK; APURVA
INDIA LTD.; CHEMBOND
COATINGS.
CICO; SAMCOCK CHEMICALS;
PEE ESS PROCESSOR & TRADERS;
IRONOTE; BASF; CHRYSO; BASF;
56. FLOOR HARDENERS SUNANDA SPECIALITY
CHEMICALS; FOSROC; BOSTIK;
POLYFLEX COATINGS AND
LININGS
BASF; SIKA; CICO; SUNANDA
SPECIALITY CHEMICALS;
FAIRMATE; PIDILITE; CHRYSO;
WATER PROOFING
57. XYPEX; IMPERMO; PENETRON;
COMPOUNDS
ALCHIMICA; BOSTIK; MC
BOUCHIME; SURFA COATS;
LIKPROOF; KRYPTON BUILDMAT;
58. CONCRETE ADMIXTURES BASF; SIKA; COCO; SUNANDA

53
SR.
DETAILS OF MATERIALS MANUFACTURER’S NAME
NO.
SPECIALITY CHEMICALS;
FAIRMATE; PIDILITE; CHRYSO;
XYPEX; IMPERMO; PENETRON;
ALCHIMICA; BOSTIK; MC
BOUCHIME; ACC
CHOWKSEY CHEMICALS
POLYSULPHIDE / CICO TECHNOLOGIES
59. POLYURETHANE / SILICON / FOSROC; BASF; SIKA; PIDILITE;
SEALANTS CHEMETALL-RAI; CHRYSO;
BOSTIK;
60. BITUMEN SEALANT STP
BASF; SIKA; COCO; SUNANDA
SPECIALITY CHEMICALS;
FAIRMATE; PIDILITE; CHRYSO;
61. CONSTRUCTION CHEMICALS
XYPEX; IMPERMO; PENETRON;
ALCHIMICA; BOSTIK; MC
BOUCHIME; ACC.
GREATWELD GRATINGS PVT LTD
62. ELECTRO-FORGED GRATING
INDIA GRATINGS PVT LTD
UNITED INSULATION
LLOYD INSULATIONS
MULTIFLOORS
A R BROTHERS
63. FALSE / RAISED FLOORING
BESTLOCKS SYSTEM &
CONCEPTS
DG FLOOR
UNIFLOOR
SAINT-GOBAIN GYPROC INDIA
LTD
64. GYPSUM BOARD
LAFARGE
DRYTECH
BEKELITE HYLAM LTD
LLOYD INSULATION
65. UNDER-DECK INSULATIONS
UP TWIGA FIBRE GLASS LTD
ROCKWOOL INDIA LTD
LLOYD INSULATION
66. OVER-DECK INSULATIONS
UP TWIGA FIBRE GLASS LTD

54
SR.
DETAILS OF MATERIALS MANUFACTURER’S NAME
NO.
ROCKWOOL INDIA LTD
BEST PLASTRONICS
OMAI PLASTICS, BASECON PASK,
ASIAN ENGG PRODUCTS,
67. PVC WATER STOPS CAPRIHANS INDIA LTD, R.C
ENTERPRISES, FIXOPAN,
WATERSEAL INDIA LIMITED.
EXPANSION JOINT BOARDS SHALITEX, STP LTD, LLLOYD
68. INSULATION, SUPREME
INDUSTIES
HYDROTITE, BASF,
69. WATER BARS
HYDROSWELL
BASF, FOSROC, SUNANDA
70. GROUT SPECIALITY COATINGS, BOSTIK,
SIKA,
71. PVC COVER BLOCKS ISHITA ENTERPRISES
LLOYD INSULATIONS
BUILDTECH PRODUCTS PVT LTD
CICO; SIKA; SHALIMAR TAR
72. APP MEMBRANE
PRODUCTS;
IWL INDIA LTD,
PURE LEATHERS PVT LTD
73. EPDM GASKETS ANAND/ ROOP/ BOHRA/ HANU
74. PARQUET FLOOR NEMO/ PRIMA/ PERGO
MINERAL FIBRE BOARD
75. LLOYD/ NITTOBO/ ARMSTRONG
CEILING
76. GYPSUM BOARD SAINT GOBAIN, LAFARGE
WEATHER SILICON MAKE
77. DOW CORNING/ MOMENTIVE (GE)
AND GRADE
BAL, LATICRETE, KERAKOLL,
78. ADHESIVES
PIDILITE
79. FIRE SMOKE SEAL HILTI, CFS, SPWB JOINTS SPRAY
BILT INDUSTRIES PVT. LTD.,
80. AAC BLOCKS AEROCON, SIPOREX INDIA
LIMITED, XTRALITE
81. ACOUSTIC INSULATION U.P. TWIGA LTD. LLOYD, SAINT

55
SR.
DETAILS OF MATERIALS MANUFACTURER’S NAME
NO.
GOBAIN, ECOPHONE
82. ANCHOR FASTENERS/ BOLTS HILTI, FISCHER, HALFEN
83. TENSILE FABRIC SYSTEM FERRARI, MEHLER, MAKMAX
3M, SUN CONTROL/ WONDER
84. MASKING TAPES
POLYMER
VYARA TILES PVT. LTD.. SUPER
DECORATIVE FLOORINGS PVT.
INTERLOCKING CONCRETE
85. LTD., SAI
BLOCKS
ENTERPRISES,HINDUSTAN TILES,
NIMCO PREFAB,R.K. TILES.

56
TECHNICAL SPECIFICATION

PLUMBING WORKS

57
 PLUMBING WORKS

3.1 SCOPE
3.1.1 This specification covers the general requirements of providing and laying water
mains and water supply piping, providing and fixing sanitary fixtures and piping
and providing and laying drainage lines.
3.1.2 The Work shall be carried out in accordance with the drawings and designs as
would be issued to the Contractor by the Engineer duly signed and stamped by
him. The Contractor shall not take cognizance of any drawings, designs,
specifications, etc. not bearing Engineer's signature and stamp. Similarly the
Contractor shall not take cognizance of instructions given by any other Authority
except the instructions given by the Engineer in writing.
3.1.3 The Work shall be executed and measured as per metric dimensions given in the
Schedule of Quantities, drawings, etc.
3.1.4 The Contractor shall acquaint himself fully with the partial provisions for
supports that may be available in the structure and utilise them to the extent
possible. In any case the Contractor shall provide all the supports regardless of
provisions that have been already made. Nothing extra shall be payable for
situations where bed plates (for supports) are not available or are not useful.
3.1.5 The Contractor shall incorporate seismic considerations of anchoring and
isolation in the design of the systems as per the requirements of the different
equipment.
3.1.6 Shop coats of paint that may be damaged during shipment or erection shall be
cleaned off with mineral spirits, wire brushed and spot primed over the affected
areas, then coated with paint to match the finish over the adjoining shop painted
surface.
3.1.7 In addition to the sectional testing carried out during the construction, the
Contractor shall test the entire installation after connections to the overhead tanks
or pumping system or mains. He shall rectify all leakage and shall replace all
defective materials in the system. Any consequential damage done to the building,
furniture and fixtures on account of Contractor‟s carelessness, like open or burst
pipes or failure of fittings during testing and commissioning shall be made good
by the Contractor at no additional cost.

3.2 SCAFFOLDING
3.2.1 Only steel tube scaffolding of approved design shall be used for all works. The
scaffold structure shall comply with the requirements of IS: 4014 and IS: 3696.
An independent tied scaffold (double scaffold), which has two lines of standards,
shall be provided with the inner line kept at least one board clear of the finished
face with extended transoms, or hop up baskets to carry an inside board. Diagonal
braces shall not prevent the material being moved along the scaffold run. The

58
 scaffolding shall be suitably packed at the ends to prevent damage to the finished
work.

3.3 PROTECTION
3.3.1 Protection against damage: Care shall be taken to avoid damage from any cause
at all stages. Packing pieces used for protection shall not disfigure or otherwise
permanently mark the Works.
3.3.2 Surface protection shall be afforded by careful handling and the avoidance of the
use of hooks, crowbars, or other implements that are likely to damage the works.
3.3.3 During installation of piping, open end of pipe shall be protected with temporary
cover to prevent dust or other materials entering it.
3.3.4 Protection during construction: Decorative surfaces shall be carefully protected
during construction by providing a temporary cover.
3.3.5 Protection of finished work: At all stages of the Contract it is essential that all
works are properly protected.
3.3.6 Suitable packing shall be used to ensure that scaffolding does not damage erected
stone, marble, granite or other finished works.
3.3.7 Any disfigurement, discolouration or imperfection whatsoever due to any reason
shall not be accepted and the Contractor shall either remedy the same or redo the
work at no extra cost. The decision of the Engineer as to whether any work either
in whole or in part is acceptable or not shall be final and binding on the
Contractor.

3.4 GUARANTEE
3.4.1 The Contractor shall guarantee and undertake to maintain and rectify the various
components of the Plumbing work installed by him for successful performance
for a period as indicated elsewhere in the tender/ contract document. The
Contractor shall indemnify the Engineer for a similar period against any damage
to property and injury to persons on account of any defective work or
maintenance carried out by the Contractor. All sanitary wares shall be guaranteed
for a period of 5 years.
3.4.2 All CP fittings shall be guaranteed for a minimum period of 5 years.

3.5 APPLICABLE CODES, STANDARDS AND PUBLICATIONS –

3.5.1 All equipment, supply, erection, testing and commissioning shall comply with
the requirements of Indian Standards and code of practices given below as
amended till date. All equipment and material being supplied by the Contractor
shall meet the requirements of IS and other Codes/ Publications as given below.
SP: 6 (1) Structural steel sections.
IS: 325 :1996 Three phase induction motors.
Dimensions for pipe threads where pressure tight joints
IS: 554 :1999
are required on the threads

59
 PVC insulated cables for working voltages up to and
IS:694 :2010
including 1100 V.
IS: 779 :1994 Specification for water meters (domestic type).
IS: 800 :2007 Code of Practice for general construction in steel.
Electroplated coatings of nickel plus chromium and
IS: 1068 :1993
copper plus nickel plus chromium.
Code of Basic requirements for water supply drainage and
IS: 1172 :1993
sanitation.
IS: 1367 (Part Technical supply conditions for threaded steel fasteners:
1):2002 General Requirements.
Technical supply conditions for threaded steel fasteners:
IS: 1367 (Part
Tolerances for fasteners – Bolts, screws, studs and nuts –
2):2002
Product Grades A, B and C.
IS: 1554 (Part PVC insulated (heavy duty) electric cables: For working
1):1988 voltages up to and including 1100 V.
IS: 1554 (Part PVC insulated (heavy duty) electric cables: For working
2):1988 voltages from 3.3 kV up to and including 11 kV.
IS: 1726 :1991 Specification for cast iron man hole covers and frames.
IS: 1742 :1983 Code of practice for building drainage.
Selection, installation and maintenance of sanitary
IS: 2064 :1993
appliances - Code of practice.
IS: 2065 :1983 Code of practice for water supply in buildings.
IS: 2373 :1981 Specification for water meters (bulk type).
IS: 2379 :1990 Colour code for identification of pipelines.
Code of practice for fixing rain water gutters and down
IS: 2527 :1984
pipes for roof drainage.
Recommended practice for hot dip galvanizing on iron
IS: 2629 :1985
and steel.
Unplasticised PVC pipes for potable water supplies -
IS: 4985:2000
specification.
Code of practice for sanitary pipe work above ground for
IS: 5329 : 1983
buildings.
IS: 5455 : 1969 Cast iron steps for manholes.
Recommended practice for design and fabrication of
IS: 6159:1998
material prior to galvanising.
IS: 7558:1974 Code of practice for domestic hot water installations.
IS: 8321 Glossary of terms applicable to plumbing work.
IS: 9668:1990 Maintenance of water supplies and fire fighting.
IS: 9842:1994 Preformed fibrous pipe insulation.
IS: 11149:1984 Rubber Gaskets.
IS: 12251 Code of practice for drainage of building basements.
BS: 5572 Code of practice for sanitary pipe work.
Specification for design, installation, testing and
BS: 6700 :2006 maintenance of services supplying water for domestic use
within buildings and their curtilages.

60
BS: 8301 Code of practice for building drainage.
Sanitary tap ware, waste fittings for basins, bidets and
BSEN274
baths. General technical specifications.
Specification for precast concrete pipes(with and without
IS: 458 :2003
reinforcement).
IS:651 :2007 Salt glazed stoneware pipes and fittings.
IS: 1239 (Part 1) Steel tubes, tubulars and other wrought steel fittings: Steel
:2004 tubes.
Centrifugally cast (spun) iron pressure pipes for water, gas
IS: 1536:2001
and sewage.
Cast iron fittings for pressure pipes for water, gas and
IS: 1538 :1993
sewage.
Sand cast iron spigot and socket soil, waste and
IS: 1729:2002
ventilating pipes, fitting sand accessories.
IS: 1879:2010 Malleable cast iron pipe fittings.
IS: 1978 :1982 Line pipe.
IS: 1979 :1985 High test line pipe.
IS: 2501 :1995 Copper tubes for general engineering purposes.
IS: 2643 (Part Dimensions for pipe threads for fastening purposes: Basic
1):2005 profile and dimensions.
IS: 2643 (Part 2) Dimensions for pipe threads for fastening purposes:
2005 Tolerances.
IS: 2643 (Part Dimensions for pipe threads for fastening purposes:
3)2005 Limits of sizes.
IS: 3468 :1991 Pipe nuts.
Seamless or electrically welded steel pipes for water, gas
IS: 3589 :2001
and sewage (168.3 mm to 2032 mm outside diameter).
Centrifugally cast (spun) iron spigot and socket soil, waste
IS:3989 :1984
and ventilating pipes, fittings and accessories.
Specifications for washers for use with fittings for water
IS: 4346 :1982
services.
IS: 4711 Methods for sampling steel pipes, tube sand fittings.
IS: 6392 Steel pipe flanges.
Cast iron and malleable cast iron flanges for general
IS: 6418
engineering purposes.
Specification for horizontally cast iron double flanged
IS: 7181
pipes for water, gas and sewage.
Specification for copper alloy gate, globe and check
IS: 778
valves for water works purposes.
Specification for sluice valves for water works purposes
IS: 780
(50 mm to 300 mm size).
Specification copper alloy float valves (horizontal plunger
IS: 1703 2000
type) for water supply fittings.
Specification for sluice valves for water works purposes
IS: 2906 2000
(350 mm to 1200 mm size).

61
IS: 3950 :1979 Specification for surface boxes for sluice valves.
IS: 5312 (Part Specification for swing check type reflux (non return)
1)2004 valves: Single door pattern.
IS: 5312 (Part Specification for swing check type reflux (non return)
2):2004 valves: Multidoor pattern.
IS: 13095 :1991 Butterfly valves for general purposes.
IS: 771 (Parts 1 to
Specification for glazed fire clay sanitary appliances.
3)1978-1985
Specification for flushing cistern for water closets and
IS: 774 2004
urinals (other than plastic cistern).
Specification for cast copper alloy screw down bib taps
IS: 781 1984
and stop valves for water services.
IS: 1700 Specification for drinking fountains.
Specification for automatic flushing cisterns for urinals
IS: 2326 1987
(other than plastic cisterns).
IS: 2548 (Part Specification for plastic seats and covers for water closets:
1)1996 Thermoset seats and covers.
IS: 2548(Part 2) Specification for plastic seats and covers for water closets:
1996 Thermoplastic seats and covers.
IS: 2556 (Part Specification for vitreous sanitary appliances (vitreous
1)2004 china): General requirements.
IS: 2556 (Part Specification for vitreous sanitary appliances (vitreous
2)2004 china): Specific requirements of wash down water closets.
IS: 2556 (Part Specification for vitreous sanitary appliances (vitreous
3)2004 china): Specific requirements of squatting pans.
IS: 2556 (Part Specification for vitreous sanitary appliances (vitreous
4)2004 china): Specific requirements of wash basins.
Specification for vitreous sanitary appliances (vitreous
IS: 2556 (Part 6. Sec
china): Specific requirements of urinals, Section 2 Half
2)1995
stall urinals.
Specification for vitreous sanitary appliances (vitreous
IS: 2556 (Part 6, Sec china): Specific requirements of urinals, Section 4
4)1995 Partition slabs.

Specification for vitreous sanitary appliances (vitreous

IS: 2556 (Part 6, Sec
china): Specific requirements of urinals, Section 5 waste
5)1995
fittings.
Specification for vitreous sanitary appliances (vitreous
IS: 2556 (Part 6, Sec
china): Specific requirements of urinals, Section 6 Water
6)1995
spreaders for half stall urinals.
IS: 2556 (Part Specification for vitreous sanitary appliances (vitreous
7)2004 china): Specific requirements of half round channels.
Specification for vitreous sanitary appliances (vitreous
IS: 2556 (Part
china): Specific requirements of siphonic wash down
8)2004
water closets.
IS: 2556 (Part Specification for vitreous sanitary appliances (vitreous

62
 11)2004 china): Specific requirements for shower rose.
IS: 2556 (Part Specification for vitreous sanitary appliances (vitreous
12)2004 china): Specific requirements of floor traps.
IS: 2556 (Part Specification for vitreous sanitary appliances (vitreous
15):2004 china): Specific requirements of universal water closets.
Glossary of terms relating to vitreous enamel ware and
IS: 2717 :1979
ceramic metal systems.
Specifications for copper alloy waste fittings for wash
IS: 2963 :1979
basins and sinks.
Specification for waste plug and its accessories for sinks
IS: 3311 :1979
and wash basins.
IS: 5961 :1970 Specification for cast iron gratings for drainage purposes.
IS: 6249 :1999 Specification for flush valves and fittings for marine use.
Specification for gel coated glass fibre reinforced
IS: 6411:1985
polyester resin bath tubs.
Specification for copper alloy fancy single taps,
IS: 8931:1993 combination tap assembly and stop valves for water
services.
Specification for flush valves and fitting for water closets
IS: 9758 :1981
and urinals.

3.6 QUALITY ASSURANCE AND QUALITY CONTROL

3.6.1 The Work shall conform to high standards of design and workmanship, shall be
structurally sound and aesthetically pleasing. Quality standards prescribed shall
form the backbone for the Quality Assurance and Quality Control system.
3.6.2 At the site level the Contractor shall arrange the materials, their stacking/ storage
in an appropriate manner to ensure quality. Contractor shall provide equipment
and manpower to test continuously the quality of materials, assemblies, etc. as
directed by the Engineer. The test shall be conducted continuously and the result
of tests maintained. In addition the Contractor shall keep appropriate tools and
equipment for checking alignments, levels, slopes and evenness of surface.
3.6.3 The Engineer shall be free to carry out tests as may be considered necessary by
him at his sole discretion, from time to time, in addition to those specified in this
document. The Contractor shall provide the samples and labour for collecting the
samples. Nothing extra shall be payable to the Contractor for samples or for the
collection of the samples.
3.6.4 The test shall be conducted at the site laboratory that may be established by
Engineer or at any other Standard Laboratory selected by Engineer.
3.6.5 The Contractor shall transport the samples to the laboratory for which nothing
extra shall be payable. In the event of Contractor failing to arrange transportation
of the samples in proper time Engineer shall have them transported and recover at
two times the actual cost from the Contractor's bills.
3.6.6 Testing charges shall be borne by the Contractor.

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3.6.7 Testing may be witnessed by the Contractor or his authorised representative.
Whether witnessed by the Contractor or not, the test results shall be binding on
the Contractor.

3.7 SANITARY AND OTHER APPLIANCES

3.7.1 SCOPE OF WORK
a) Without restricting to the generality of the foregoing, sanitary and other
appliances shall inter-alia include the following: All Sanitary appliances
and fittings shall be as per Green Rating for Integrated Habitat Assessment
(GRIHA) Rating 2015.
b) Sanitary appliances and fixtures for toilets.
c) Chromium plated brass fittings.
d) Accessories e.g. towel rods, toilet paper holders, towel rails, coat hooks,
etc.
e) Drinking water dispenser , etc
f) Whether specifically indicated or not the Contractor shall provide for all
appliances and fixtures, all fixing devices, nuts, washers, teflon tape,
sealant, cement, brackets, supports, paints, connectors, Chromium Plated
(CP) riser pipes, adopters, bolts, screws, hangers, etc., as required.
g) All exposed pipes within toilets and near appliances/ fixtures shall be of
CP brass or copper unless otherwise specified.
3.7.2 GENERAL REQUIREMENTS

a) All materials shall be new and of quality conforming to specifications and

subject to the approval of the Engineer. Wherever particular makes are
mentioned, the choice of selection shall remain with the Engineer.
b) All appliances, fixtures and fittings shall be provided with all such
accessories as are required to complete the item in working condition
whether specifically mentioned or not in the Schedule of Quantities,
specifications, and drawings. Accessories shall include proper fixing
arrangement, brackets, nuts, bolts, washers, screws and required
connection pieces.
c) Fixing screws shall be half round head CP brass screws, with CP brass
washers unless otherwise specified.
d) Porcelain sanitary ware shall be glazed vitreous china of first quality free
from warps, cracks and glazing defects conforming to IS: 2556. The
choice of the colour of the Sanitary ware shall be that of the Engineer and
nothing extra shall be payable to the Contractor for fixing of Sanitary ware
of any colour.
e) Sinks for Kitchen shall be of stainless steel or as specified in the Schedule
of Quantities.
f) CP fittings shall be cast brass CP of the best quality approved by the
Engineer.
g) If Supply of sanitary appliances, fixtures are fittings are in Employer‟s
scope, Contractor shall ensure that no damages occur to the same during

64
 shifting, transportation, installation and successful handing over. If any
damage occurs, the same shall be replaced by the Contractor at his own
cost.
h) All appliances, fittings and fixtures shall be fixed in a neat workmanlike
manner true to level and to heights shown on the drawings and in
accordance with the manufacturer‟s recommendations. Care shall be taken
to fix all inlet and outlet pipes at correct positions. Faulty locations shall
be made good and any damage to the finished floor, tiling, plaster, paint,
insulation or terrace shall be made good by the Contractor at his own cost.
i) All materials shall be rust proofed; materials in direct or indirect contact
shall be compatible to prevent electrolytic or chemical (bimetallic)
corrosion.
j) Sanitary appliances, subject to the type of appliance and specific
requirements, shall be fixed in accordance with the relevant standards and
the following:
k) Contractor shall, during the entire period of installation and afterwards
protect the appliances by providing suitable cover or any other protection
in order to absolutely prevent any damage to the appliances until
satisfactory handing over. (The original protective wrapping shall be left
in position for as long as possible).
l) The appliance shall be placed in correct position or marked out in order
that pipe work can be fixed or partially fixed first.
m) The appliance shall be fixed in a manner such that it will facilitate
subsequent removal, if necessary.
n) All appliances shall be securely fixed. Manufacturers' brackets and fixing
methods shall be used wherever possible. Compatible rust proofed fixings
shall be used. Fixing shall be done in a manner that minimizes noise
transmission.
o) Appliances shall not be bedded (e.g. WC pans and pedestal units) in thick
strong mortar that could crack the unit (e.g. a ceramic unit).
p) Pipe connections shall be made with de-mountable unions. Pipe work shall
not be fixed in a manner that it supports or partially supports an appliance.
q) Appliances shall be fixed so that water falls to the outlet (e.g. baths).
r) All appliances shall be secured as per the recommendations of
manufacturer.
s) Appliances shall be fixed true to level firmly fixed to anchor or supports
provided by the manufacturer and additional anchors or supports where
necessary.
t) Sizes of Sanitary fixtures given in the Specifications or in the Schedule of
Quantities are for identification with reference to the catalogues of makes
considered. Dimensions of similar models of other makes may vary within
+10% and the same shall be provided and no claim for extra payment shall
be entertained nor shall any payment be deducted on this account.

3.7.3 URINAL PARTITIONS

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 a) Urinal partitions shall be Granite /white glazed vitreous china of size specified
in the Schedule of Quantities.
b) Porcelain partitions shall be fixed at proper heights with CP brass bolts,
anchor fasteners and MS clips as recommended by the manufacturer and
directed by the Engineer.

3.7.4 WASH BASIN

a) Wash basins shall be white glazed vitreous china of size, shape and type
specified in the Schedule of Quantities.
b) Each basin shall be provided with painted MS angle or CI brackets and clips
and the basin securely fixed to wall. Placing of basins over the brackets
without secure fixing shall not be accepted. The MS angle shall be provided
with two coats of red oxide primer and two coats of synthetic enamel paint of
make, brand and colour as approved by the Engineer.
c) Each basin shall be provided with 32 mm dia. CP waste with overflow, pop-
up waste or rubber plug, CP angle valve, CP riser pipe with connectors/
adaptors and CP brass chain as specified in the Schedule of Quantities, 32 mm
dia. CP brass bottle trap with CP pipe to wall flange.
d) Wash basin shall be provided with hot and cold water mixing fitting or as
specified in the Schedule of Quantities.
e) Basins shall be fixed at proper heights as shown on drawings. If height is not
specified, the rim level shall be 790 mm from finished floor level or as
directed by the Engineer.

3.7.5 SINKS

a) Sinks shall be stainless steel or any other material as specified in the Schedule
of Quantities.
b) Each sink shall be provided with painted MS or CI brackets and clips and
securely fixed. Counter top sinks shall be fixed with suitable painted angle
iron brackets or clips as recommended by the manufacturer. Each sink shall be
provided with 40 mm dia. CP waste, CP angle valve, CP riser pipe with
connectors/ adaptors and rubber plug with CP brass chain as given in the
Schedule of Quantities. The MS angle shall be provided with two coats of red
oxide primer and two coats of synthetic enamel paint of make, brand and
colour as approved by the Engineer.
c) Supply fittings for sinks shall be deck mounted CP swivel faucets with or
without hot and cold water mixing fittings as specified in the Schedule of
Quantities. These shall be measured and paid for separately.

3.7.6 SHOWER SET

Shower set shall comprise of two CP brass concealed stop cocks, four/ five way
auto-diverter, adjustable type overhead shower, all with CP wall flanges of
approved quality all as specified in the Schedule of Quantities. Bath spout, shower

66
 head/ rose, hand showers and pop up wastes shall also be provided wherever
specified.
Wall flange shall be kept clear off the finished wall. Wall flanges embedded in the
finishing shall not be accepted.

3.7.7 DRINKING WATER FOUNTAIN

It shall have built-in RO Filtration and UV System.Drinking water fountain shall

be wall mounting type made of stainless steel or any other material as given in the
Schedule of Quantities.The drinking water fountain shall be with anti-squirt
bubble less, self closing valve type with automatic volume regulator.The drinking
water fountain shall be provided with an anti-splash back and integral strainer
with 32 mm or 40 mm cast brass trap.

3.7.8 MEASUREMENT AND RATES

Sanitary fixtures (Porcelain ware and CP fittings) shall be measured by numbers.
Rate for providing and fixing of sanitary fixtures, accessories, shall include all
items, and operations stated in the respective specifications and Schedule of
Quantities and nothing extra is payable.
Rates for all items under specification Clauses above shall be inclusive of cutting
holes and chases and making good the same, CP brass screws, nuts, bolts and any
other fixing arrangements required and recommended by manufacturers, testing
and commissioning etc. complete.

3.7.9 Toilet Paper Holder

Toilet paper holder shall be white glazed vitreous china or chrome plated of size,
shape and type specified in the Schedule of Quantities.
Porcelain toilet paper holder shall be fixed in walls and set in cement mortar 1:2
(1 cement : 2 coarse sand) and fixed in relation to the tiling work.
The latter (chrome) shall be fixed by means of screws/capping having finish
similar to the toilet paper holder in wall/temper partitions with raw l plugs or
nylon sleeves. When fixed on timber partition, it shall be fixed on a solid wooden
base member provided by the Owner‟s Site Representative.

3.7.10 P.V.C Connectors

These shall be of specified size, of appropriate length with brass unions and wiped
solder joint, shall be bent to correct shape without any distortions, and work shall
include all the operations, such as fixing, as necessary for satisfactory working of
the same.
3.7.11 TOILETS FOR THE DISABLED

Where specified, in washroom facilities designed to accommodate physically

disabled, accessories shall be provided as directed by the Owner‟s Site
Representative.

67
 Stainless steel garb brass of required size suitable for concealed or exposed
mounting and opened non-slip gripping surface shall be provided in all
washroom. The flushing cistern/valve shall be provided with chromium plated
long handles.
3.7.12 MOCKUP AND TRIAL ASSEMBLY

The installation of the sanitary fixtures and fittings shall be as per the shop
drawings approved by the Architect/Consultant. Contractor has to make sure the
availability of every fixture to be displayed in the mock-up. Mock-up shall
present the exact presentation which is going to be finalised for the installation.
Only after the approval of the client and architect, contractor shall consider it as a
benchmark and follow the same procedure to do the rest of the installation.
Owners Site representative shall make sure contractor follows the same and
maintains the quality.
Relevant instructions from manufacturers shall be followed as applicable. This
trial assembly shall be developed to determine the location of puncture holes,
holding devices etc. which will be required for final installation of all sanitary
fixtures and fittings. The above assembly shall be subject to final approval by the
Architect / Interior Designer.
The fixtures in the trial assembly can be re-used for final installation without any
additional payments for fixing or dismantling of the fixtures

3.8 SOIL, WASTE, VENT AND RAINWATER PIPES

3.8.1 SCOPE OF WORK

a) Soil, waste, vent and rain water disposal scope shall include Supply,
Installation, testing, commissioning and successful handing over to
Employer as per the drawings, specifications and Schedule of Quantities.
b) All soil, waste and storm water disposal for the portion above ground level
to the public sewers shall be by gravity, whereas from the basement it
shall be by pumping. Without restricting to the generality of the foregoing,
the soil, waste, vent and rain water pipes system shall inter-alia include the
following:
c) Vertical and horizontal soil, waste, vent and rainwater pipes and fittings,
joints, supports, paints and connections to fixtures.
d) Connection of all pipes to sewer lines as shown on the drawings at ground
level.
e) Floor and urinal traps, clean out plugs, inlet fittings and rainwater (roof)
outlets.
f) Testing of all pipes and fittings in the workshop.
g) Testing, commissioning and handing over of all pipes lines after
installation.

3.8.2 GENERAL REQUIREMENTS

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 a) Pipes and fittings shall be fixed truly vertical, horizontal or in slopes as
required in a neat workmanlike manner.
b) Pipes shall be fixed in a manner so as to provide easy accessibility for
repair and maintenance and shall not cause obstruction in shafts, passages
etc.
c) Pipes shall be securely fixed to walls and ceilings by suitable clamps at
intervals specified. Only approved type of anchor fasteners shall be used
for fixing pipes on RCC ceilings and RCC/ masonry walls.
d) Access doors for fittings and clean outs shall be so located that they are
easily accessible for repair and maintenance.
e) Long bends shall be used on all main pipelines as far as possible. Use of
elbows shall be restricted for short connections.
f) Wherever piping is going across the separation/ expansion joints of
buildings, piping shall be provided with flexible connectors on both sides
of such joints or on single side depending on whether any wall is to be
crossed or not.

3.8.3 UPVC PIPE WORK

UPVC SWR(Soil Waster and Rain water ) pipe work shall be provided for above
ground soil, waste, vent and rain water pipe work as shown in drawings. UPVC
SWR pipes and fittings shall confirm to IS: 13592 and IS: 14735 respectively.
Pipes shall be of Type - B, pressure rating 6 kg/cm2. The pipes shall be supplied
in nominal lengths of 2, 3, 4 or 6 metres, tolerance on specified lengths shall be
+10 mm and -0 mm. Any physical test requirements shall be as per IS: 13592 -
1992.

3.8.4 Handling

Because of their light weight, there may be a tendency for the UPVC pipes to be
thrown often during installation. Reasonable care should be taken in handling and
storage to prevent damage to the pipes. The pipes shall be stored as per
manufacturer‟s recommendation. The Contractor shall be fully responsible in this
case. In no case, pipes should be dragged on the ground. Pipes should be given
adequate supports at all times.

3.8.5 Pipe Work Installation

a) UPVC pipes shall be laid under the flooring or hanging below slab or
fixed on walls either buried or exposed as the case may be, as shown in the
drawings. The minimum thickness of fittings shall be of 3.2 mm. the
fittings shall be of injection mould type with solvent cement joint (for
exposed piping) or rubber ring joint (for concealed piping). The pipes and
fittings shall be capable of withstanding sun‟s rays. UPVC pipes laid
below slab or suspended from ceiling shall be supported by GI angle
brackets/ supports as detailed in the drawings.

69
 b) All vertical pipes shall be fixed by GI clamps truly horizontal. Branch
pipes shall be connected to the stack at the same angle as that of the
fittings. No collars shall be used on vertical stacks. Each stack shall be
terminated at top with a vent cowl (terminal guard).
c) Horizontal pipes running along ceiling shall be fixed on structural
members by adjustable clamps of special design shown on the drawings or
as directed. Horizontal pipes shall be laid to uniform slope and the clamps
adjusted to the proper levels so that the pipes fully rest on them.
d) Contractor shall provide all sleeves, openings, hangers and anchor
fasteners during the construction. Sleeves shall be one size higher then
pipe or there should be at least 12 mm gap all around between pipes and
sleeves. Wherever pipe passes through fire rated wall, the gap shall be
filled with fire rated sealant as directed by Engineer. For non-fire rated
wall, gap shall be filled with wool and silicon sealant (20 mm depth).
Contractor shall provide all necessary information to the building work
Contractor for making such provisions in the structure as necessary. All
damages shall be made good by the Contractor at his own cost to restore
the surface.
e) Door type fittings shall be used in vertical piping installations. Door
position of fittings shall be on top of fitting. Easy removal of access door
should be possible. The access door shall be air and water tight. Single -
yee shall be used for horizontal branch connection. Double - yee fittings
shall be used in vertical piping branch connection only.

3.8.6 Jointing

a) UPVC pipes and fittings shall be joined as per the manufacturer‟s

instructions/ recommendations. UPVC pipes and fittings shall be joined
with Solvent Cement and jointing shall be carried out as follows:
b) Cut the spigot end of the pipe square.
c) All burrs from the internal and external surfaces should be removed.
d) The spigot should be marked with a pencil line at a distance equivalent to
the socket depth. Clean the surface within the marked area.
e) Apply uniform coat of approved solvent cement on the external surface to
the pipe and a lighter coat on the internal surface of the fitting.
f) Insert the pipe end into the socket of the fitting and push it in upto the
mark.
g) The pipe work should be assembled in a manner such that it does not
entail making of joints in restricted area.
h) UPVC Pipe Work Testing
i) UPVC pipes and fittings assembled shall be tested in accordance with IS
13592 - 1992. The openings of the pipes shall be sealed for the section to
be tested. The water column of 2 m shall be maintained for a maximum of
15 minutes. Contractor with his team shall examine carefully all the joints
for leakage.

70
 j) The Contractor shall test all vent pipes by a smoke testing machine.
Smoke shall be pumped into the stack after plugging all inlets and
connections and filling water in all trap seals. The test shall be conducted
under a pressure of 25 mm of water and shall be maintained for 15
minutes. The stack shall then be observed for leakages and all defective
pipes and fittings removed or repaired as directed by the Engineer.
k) A test register shall be maintained and all entries signed and dated by
Contractor and Engineer. A proforma of the proposed test register shall be
submitted to the Engineer for approval.
l) All pipes in wall chase or meant to be encased or buried shall be hydro
tested before the chase is plastered or the pipe encased or buried.
m) All systems shall be tested in sections as required to expedite the work for
other trades and meet construction schedules and final test on completion.

3.8.7 WASTE PIPE FROM APPLIANCES

Waste pipe from appliances e.g. washbasins, baths, sinks and urinals, etc. shall be
of UPVC confirming IS: 4985 as given in the Schedule of Quantities.
The internal diameter sizes of outlet branch waste pipes for different fittings shall
be as follows:
Wash Basin 40 dia.
Urinals 50 dia.
Sink 50 dia.
Nahani Trap 75 dia., 50 mm seal.
75 or 100 dia. as required, with 50
Multi Floor Trap
mm or 75 mm seal.
Wash troughs 50 dia.
Canteen wash areas 50 dia.
All pipes shall be fixed in gradient towards the outfalls of drains. Pipes inside a
toilet room shall be in chase unless otherwise shown on drawings. Where required
pipes may be run at ceiling level in suitable gradient and supported on structural
clamps as directed by the Engineer. Spacing for the clamps shall be 3,000 mm for
vertical runs and 2,400 mm for horizontal runs.
Pipes shall be UPVC tubes conforming to IS: 4985 and quality certificates shall
be furnished. Pipes shall be provided with all required fittings conforming to IS:
4985 e.g. tees, couplings, bends, elbows, unions, reducers, nipples, plugs, etc. All
UPVC waste pipes shall be terminated at the point of connection with the
appliance with an outlet of suitable diameter. Pipes shall be painted as specified
under Clause Error! Reference source not found..

3.9 DRAINAGE ACCESSORIES

3.9.1 Floor Trap/ Urinal Trap Grating
Floor/ urinal traps grating shall be of stainless steel square/ round of size 125 mm
x 125 mm square/ round as approved by Employer and shown in the drawing.
Floor trap assembly shall be provided with round stainless steel strainer basket as

71
 a cockroach trap. Entire assembly shall be complete with ring, frame, outer cup,
inner cup, grating, screws, etc. of an approved make.

3.9.2 Floor Cleanout

Floor cleanout cover shall be of stainless steel square/ round of size 125 mm x
125 mm square/ round as approved by Employer and shown in the drawing. Floor
cleanout assembly shall be complete with ring, outer frame, cover, screws, etc. of
an approved make.

3.9.3 Ceiling Cleanout

Ceiling cleanout cover shall be in nickle bronze/ PVC plug type/ GI flanged type
of round shape matching pipe size as approved by Employer and shown in the
drawing. Ceiling cleanout assembly shall be threaded with key hole for opening/
flanged type suitable for pipe. Threaded cover shall be used upto 100 mm size and
above shall be GI flanged type with GI nuts and bolts. PVC cover shall be used
for PVC drainage piping only, whereas nickle bronze and GI flanged type cover
shall be used for HDPE/ CI/ CI LA pipe work.

3.9.4 RAINWATER PIPES

All rainwater pipes shall be of UPVC/ HDPE as shown in drawing and specified
in specification. UPVC piping shall conform to IS: 4985 and 6 kg/cm2 minimum
pressure rating or as specified in the Schedule of Quantities.

3.9.5 RAIN WATER OUTLET

a) Rain water outlet shall be preferably scupper type drain with cast iron
body and cast aluminium grating with stainless steel screws. Suitable
adapter/ connector shall be used to match the pipe. Wherever shafts are
not available near rain water outlet, dome type rain water outlet shall be
installed.
b) Rain water outlet shall be tested for water leaking, prior to waterproofing
treatment. Extreme care shall be taken, while sealing gap between rain
water outlet and wall/ slab.

3.10 MEASUREMENT AND RATES

3.10.1 General
a) Rates for all items shall be inclusive of all work and items called for in the
specifications given above and the Schedule of Quantities as applicable for
the work under floors, in shafts or at ceiling level at all heights and depths.
b) All rates are inclusive of cutting holes and chases in RCC and masonry
work and making good the same.

72
 c) All rates are inclusive of shop testing, pre-testing at site and final testing
of the installations, materials and commissioning.

3.10.2 Pipes

a) The unit of measurement shall be linear metre to the nearest centimetre.

b) All CI/ UPVC/ HDPE soil, waste, vent, anti-siphonage and rain water
pipes shall be measured net, correct to a centimetre, including all fittings
along their length after fixing. The length shall be taken along centre line
of the pipes and fittings. No allowance shall be made for the portions of
pipe lengths entering the sockets of the adjacent pipes or fittings. The
above shall apply to all cases i.e. whether pipes are fixed on wall face or
pillars or embedded in masonry or pipes running at ceiling level. The
quoted rate shall include lead jointing.
c) All CI/ UPVC/ HDPE pipes shall be measured in running metre correct to
a centimetre for the finished work which shall include fittings e.g. bends,
tees, elbows, reducers, crosses, sockets, nipples, nuts, unions, etc. The
length shall be taken along centre line of the pipes and fittings. All pipes
and fittings shall be classified according to their diameter, method of
jointing and fixing substance, quality and finish. The diameters shall be
nominal diameter of internal bore. In case of fittings of unequal bore, the
largest bore shall be considered.

3.10.3 Pipe Encasing/ supports

a) Cement concrete around pipes shall be measured along the centre of the
pipe line measured per linear metre and include any masonry supports,
shuttering and centering, curing, cutting, etc. complete as described in the
relevant specifications.
b) GI Supports
c) GI Supports rate for pipe work shall be included in the quoted BOQ/ SOQ
rate and shall include GI channels/ angles (structural steel members), GI
bolts, GI nuts, GI washers, brass screws, SS fasteners, GI threaded rod, GI
clamps, GI hangers, primer coating, painting, etc. Length of supports
embedded in the cement concrete blocks of 1:2:4 (1 cement : 2 coarse
sand : 4 stone aggregate 20 mm nominal size) formed in the masonry
walls shall not be paid extra. Also nothing shall be paid extra for the
cement concrete block and making good the masonry wall, anchor
fasteners, etc. complete.

3.10.4 Traps

Unit of measurement shall be the number of pieces. All urinal traps, trap gratings,
hoppers, clean out plugs shall be measured by number and shall include all items
described in the relevant specifications and Schedule of Quantities. Cockroach

73
 traps shall not be measured separately and are deemed to be included in the rate
for Traps.
3.10.5 Painting

Painting of pipes shall be measured per running metre for each diameter of pipe
and shall be inclusive of all fittings and clamps. No deduction shall be made for
fittings.

3.10.6 Excavation for Soil Pipes

No extra payment shall be admissible for excavation, dewatering, back filling,
consolidation and disposal of surplus earth for soil and waste pipes.

3.10.7 Rain Water Outlet

Rain water outlet shall be measured by numbers for different sizes.

Leaf and gravel grates along with the perforated ring shall be measured in
kilograms.

3.11 WATER SUPPLY SYSTEM

3.11.1 SCOPE OF WORK

a) The scope shall include supply, installation, testing, commissioning and

satisfactory handing over of the complete water supply system to
Employer as per drawings, specifications and Schedule of Quantities. The
water supply system shall include the following:
b) Distribution system from main supply or overhead tank to all fixtures and
appliances for cold and hot water.
c) Insulation for hot water pipes.
d) Pipe painting.
e) Control valves, masonry chambers and other appurtenances.
f) Connections to all plumbing fixtures, tanks, appliances.
g) Inserts, nozzles for Reinforced Concrete tanks.
h) The term water supply is used as indicative of all water supply work
required and necessary for the building including such external work as
may be necessary to make the system functional.

3.11.2 GENERAL REQUIREMENTS

If necessary and if approved by the Engineer, where unavoidable, bends may be

formed by means of a hydraulic pipe bending machine for pipes up to 20 mm dia.
No bending shall be done for pipes of 25 mm dia. and above. After bending zinc
rich paint shall be applied wherever the zinc coating is damaged.
Valves and other appurtenances shall be so located as to provide easy accessibility
for operations, maintenance and repairs. Valves shall be located at a height not

74
 exceeding 1.6 m above their operating floor/ platform level. Where such a
provision is not possible and the valve is to be frequently operated a MS chain
shall be provided for its operation.

3.11.3 GI PIPES, FITTINGS AND VALVES

a) All pipes inside the buildings and where specified, outside the building
shall be MS galvanised steel tubes conforming to IS: 1239 of Class
specified. When Class is not specified they shall be Heavy Class. All
embedded/ concealed pipes shall be of heavy duty.
b) Fittings shall be of malleable cast iron galvanised, of approved make.
Each fitting shall have manufacturer's trade mark stamped on it. Fittings
for GI pipes shall include couplings, bends, tees, reducers, nipples, unions,
bushes, etc. Fittings, etc. shall conform to IS: 1879.
c) Pipes and fittings shall be jointed with screwed joints using Teflon tape
suitable for water pipes. Care shall be taken to remove burr from the end
of the pipe after cutting by a round file. All pipes shall be fixed in
accordance with layout and alignment shown on the drawings. Care shall
be taken to avoid air pockets. Necessary vents and drains shall be provided
at all high and low points respectively. GI pipes inside toilets shall be
fixed in wall chases well above the floor. No pipes shall be run inside a
sunken floor as far as possible. Pipes may be run under the ceiling or
floors and other areas as shown on drawings. All pipe joints after testing
of the line shall be seal welded and the weld plus the adjoining portion
shall be given two coats of zinc rich primer.

3.11.4 Clamps

GI pipes in shafts and other locations shall be supported by GI clamps of design

approved by the Engineer. Pipes in wall chases shall be anchored by iron hooks.
Pipes at ceiling level shall be supported on structural clamps fabricated from MS
structural sections. Pipes in shafts shall be supported on slotted angles/ channels
as specified/ as directed.

3.11.5 Unions

Contractor shall provide adequate number of unions on all pipes to enable easy
dismantling later when required. Unions shall be provided near each gunmetal
valve, stop cock or check valve and on straight runs as necessary at appropriate
locations as required for easy dismantling and/ or as directed by the Engineer.

3.11.6 Flanges

Flanged connections shall be provided on pipes as required for maintenance/ ease

in dismantling or where shown on the drawings, all equipment connections as
necessary and required or as directed by the Engineer. Connections shall be made

75
 by the correct number and size of the GI nuts/ bolts as per relevant IS Standards
and made with 3mm thick insertion rubber washer/ gasket. Where hot water or
steam connections are made insertion gasket shall be of suitable high temperature
grade and quality approved by the Engineer. Bolt hole dia. for flanges shall
conform to match the specification for CI sluice valve as per IS: 780. Gaskets
shall conform to IS: 11149.

3.11.7 Trenches

All GI pipes below ground shall be laid in trenches with a minimum cover of 600
mm. The width and depth of the trenches shall be as follows except at places
where welding/ jointing, etc. needs larger width of trench. Additional width/ depth
shall be provided as necessary for welding/ jointing, etc. at no additional cost:
3.11.9 Width of 3.11.10 Depth of
3.11.8 Diameter of
trench trench
pipe (mm)
(mm) (mm)
3.11.11 15 to 50 3.11.12 300 3.11.13 750mm
3.11.14 65 to 100 3.11.15 450 3.11.16 1000mm
3.11.17 Sand Filling

GI pipes in trenches shall be protected with fine sand 150mm all around before
filling in the trenches.

3.11.18 Painting

All pipes above ground shall be painted with one coat of red lead and two coats of
synthetic enamel paint of approved shade and quality to give an even shade, or as
specified by the Engineer.

3.11.19 Hot water pipes in chase:

All hot water pipes fixed in wall chase shall be properly insulated by elastomeric
tape as per manufacturer‟s recommendation.

3.11.20 Pipe Protection

Where specified, pipes below floor or below ground shall be protected against
corrosion by the application of two or more coats of solvent based rubberised
asphaltic primer to give a uniform coat covered with two layers of 2 mm thick
bituminous based anti-corrosive tape. The application of primer and anti-corrosive
tape shall be done as specified by the manufacturer.

3.11.21 Reverse Osmosis Unit

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 Supplying & fixing potable Reverse Osmosis Unit (RO Unit) includes with ultra
filtration & ultra violet treatment, shall have purified water flow rate of 15 litres/
hour, and 7 litres water storage capacity suitable for all kind of raw water. RO
unit shall be suitable for minimum 90 % of TDS reduction & minimum 25 %
water recovery. RO unit shall consist of all accessories, valves, fittings etc
required for complete satisfactory installations as required by client / engineer-in-
charge.

3.11.22 Drinking Water Cooler Unit

Supplying & fixing two tap stainless steel storage type drinking water cooler,
which includes ultra filtration shall have 100 litres storage capacity and 100
litres/hour water cooling capacity. Water cooler unit shall have adjustable cold
water thermostat, overload compressor protection and mechanically expanded
compressor. Water cooler unit shall consist of all accessories, valves, fittings etc
required for complete satisfactory installations as required by client / engineer-in-
charge.

3.12 VALVES & FITTINGS

3.12.1 Gunmetal Valves

Valves 50 mm dia. and below shall be heavy gunmetal full way valves or globe
valves conforming to Class I of IS: 778. Valves shall be tested at manufacturer's
works and the same stamped on it.All valves shall be approved by the Engineer-
in-Charge before they are allowed to be used in the Work.

3.12.2 Sluice Valves

Unless otherwise specified all valves 80 mm dia. and above shall be CI double
flanged sluice valves with non rising spindle. Sluice valves shall be provided with
wheel when they are in exposed positions and with a cap top when they are
located underground. Contractor shall provide suitable operating keys for sluice
valves with cap tops.Sluice valves shall be of approved makes conforming to IS:
780 of Class as specified

3.12.3 Butterfly Valves

a) Where specified, Valves 65mm dia. and above shall be cast iron butterfly
valve to be used for isolation and/ or flow regulation as directed by the
Engineer. The valves shall be tight shutoff/ regulatory type with resilient
seat suitable for flow in either direction and seal in both directions.
b) The butterfly valve shall be suitable for waterworks and rated Pressure
requirement as mentioned in the Schedule of quantities.
c) The body shall be of cast iron to IS:210 in circular shape and of high
strength to take the water pressure. The disc shall be heavy duty cast iron
with anti corrosive epoxy or nickel coating.

77
 d) The valve seat shall be of high grade elastomer or nitrile rubber. The valve
is closed position shall have complete contact between the seat and the
disc throughout the perimeter. The elastomer rubber shall have a long life
and shall not give away on continuous applied water pressure. The shaft
shall be EN 8 grade carbon steel.
e) The valve shall be fitted between two flanges on either side of pipe
flanges. The valve edge rubber shall be projected outside such that they
are wedged within the pipe flanges to prevent leakages.
f) Butterfly valve shall conform to IS: 13095.

3.12.4 Non Return Valve

Where specified non return valve (swing check type) shall be provided through
which flow can occur in one direction only. It shall be single door swing check
type of best quality conforming to IS: 5312.

3.12.5 Forged Brass Ball Valve

Valves of size 50 mm dia. and below shall be full bore quarter turn lever operated
female threaded forged brass hard chrome plated ball valves conforming to IS:
554. Valve shall have PTFE body seat rings and gland packing, forged brass ball,
stem and bonnet, carbon steel nut washer and lever and finished in chrome.
Valves shall have minimum working pressure of 16 bar. Valves shall be tested at
manufacturer's works and the same stamped on it.

3.12.6 Ball Type Non Return Valve (NRV)

Ball type NRV shall be used in water treatment plants and sewage sump pump
piping. NRV shall be constructed in cast iron body with epoxy coating, phenolic
resin and NBR (Nitrile) seal. NRV shall have flanged ends and can be installed in
horizontal as well as vertical position. NRV shall have minimum working
pressure of 10 bar or as per system requirements. Valves shall be tested at
manufacturer's works and the same stamped on it.

3.12.7 Air Release Valve (ARV)

Pressurised water supply lines shall be provided with air release valve at highest
point to release accumulated air for piping system. Air release valve shall be
automatic float operated; the diameter shall be as specified in the Schedule of
Quantities. Air release valve shall be provided with ball valve for ease in
Operation and Maintenance. Valve body shall be in cast iron stainless steel, brass
and EPDM internal components. Valves shall have minimum working pressure of
10 Kgs.
3.12.8 Ball float valve

Ball valves with floats to be fixed in storage tanks shall consist of cast brass lever
arm having copper balls (26 SWG) screwed to the arm integrally. The copper ball

78
 shall have bronze welded seams. The closing/opening mechanism incorporating
the piston and cylinder shall be non-corrosive metal and include washers. The size
and construction of ball valves and float shall be suitable for desired working
pressure operating the supply system. Where called for brass valves shall be
supplied with brass hexagonal back nuts to secure them to the tanks and a socket
to connect to supply pipe.
These valves are required to maintain a constant level in service reservoirs and
steel storage tanks. These shall be available for static pressure of 7 Kg/cm2
flanges faced and drilled to BS 10, table C, tested to 250 pounds per square inch.
These shall conform to BS-1212 Part-2 and IS 1703

3.13 TESTING

3.13.1 All pipes, fittings and valves shall be tested in accordance with IS: 2065 except
as may be modified herein under. All pipes, fittings and valves, after fixing at site,
shall be tested to a hydrostatic pressure of 10 kg/cm2 or 1.5 times the shut off
head of the pump whichever is greater.
3.13.2 The test pressure shall be maintained for a period of at least thirty minutes
without any drop in pressure.

3.13.3 A test register shall be maintained and all entries shall be signed and dated by
Contractor(s) and the Engineer.
3.13.4 After commissioning of the Water Supply System, the Contractor shall test each
valve by closing and opening it a number of times to observe if it is working
efficiently and effectively. Valves which do not operate efficiently and effectively
shall be replaced by new ones at no extra cost and the same shall be tested as
above.
3.13.5 All pipes in wall chase or meant to be encased or buried shall be hydro tested
before the chase is plastered or the pipe encased or buried.

3.13.6 INSULATION

a) All open hot water flow and return pipes shall be insulated with preformed
fibrous pipe sections conforming to IS: 9842.
b)
c) Insulation to pipes shall be with pre-moulded pipe sections, thickness for
sections shall be:
d) Pipe 50 mm dia. and below - 25 mm thick.
e) Pipe 65 mm dia. and above - 40 mm thick.

3.13.7 Application

a) All surfaces shall be thoroughly cleaned with a wire brush.

b) One layer of approved primer shall be applied and premoulded pipe
insulation sections shall be fixed.

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 c) One layer of aluminium foil of thickness 0.711 mm (20 SWG), shall be
applied as a finish layer.
d) Insulation for hot water pipes in chase:
e) All hot water pipes in chase shall be insulated with 3 mm elastomeric tape
as per manufacturer‟s recommendations.

3.13.8 DISINFECTION OF INSTALLATION

a) The water supply installation shall be disinfected as per standards and as

follows:
b) Tanks and pipes shall be filled and flushed out.
c) All bib cocks (taps) shall be closed.
d) Tanks and pipes shall be re-filled while adding a sterilising admixture
containing 50 parts chlorine to one million parts water.
e) When the installation is filled all bib cocks (taps) shall be opened
progressively and each allowed to run until the water smells of chlorine.
f) The installation shall be topped up and more steriliser added.
g) The installation shall then be left for three hours and shall then be tested
for residual chlorine; if none is found, the installation shall be drained and
the process repeated.
h) The installation shall be finally drained and flushed with potable water
before use.

3.13.9 MEASUREMENT AND RATES

3.13.9.1 GI and CPVC Pipes

a) GI pipes above ground shall be measured per linear metre (to the nearest
cm) along the centre line of the pipe and shall be inclusive of all fittings
e.g. couplings, tees, bends, elbows, unions, flanges, etc. Deduction for
valves shall be made. Rates quoted shall be inclusive of all fittings,
clamps, cutting holes chases and making good the same and all other items
mentioned in the specifications and Schedule of Quantities.
b) GI pipes below ground shall be measured per linear metre (to the nearest
cm) along the centre line of the pipe and shall be inclusive of all fittings
e.g. couplings, tees, bends, elbows, unions and flanges, etc. Deduction for
valves shall be made. Rates quoted shall be inclusive of all fittings, cutting
holes and chases and making good the same and all other items mentioned
in the specifications and Schedule of Quantities. Excavation, filling, back
filling with selected excavated earth, compaction and disposal of surplus
earth, fine sand filling around GI pipes, in external work shall be measured
separately, as per respective items.

3.13.10 VALVES, BIB COCKS AND STOP COCKS

a) Gunmetal and cast iron valves, Bib cocks and stop cocks shall be
measured by numbers.
b) Flanges for Nozzles

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 c) Flanges for nozzles shall be measured by numbers and the quoted rate
shall include welding of the flanges to the pipe nozzles.
d) Painting/ Pipe Protection/ Insulation
e) Unless otherwise specified painting/ pipe protection/ insulation for pipes
shall be measured and paid for separately. These shall be measured per
linear metre along the centre line of the pipe, over the finished surface and
shall include all valves and fittings for which no deduction shall be made.

3.13.11 Pressure Reducing Valve Set

a) Each pressure reducing valve set shall be complete with pressure reducing
or pressure regulating valve, isolating valves, pressure gauges (fix with
symphonic check) on inlet and outlet, pressure relief valve on outlet and
filter on inlet.
b) Each pressure reducing valve shall contain loading neoprene diaphragm
and a full floating, self aligning, ignition resistant seat and shall be of the
single stage, pressure reduction type with provision for manually adjusting
the delivery pressure. The valve shall fail safe to the low pressure.
c) Valves shall be capable of operating at the maintaining automatically the
respective delivery pressure and flow rates as indicated and shall not be
liable to creep. Valves shall also be capable of maintaining the pre-set
down stream pressure under static condition.
d) The filter on each inlet to a pressure reducing valve shall be of replaceable
porous sintered metal type.
3.13.12 Water Meters.
a) Water meter shall communicate with DDC or PLC through open
communication protocol such as RS-485, MODBUS, BACnet etc.
Plumbing Contractor shall co-ordianate with IBMS contractor for the
connection purpose
b) Water meters of approved make and design shall be supplied for
installation at locations as shown.
c) The water meters shall meet with the approval of local supply authorities.
Suitable valves and chambers or wall meter box to house the meters shall
also the be provided along with the meters.

d) The meters shall conform to Indian Standard IS:779 and IS:2373.

Calibration certificate shall be obtained and submitted for each water
meter.

e) Provision shall also be made to lock the water meter. The provision shall
be such that the lock is conveniently operated from the top. Where the
provision is designed for use in conjunction with padlocks, the hole
provided for padlocks shall be a diameter notlessthan4mm.

f) The G.I. lines shall be cut to the required lengths at the position where the
meter and stop cock are required to be fixed. Suitable fittings shall be

81
 attached to the pipes. The meter and stop cock shall be fixed in a position
by means of connecting pipes, jam nut and socket etc.

g) The stop cock shall be fixed near the inlet of the water meter. The paper
disc inserted in the ripples of the meter shall be removed. And the meter
installed exactly horizontal or vertical in the flow line in the direction
shown by the arrow cast on the body of the meter. 15.8 Care shall be taken
that the factory seal of the meter is not disturbed. Wherever the meter shall
be fixed to a newly fitted pipe line, the pipe line shall have to be
completely washed before fitting the meter.

3.13.13 Expansion Bellow

a) Rubber expansion joint with unit control (tie rod & gusset plate) shall be
as per manufacturers specifications of standard length complete with all
accessories tested to a pressure not less than 15 Kg./sqcm including
rubber gaskets, flanges, nuts, bolts & washers complete as required.
b) Pressure Gauge
c) The pressure gauge shall be constructed of die cast aluminium and stove
enamelled. It shall be weather proof with an IP 55 enclosure. It shall be a
stainless steel Bourden tube type pressure gauge with a scale range from 0
to 16 Kg / cm square and shall be constructed as per IS:3524. Each
pressure gauge shall have a siphon tube connection. The shut off
arrangement shall be by Ball Valve. Calibration certificate shall be
obtained and submitted for each pressure gauge

3.14 DRAINAGE

3.14.1 SCOPE OF WORK

a) The scope shall include supply, installation, testing, commissioning and

satisfactory handing over of the complete drainage system to client as per
drawings, specifications and schedule of quantities.
b) Without restricting to the generality of the foregoing, the drainage system
shall inter-alia include:
c) Sewer lines including earthwork for excavation, disposal, backfilling and
compaction, pipelines, manholes, drop connections and connections to the
municipal or existing sewer.
d) Storm water drainage, earth works for excavation, disposal, backfilling
and compaction, pipe lines, manholes, catch basins and connections to the
existing municipal storm water drain or connected as indicated by the
Engineer.

3.14.2 GENERAL REQUIREMENTS

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 a) Drainage lines and open drains shall be laid to the required gradients and
profiles.
b) All drainage work shall be done in accordance with the Local municipal
bye-laws.
c) Contractor shall obtain necessary approval and permission for the drainage
system from the municipal or any other competent Authority.
d) Location of all manholes, etc. shall be got confirmed by the Engineer-in-
Charge before the actual execution of work at site. As far as possible, no
drains or sewers shall be laid in the middle of road unless otherwise
specifically shown on the drawings or directed by the Engineer-in-Charge
in writing.

3.14.3 GULLY TRAPS

Gully traps shall be of the same quality as described for stoneware pipes. Gully
traps shall be fixed in a masonry chamber as per specifications. The CI sealed
cover and frame shall weigh not less than 7.3 kg. Where necessary, sealed cover
shall be replaced with CI grating of the same size. Rubber rings shall conform to
IS: 5382. Gully traps shall be measured by the number and rate shall include all
excavation, back filling, foundation, concrete brick masonry, cement plaster
inside and outside, CI grating and sealed cover and frame, etc. complete.

3.14.4 CAST IRON PIPES

Cast iron pipes and fittings shall be of good and tough quality and dark grey on
fracture. The pipes and fittings shall be true to shape, smooth and cylindrical, their
inner and outer surface being as nearly as practicable concentric. They shall be
sound and nicely cast, shall be free from cracks, taps, pinholes and other
manufacturing defects.

The pipes and fittings shall conform to IS:3989 / IS:1729 as called for. Fittings shall
be of required degree with or without access door. All access doors shall be made up
with 3mm thick insertion rubber gasket of white lead and tightly bolted to make the
fittings air and water tight. The fittings shall be of the same manufacture as the pipes
used for soil and waste.

All CI pipes and fittings shall bear the manufacturer's name and ISI specification to
which it conforms.

All pipes and fittings shall be coated internally and externally with the same material
at the factory, the fittings being preheated prior to total immersion in a bath
containing a uniformly heated composition having a tar/other suitable base. The
coating material shall have good adherence and shall not scale off. The coating shall
be smooth and tenacious and hard enough not to flow when exposed to a
temperature of 77 degree C but not so brittle at a temperature of '0' degree C as to
chip off when scratched lightly with a pen knife.

83
All pipes and fittings before installation at site shall be tested hydrostatically to a
pressure of 0.45 Kg/sq. cm without showing any sign of leakage, sweating or other
defects of any kind. The pressure shall be applied internally and shall be maintained
for not less than 15 minutes. All these tests shall be carried out in the presence of the
representative of the Project Manager. Alternatively a test certificate from
manufacturers be obtained before dispatch of material to site.

Cast Iron Specialities

If required, Cast iron speciality items such as deep seal floor traps, urinal traps, trap
integral pieces with integral inlet/outlet connections, manhole cover with frame,
chamber cover etc. shall be fabricated to suit individual location requirements. The
contractor shall arrange the fabrication of these items from an approved source.

Lead Caulked joints with pig lead:

The approximate depth and weights of pig lead for various diameters of CI pipes and
specials shall be as follows:

Nominal size of Pipe Lead per Joint (Kg) Depth of Lead Joint
(mm) (mm)
50 0.77 25
80 0.88 25
100 0.99 25
150 1.5 38

Pipe Joint Sealant:

Pipe joint sealant shall be used for joining various diameters of C.I. pipes and
specials. This sealant replaces the standard lead caulked joints. The application is by
Homogenously mixing the two pack system in cold condition.

Application Procedure:

Clean the pipe joints thoroughly to ensure it is free from any traces of oil, dirt or any
other foreign body. Mix two parts of Drip Seal thoroughly with an iron flat to get a
homogenous compound. * Place Spun yarn in the pipe joint as a filler and then take
the required quantity of the compound and push it in the joint with a caulking tool,
MS flat / damp finger uniformly all over to obtain a smooth and uniform joint. Dip
the fingers in water every often to ensure the compound does not stick to the hands
of the workmen, but this will ensure perfect sealing and the smooth surface for the
joint cement. (* The compound prepared from the two mixtures is to be used within
30 minutes) Precaution to be taken to wash hands thoroughly with soap before and
after use. Preferably use disposable gloves for hand application.

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3.15 PUMPS
3.15.1 Inline Pumps
a) Pumps shall be suitable for single as well as parallel efficient operation at
any point in between the maximum and minimum system resistances.
b) Pumps shall run smooth without undue noise and vibration, cavitations, oil
or water leaks over the range of operation. To ensure vibration free
operation, all rotating components of pump shall be statically and
dynamically balanced to BS 6861/ as per zones A & B of ISO 10816 -1
c) The pump set shall be suitable for starting with discharge valve open
and/or closed.
d) The pump set shall be capable of withstanding the accidental rotation in
reverse direction.
e) Pumps shall be so selected that the design duty point is within 5% of the
maximum efficiency point.
f) The pump casing shall have ample space to take an impeller one size
larger than that capable of performing the design duty.
g) The pump shall have a speed of not more than 1500 rpm. The pump shall
be lubricated in strict accordance with the manufacturer`s instructions and
shall be factory aligned prior to shipment.
h) Facilities to select which pump to be duty pump and standby pump shall
be provided and shall be interchangeable. Leakage from pump gland shall
be drained to the nearest floor waste.

3.15.2 . Features of construction

a) Pump shall be Vertical, centrifugal, with enclosed, radial impeller.

Impeller shall be hydraulically balanced and keyed to shaft. The impeller
shall have superior suction eye design to ensure the lower NPSH.
b) Pump casing shall be of robust construction. Liquid passages shall be
finished smooth and designed as to allow smooth flow. The volute tongue
shall be filed to a smooth rounded edge.
c) The vertical shaft shall be of high tensile stainless steel supported by bush
bearings shall. The shaft shall be sealed with mechanical seal of DIN
24960 standard.
d) The bearing shall be radial type bush bearing of tungsten carbide on shaft
and ceramic bearing in the diffuser. The bearing shall be self lubricated
and highly wear resistant. The motor bearing shall be capable of
withstanding the axial thrust. Bearings shall be capable of taking the static
weight of the rotating parts and any thrust generated by the operation of
the pump. The bearing life shall be minimum 40,000 hrs of operation.
e) The diffusers shall be made with pressed stainless steel and shall be
designed to reduce the internal losses.
f) Each pump shall be provided with an automatic coupling device for
attaching the crane hook to the pump at low level, this automatic coupling

85
 device shall easily and automatically couple and uncouple the hoist hook
and be complete with necessary accessories.
The materials of construction for Vertical in line pumps shall be as follows:
3.15.3 Capacity: 3.15.4 Refer GA drawing
3.15.5 Head 3.15.6 Refer GA drawing
3.15.7 Shut off head 3.15.8 110% of head
3.15.9 Efficiency 3.15.10 Bidder to furnish
3.15.11 3.15.12
3.15.13 Component 3.15.14 Material
3.15.15 Impeller 3.15.16 AISI 304
3.15.17 Casing 3.15.18 Cast Iron to IS:210 Gr
FG 200 with 1.5 to 2%
Nickel
3.15.19 Shaft 3.15.20 Stainless Steel : BS:970
Gr 316
3.15.21 Fasteners and 3.15.22 Stainless Steel AISI 316
Foundation Bolts
3.15.23 Motor Stool 3.15.24 Cast Iron
3.15.25 „O‟ Rings 3.15.26 EPDM
3.15.27 Drain Plug 3.15.28 Brass

g) Material test certificates from Government approved metallurgical

laboratory shall be furnished by the Contractor
h)
i) Each pump shall be tested at the manufacturers premises for the full
operating range of the pump to BS 5316 Part 1 .Pump performance shall
be within the tolerance limits specified in the above said BS.
j) Y-Strainers shall be provided as the suction side of the pump as shown in
GA of UGT

3.15.29 Tests

a) Hydro test pressure on casing shall be 1.5 times maximum discharge head
or twice differential head whichever is higher. (Maximum discharge head
= shut-off head + maximum suction head). Unless otherwise stated in data
sheet A, the hydrostatic tests on the casing shall be conducted for a
minimum duration of 30 minutes.

b) The pumps shall be tested as per IS 11346:2004, at rated speed at

MANUFACTURER's works to measure capacity, total head, efficiency
and power. These tests shall form the basis for acceptance of pumps
except for vibration and noise. The pumps shall be tested over the range
covering from shut-off head to the maximum flow. The duration of the test
shall be minimum one (1) hour. Minimum five (5) readings approximately
equidistant shall be taken for plotting the performance curves.

86
 c) After installation, the pumps shall be subjected to performance testing at
site also. If the site performance is found not to meet the requirements
regarding vibration and noise as specified, the equipment shall be rectified
or replaced by the VENDOR, at no extra cost to the EMPLOYER.

3.15.30 Inspection
a) The contractor shall provide facilities for inspection of the components of
the pump during all stages of manufacture to check conformity to
specification. The following inspection shall be invariably be witnessed by
the Employer.
b) Vertical inline pumps - Casing Hydro test, Performance Testing
c) General purpose induction motor Performance and characteristics

d) Motors shall be capable of giving rated output without reduction in the

expected life span when operated continuously under either of the
following supply conditions:
e) Variation of supply voltage from rated motor voltage ±10%
f) Variation in supply frequency from rated frequency ±5%
g) Combined voltage and frequency variation ±10%
h) Motors shall be capable of starting and accelerating the load with the
applicable method of starting, without exceeding acceptable winding
temperature, when the supply voltage is in the range of 85% of the rated
voltage. Starting current of motor shall not exceed 200% of rated full load
current.
i) Motors shall be capable of satisfactory operation at full load at a supply
voltage of 80% of the rated voltage for 5 minutes, commencing from hot
condition.
j) Motors shall be capable of developing the rated full load torque even when
the supply voltage drops to 70% of the rated voltage. Such operation is
envisaged for a period of 1 second. The pull out torque of the motor, to
meet this requirement, shall be at least 205% of full load torque.
k) The locked rotor current of the motors shall not exceed (inclusive of 20%
tolerance) 600% of full load current for motors.
l) Motors shall be capable of giving rated output without reduction in the
expected life span when operated continuously under the specified supply
conditions.
m) The locked rotor withstand time under hot conditions at 110% rated
voltage shall be more than the starting time at 80% voltage by at least two
seconds or 15% of the accelerating time whichever is greater.
n) Motors when started with the drive imposing its full starting torque under
the supply voltage variations specified shall be capable of withstanding at
least two successive starts from cold condition and one start from hot
condition without injurious heating of windings. The motors shall also be
suitable for four equally spread starts per hour under the above referred
supply conditions.

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3.15.31 Insulation
Any joints in the motor insulation such as at coil connections or between slot and
winding sections, shall have strength equivalent to that of slot sections of the coil.
The insulation shall be given tropical and fungicidal treatment for successful
operation of the motor in hot, humid and tropical climate. The motors shall be
provided with Class F insulation with temperature rise limited to that of Class B
insulation

3.15.32 Temperature rise

The temperature rises shall not exceed the values given in IS 12802. Under
extremes of supply condition, the temperature rise shall not exceed the value
indicated in IS by 10oC.

3.15.33 Constructional features

The motor construction shall be suitable for easy disassembly and re-assembly.
The enclosure shall be sturdy and shall permit easy removal of any part of the
motor for inspection and repair.Motors weighing more than 25 kg shall be
provided with eyebolts, lugs or other means to facilitate safe lifting.The rotor bars
shall not be insulated in the slop portion between the iron core laminations for
squirrel cage motors.

3.15.34 Bearings

Unless otherwise specified motor bearings shall not be subjected to any external
thrust load. Unless otherwise specified, motor bearings shall have an estimated
life of at least 40,000 hrs. The bearings shall permit running of the motor in either
direction of rotation. It shall be possible to lubricate the bearings without
dismantling any part of the motor.

3.15.35 Terminal box

a) Terminal boxes shall be of weather proof construction designed for

outdoor service, to eliminate entry of dust and water, gaskets of neoprene
or approved equivalent shall be provided at cover joints and between box
and motor frame. The cable terminal box shall be right hand side looking
from coupling end.

b) The terminal box shall be capable of being turned through 360 deg instead
of 90 deg. The terminals shall be of the stud type with necessary plain
washers, spring washers and check-nuts. Ample phase to phase and phase
to ground clearances shall be kept.Suitable cable glands and cable lugs
shall be supplied along with the motor. Separate terminal boxes shall be
provided for stator leads and space heater.

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3.15.36 Paint and finish

All motor parts exposed directly to atmosphere shall be finished and painted to
produce a neat and durable surface which would prevent rusting and corrosion.
The equipment shall be thoroughly degreased, all rust, sharp edges and scale
removed and treated with one coat of primer and finished with two coats of grey
enamel paint.

3.15.37 Heating during idle periods

Motors rated above 30 kW shall have space heaters suitable for 240V, single
phase, 50 Hz, AC supply. Space heaters shall have adequate capacity to maintain
motor internal temperature above dew point to prevent moisture condensation
during idle period. The space heaters shall be placed in easily accessible positions
in the lowest part of the motor frame.

3.15.38 Accessories
Motors shall have drain plugs so located that they will drain water, resulting from
condensation or other cases from all pockets in the motor casing. The earthing
pads shall be of non-corrodible metal welded or brazed at two locations on
opposite sides.
3.15.39 Tests

a) Motor shall be subjected to all the routine tests as per applicable standard
in the presence of the EMPLOYER'S representative. Copies of test
certificates of type and routine tests shall be furnished as specified in the
distribution schedule, for the EMPLOYER'S approval. The VENDOR
shall ensure to use calibrated test equipment/instruments having valid
calibration test certificates from standard laboratories traceable to
national/international standards

b) If type tests have not been carried out on similar Motors, or if the type test
reports submitted are not found in order, then VENDOR shall carry out
these tests without any extra cost to the Employer.

This specification covers the general design, materials, construction features,

manufacture, shop inspection and testing at manufacturer‟s works and delivery at
site of Horizontal Centrifugal Pumps.

3.15.40 CODES AND STANDARDS

The design, materials, construction, manufacture, inspection, testing and

performance of horizontal centrifugal pumps shall comply with all currently
applicable statutes, regulations and safety codes in the locality where the
equipment is to be installed. The equipment shall also conform to latest applicable
Indian or equivalent standards. Other international standards are also acceptable,

89
 if these are established to be equal or superior to the listed standards. Nothing in
this specification shall be construed to relieve the VENDOR of this responsibility.

3.15.41 DESIGN REQUIREMENTS

a) Pumps of a particular category shall be identical and shall be suitable for

parallel operation with equal load division. Components of identical
pumps shall be inter-changeable.
b) Flow rate versus head curve shall have stable and continuously rising
characteristics towards the shut-off head. In case of unstable (drooping)
characteristics the duty point shall be well away from the unstable region.
Besides the actual flow rate versus head curve, curves for minimum and
maximum impeller diameters shall also be shown.
c) The shut-off head shall be at least 110% of the differential head.
d) The required NPSH at duty point shall be at least one (1) metre less than
the available NPSH.
e) The rating of the pump driver shall be the larger of the following:
f) The maximum power required by the pump from zero discharge to run-out
discharge at site climatic conditions.
g) 110% of the power required at the duty point at site climatic conditions.
h) The corrosion allowance for pressure parts shall be 3 mm
i) Pumps shall run smooth without undue noise and vibration. Noise level
produced individually or collectively shall not exceed 85 dB (A) measured
at a distance of 1.86 metres from the source in any direction. The overall
vibration level shall be as per zones A and B of ISO 10816-1.

3.15.42 CONSTRUCTION FEATURES

a) In addition to static balancing, impeller and balancing drum shall be

balanced dynamically at or near the operating speed.
b)
c) Pump shall be provided with renewable type casing ring. Pump having
capacity 1,000 M3/Hr and above shall be provided with impeller ring in
addition to casing ring. The hardness of impeller ring shall be 50 BHN
higher than that of casing ring.
d) Pump casing shall be provided with drain and vent connection with
plugged or valve connection.
e) Bearing shall be oil-lubricated or grease-lubricated and shall have a life of
40,000 hours of working. In case of oil-lubricated bearing, constant oil
leveller with magnetic drain plug shall be provided.
f) Replaceable shaft sleeves shall be provided to protect the shaft where it
passes through stuffing box.
g) Stuffing box shall be of such design that it can be repacked without
removing any part other than the gland and lantern ring.
h) Mechanical seals shall be provided if called for in data sheet - A. If
required, a flushing line shall be furnished, complete with strainer and

90
 orifice, from the pump discharge to the sealing face. When pumping
liquid is not suitable for this purpose, a flushing connection shall be
provided so that it can be connected to an external source.
i) All pumps, except for back-pull out type, shall be provided with flexible
coupling. Back-pull out type pumps shall be provided with spacer type
coupling.
j) Coupling guard made of expanded metal and bolted to the base plate shall
be furnished for all coupled pumps.
k)
l) In addition to accessories listed in data sheet A, any other accessories
required for safe and efficient operation of pump shall be provided.

m) All incidental piping and valves required for sealing, lubrication and
cooling for stuffing box packing and/or bearing of pump shall be furnished
by the VENDOR.
n)
o) Leakage from the pump shall be led to the nearest surface drain by
OTHERS. Pump vendor shall provide necessary arrangement like drip
tray, base plate drain connection etc.

3.15.43 TESTS AND INSPECTION

a) Hydro test pressure on casing shall be 1.5 times maximum discharge head
or twice differential head whichever is higher. (Maximum discharge head
= shut-off head + maximum suction head). Unless otherwise stated in data
sheet A, the hydrostatic tests on the casing shall be conducted for a
minimum duration of 30 minutes.
b) The pumps shall be tested as per IS 5120, at rated speed at
MANUFACTURER's works to measure capacity, total head, efficiency
and power. The negative tolerance on efficiency shall be limited to 2.5%
and not 5% as indicated in IS 5120. These tests shall form the basis for
acceptance of pumps except for vibration and noise. The pumps shall be
tested over the range covering from shut-off head to the maximum flow.
The duration of the test shall be minimum one (1) hour. Minimum five (5)
readings approximately equidistant shall be taken for plotting the
performance curves.
c) After installation, the pumps shall be subjected to testing at site also. If the
site performance is found not to meet the requirements regarding
vibration and noise as specified, the equipment shall be rectified or
replaced by the VENDOR, at no extra cost to the EMPLOYER.

3.15.44 PERFORMANCE GUARANTEE

Performance parameters to be guaranteed by the VENDOR and tolerances
permitted shall be as indicated. BIDDER shall confirm acceptance of these by

91
 indicating values in data sheet B. Pump or any portion thereof is liable for
rejection, if it fails to give any of the guaranteed performance parameters.

3.16 SUBMERSIBLE PUMPS FOR WASTE WATER

3.16.1 SCOPE
This specification covers the general design, materials, manufacture, shop
inspection and testing at manufacturer‟s works, delivery at site, handling at site,
installation, testing, commissioning and carrying out performance test of
submersible pumps for waste water with their accessories.
3.16.2 CODES AND STANDARDS
The design, materials, manufacture, inspection, testing and performance of the
submersible (waste water) pumps shall comply with all currently applicable
statutes, regulations and safety codes in the locality where equipment is to be
installed. The equipment shall also conform to the latest editions of the relevant
codes and standards existing as on the date 180 days prior to the deadline for
submission of bids, unless otherwise specified. Nothing in this specification shall
be construed to relieve the VENDOR of this responsibility.

3.16.3 DESIGN REQUIREMENTS

a) Pump shall be submersible, non-clog, wet & dry pit installation, fixed or
portable type and shall be suitable for working with the minimum liquid
level.The Pump shall be designed to handle solid sizes Fixed type pump
set shall be with control panel with all safety devices.The pump shall be
capable of delivering the required flow rate for both continuous and
intermittent operations, at the specified operating conditions. The pump
shall be designed to have minimum maintenance and easy accessibility to
all components.Flow rate versus head curve shall have stable
and continuously rising characteristics towards the shut-off with the
highest at shut off. In case of unstable (dropping) characteristics the duty
point shall be well away from the unstable region. Besides the actual flow
rate versus head curve, curves for minimum and maximum impeller
diameters shall also be shown.
b)
c) Pumps of a particular category shall be identical and shall be suitable for
single as well as parallel operation with equal load division at any point in
between the maximum and minimum system resistance. Components of
identical pumps shall be inter-changeable.
d) Pumps shall run smooth without undue noise and vibration. Noise level
produced individually or collectively shall not exceed 85 dB (A) measured
at a distance of 1.0 metres from the source in any direction. The overall
vibration level shall be as per zones A and B of ISO 10816-1.
e) The power rating of the pump driver shall be the larger of the following
considering the frequency variation indicated in Data Sheet -A:
f) The maximum power required from zero discharge to run-out
discharge at site climatic condition.

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 g) 110% of the power required at any operating point in between the
maximum and minimum system resistance curves for any
combinations of pumping.
h) 115% of the power required at the design point.
i) The critical speed of the pump shall be not less than 130% of the normal
operating speed of the pump.The pump set shall be capable of
withstanding the accidental rotation in reverse direction. The direction of
rotation shall be clockwise viewed from the drive end.
3.16.4 CONSTRUCTION FEATURES
a) Pump casing shall be of robust construction. Liquid passages shall be
finished smooth and designed as to allow free passage of solids and
stringy materials.
b)
c) Impeller shall be non-clog, vortex or vane type with smooth blunt inlet
edge and large waterways so as to allow free passage of the large size
solids. It shall be free from sharp corners and projections likely to catch
and hold rags and stringy materials. The impeller shall be statically and
dynamically balanced. Pumps up to 1000 M3/Hr shall have maximum 2
vanes; pumps having capacity 1000 M3/Hr and above shall have
maximum 3 vanes.
d) Double Mechanical seals shall be provided to protect the motor from
ingress of waste water along the shaft. The preliminary and secondary
seals shall be oil- lubricated with tungsten carbide or silicon-carbide faces
and they should be equipped with an electrical monitoring system for seal
failure detection.
e) Motor and Pump shall have a common shaft with bearings. The
bearing shall be permanently greased and maintenance free.
f) Portable type submersible pump should be equipped with pump base
stand / legs, adequate length of chain and flexible type discharge hose pipe
suitable for directly lowering into the well.
g) Fixed type submersible pump shall be provided with a 90° duck foot bend
for fixing to the concrete floor of the well. The joint between the pump
discharge flange and the delivery piping shall be made by merely lowering
the pump into guide system at the access level. It shall be provided with
all necessary fixings for guiding the pumps during lifting/lowering.
h) Replaceable shaft sleeves shall be securely locked or keyed to the
shaft to prevent loosening. The surface hardness of the shaft sleeve shall
be minimum.
i) In addition to accessories listed in data sheet A, any other
accessories required for safe and efficient operation of pump shall be
provided.

3.16.5 INDUCTION MOTOR FOR SUBMERSIBLE PUMPS

3.16.6 The submersible motor shall confirm to IS: 9283:2013.

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3.16.7 PERFORMANCE AND CHARACTERISTICS
a) Motors shall be capable of giving rated output without reduction in the
expected life span when operated continuously under varying voltage
and frequency supply conditions as called for in Data Sheet - A.
b) Motors shall be suitable for full voltage direct-on-line starting or star-delta
starting.
c) The starting current of motor shall not exceed 200% of rated full load
current for star/delta starting and 600% of rated full load current for DOL
starting, under any circumstances.
d) Motors shall be capable of starting and accelerating the load with the
applicable method of starting, without exceeding acceptable winding
temperatures, when the supply voltage is in the range 85% of the rated
motor voltage to maximum permissible voltage, for category B type
motors.
e) The locked rotor current of the motor shall not exceed 600% of full load
current (subject to tolerance as per the applicable standard).
f) Motors shall be designed to withstand 120% of rated speed for two
minutes without any mechanical damage, in either direction of rotation.
g) The motor vibrations shall be within the limits specified in applicable
standard unless otherwise specified for the driven equipment.
h) Except as mentioned herein, the guaranteed performances of the motor
shall be met with tolerances specified in applicable standard (IS:
9283:2013).
i) Protection against increase in stator winding temperature, bearing
temperature, leakage in stator housing and terminal box shall be provided.
Minimum 3 nos. thermostats in series to be provided to sense the stator
winding temperature. Sensors to be provided to detect leakage of waste
water into oil housing.
3.16.8 SUBMERSIBLE CABLE
a) The cable shall be PVC insulated and PVC sheathed, flexible, 3 core flat
type. The size of the conductor shall be adequate for continuous use under
water and air.
b) In case a joint is required to be made between the lead cable supplied with
the motor and the user's cable connectors, a detailed procedure of cable
jointing to make a watertight joint shall be provided by the manufacturer.
c) The size of the conductor and length of cable should be suitably selected
so that the voltage drop at motor terminals does not exceed 3 percent of
the rated voltage.
3.16.9 EARTHING

a) Earthing of the motor shall be done in accordance with the relevant

provisions of IS: 3043:1987.

b) For fixed installation, earthing connection may be made to discharge pipe

clamp.

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3.16.10 INSULATION
Any joints in the motor insulation such as at coil connections or between slot and
end winding sections shall have strength equivalent to that of the slot sections of
the coil.
The insulation shall be given tropical and fungicidal treatment for successful
operation of the motor in hot, humid and tropical climate. The tropical sing
treatment shall be as per the applicable standard.

3.16.11 TEMPERATURE RISE

The temperature-rise test of the motor shall be taken with the motor coupled to the
suitable pump to give the full load output of the motor. When the various
temperatures are stabilized, the set is stopped and the temperature-rise of the
stator winding by the resistance method shall not exceed 35°C at rated voltage
and 45°C at 85% of the rated voltage. During the test, the temperature of the
cooling water may not exceed 45°C. As the cable resistance will also be
substantial, it is necessary that while calculating the temperature rise by
resistance method, due care is taken to account for the correct hot and cold
resistance of windings.
3.16.12 CONSTRUCTION FEATURES OF MOTOR
The motor shall be suitable for continuous use in fully or partially submerged
condition. A built-in cooling system if required shall be provided to allow the
motor to operate continuously at its rated output regardless of whether the
electric motor is submerged or not by providing either external or internal cooling
arrangement.
3.16.13 TESTS AND INSPECTION
a) Hydro-test pressure on casing shall be 1.5 times maximum discharge head
or twice differential head whichever is higher. Maximum discharge head
is defined as the sum of the shut-off head and maximum suction head.
Unless otherwise stated in data sheet A, the hydrostatic tests on the casing
shall be conducted for a minimum duration of 30 minutes.
b) The pumps shall be tested in accordance with HIS, ISO 9906 and IS 5120,
at rated speed at MANUFACTURER's works to measure capacity, total
head, efficiency and power. The negative tolerance on efficiency shall be
limited to 2.5% and not 5% as indicated in IS 5120. These tests shall
form the basis for acceptance of pumps except for vibration and noise.
The pumps shall be tested over the range covering from shut-off head to
the maximum flow. The duration of the test shall be minimum one (1)
hour. Minimum five (5) readings approximately equidistant shall be taken
for plotting the performance curves.
c) After installation, the pumps shall be subjected to testing at site
also. If the site performance is found not to meet the requirements
regarding vibration and noise as specified. The equipment shall be
rectified or replaced by the VENDOR, at no extra cost to the
EMPLOYER.
3.16.14 PERFORMANCE GUARANTEE

95
 Performance parameters to be guaranteed by the VENDOR and tolerances
permitted shall be as indicated. BIDDER shall confirm acceptance of these by
indicating values in data sheet B. Pump or any portion thereof is liable for
rejection, if it fails to give any of the guaranteed performance parameters.
3.16.15 DRAWINGS
The following drawings shall be submitted by the BIDDER along with
their proposal.Preliminary outline dimensional drawing showing details of pump
set, installation details, civil foundation, clearances, minimum submergence, etc.
Performance curves for capacity vs total head, efficiency, and input to motor. The
capacity range shall be zero flow to run out flow.Typical cross sectional drawing
showing constructional details.

3.16.16 BID EVALUATION

For every kW of differential power input to the motor at duty point, pump sets
will be cost loaded at the rate specified in data sheet A.

3.16.17 Submersible
These shall be fully submersible with a fully submersible motor. The pumps shall
be provided with an automatic level controller and all interconnecting power and
control cabling which shall cause the pumps to operate when the water level in the
sump rises to a preset level and stop when the preset low level is reached.
Pumps for drainage shall be single stage, single entry.
Pump shall be C.I. casing and C.I. two vane open type with a dynamically
balanced impeller connected to a common shaft of the motor. The vane for
sewage pump will be open type, while for drainage pump, etc. it will be of semi
open type. The MOC of the sump shall be in accordance to schedule of quantity.
Stuffing box shall be provided with mechanical seals.
Each pump shall be provided with a suitably rated induction motor suitable for
415 volts, 3 phase, 50 Hz A.C. power supply.
Each pump shall be provided with in built liquid level controller for operating the
pump between predetermined levels.
The pumping set shall be for stationary application and shall be provided with
pump connector unit. The delivery pipe shall be joined to the pump through a
rubber diaphragm, and bend and guide pipe for easy installation.
Pump shall be provided with all accessories and devices necessary and required
for the pump to make it a complete working system.
Sump pump shall be complete with level controllers, power and control switch
gear, Auto/off/Manual switches, pumps priority selections and control and power
cabling upto motor and controller/probes etc. (Including earthing). Level control
shall be such that one pump starts on required level, 2nd pump cuts in at high
level and alarms is given at extra high level. All level controllers shall be
provided with remote level indications

3.16.18 Motor Design

96
 The pump motor shall be a squirrel cage induction, housed in air filled water-tight
enclosure. Oil filled motors are not acceptable. The stator windings shall be Class
"F" insulation (155 degree C or 311 degree F) for general usage and class `H'
insulation (180 degree C or 317-8 grade 2) for submersible type.
The stator shall be heat shrunk fitted into the enclosure and shall not use bolts,
pins or other fasteners that penetrate through the stator enclosure. The starter shall
be equipped with a thermal switch embedded in series in the coils of the stator
windings to protect the stator from wheel.The motors shall be designed for
continuous running duty type at 415 volts, 3 phase, 50 Hz power supply and
capable of sustaining a minimum of 20 starts/stops per hour.Between stator
housing and pump, a tandem seal arrangement will be provided with an oil
barrier. Both seals run in oil, allowing dry running without seal damage. Both
seals shall be of the rubber bellows or metallic bellow type with positive drive
between shaft and rotating seal face.

3.17 PLUMBING SYSTEM-ELECTRICAL REQUIREMENTS

3.17.1 SCOPE OF WORK

a) Power and Control cabling from MCC to Plumbing pumps panel including
cable carrier system.
b) Local Push button station
c) Earthing system above ground
d) Structural steel for supporting the panels, LPBS, Cable trays etc.

3.17.2 ELECTRICAL PANELS

a) The Contractor‟s scope includes 1 No. MCC for Plumbing System.

b) 415 Volts, 50 Hz, TPN supply at the incomer of MCC will be made
available by the Employer. Further distribution of power and derivation of
any other voltage shall be in Contractor‟s scope.
c) MCC incomer shall be suitable for termination of 1RX3.5CX120 sqmm,
AL, XLPE The Contractor‟s scope includes 1 No. MCC for Plumbing
System.
d) All potential free contacts (Feedback & command from PLC) shall be
wired upto Marshalling compartment of MCC.

3.17.3 LOCAL PUSH BUTTON STATIONS (LPBS)

a) LPBS for motors shall be provided by contractor. Necessary supporting

structural steel for the same is in Contractor‟s scope.
b) LPBS shall be metal enclosed, weather proof, dust and vermin-proof,
suitable for mounting on wall or structures. The enclosure shall be sheet
steel, 2 mm thickness and shall have degree of protection not less than
IP55. The enclosure shall be painted with one coat of epoxy primer and
two coats of Epoxy Light Gray paint – 631 shade as per IS-5.

97
 c) LPBS for shall be provided with 1no. recessed type start push button and
1No. Palm push, mushroom head type stop push button.
d) All push buttons shall be fitted with two (2) NO and two (2) NC contacts,
rated for 10 A at 240V AC.
e) LPBS shall be suitable for bottom cable entry with stopping plugs.
f) Internal wiring shall be done with copper conductor HFFR wires shall be
neatly done.
g) All spare contacts shall be wired upto terminal block.
h) Distance between cable gland plate and terminal block shall be minimum
75mm for ease of termination.
i) Two (2) Nos. earthing terminals shall be provided for external earthing.
Earthing continuity bonds shall be provided

3.17.4 CABLING SYSTEM

a) For MCC, Power supply will be made available at incomer with the help
of 1.1 kV, XLPE Power Cables by others. Further Power and control
cabling from MCC to motors shall be in the in scope of Contractor.
Incoming Cable sizes will be indicated to successful bidder during
execution based on total load of each plant.
b) FPS MCC shall be installed in Pump House.
c) MCC shall be provided with Top Cable entry. Anchor Fasteners, Bolts and
other necessary supporting structure required for Panel installation shall be
provided by bidder.
d) Contractor shall furnish Cabling layout & Cable Schedule for each Area.
e) For overhead cable trays, foundation (if required) for cable tray supporting
structure will also be provided by Bidder.
f) LV Power Cables shall be 1.1 kV grade stranded copper conductor (up to
6 sq. mm) and stranded aluminium conductor (above 6 sq. mm) multi
core, XLPE insulated, extruded PVC inner sheathed, GI wire / strip
armoured, and extruded FRLS PVC outer sheathed, as per IS:7098 (Part-
1).
g) Control Cables shall be 1.1 kV grade stranded copper conductor (of
minimum 2.5sq.mm.), XLPE insulated, extruded PVC inner sheathed, GI
wire / strip armoured, extruded FRLS PVC outer sheathed as per IS:7098
(Part-1).
h) Minimum 1 core shall be kept spare in control cable.
i) Cable trays shall be Hot dipped Galvanised Iron (85 micron galvanising)
with accessories such as coupling plates (with minimum 8 nos. holes),
bends, tees, reducers, coupling nut-bolts etc. of following width. All the
hardwares used for cable tray jointing, cable supporting & clamping shall
be of SS304 material.
j) Nylon ties shall not be used for clamping cables, GI strip with SS304
hardware shall be used.
k) While sizing of Cables, Bidder shall consider voltage drop of 1.0% (max.)
from MCC to Motor.

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 l) Cable sizes indicated in data sheets of low voltage induction motor are for
General Guidelines only. Contractor shall provide cable sizing calculation
based on design criteria mentioned above.

3.17.5 EARTHING SYSTEM

a) Earthing below ground shall be by others. Earthing above ground i.e.

equipment earthing upto earthing bus shall be in the scope of Bidder.
b) Earthing shall be of GI.
c) Earthing connection at equipment shall be of bolted type.
d) 1 Run of 50x10mm GI Strip shall be provided by contractor along Cable
Tray and shall be connected at suitable point to Earth Grid.
e) Bidder shall furnish the Earthing layout along with calculations (below as
well as above ground).
f) LV MOTORS
g) Motors shall be suitable for 415 V, 3 phase, 50 Hz supply, squirrel cage
type.
h) Motors shall be squirrel cage type, energy efficient (IE-3 class as per IS-
12615, 2011) squirrel cage induction motors having TEFC, IP-55
enclosure (including terminal boxes and bearing housing) with Class-F
insulation (and temperature rise limited to Class B) conforming to IS 325.
i) Motors shall be energy efficient (IE-3) type.
j) Motors will be with Direct On Line starter (DOL).
k) Bidder shall follow below mentioned values of Efficiency as per ECBC.

Efficiency (%)
Motor Size (kW)
2 Pole 4 Pole
1.1 (1.5 hp) 82.2 83.8
1.5 (2 hp) 84.1 85
2.2 (3 hp) 85.6 86.4
3.0 (4 hp) 86.7 87.4
4.0 (5.5 hp) 87.6 88.3
5.5 (7.5 hp) 88.5 89.2
7.5 (10 hp) 89.5 90.1
11.0 (15 hp) 90.6 91
15.0 (20 hp) 91.3 91.8
18.5 (25 hp) 91.8 92.2
22.0 (30 hp) 92.2 92.6
30.0 (40 hp) 92.9 93.2
37.0 (50 hp) 93.3 93.6
45.0 (60 hp) 93.7 93.9
55.0 (75 hp) 94 94.2
75.0 (100 hp) 94.6 94.7

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3.17.6 TERMINAL POINTS (BATTERY LIMIT)

a) 415 Volts, 50 Hz, TPN supply at the incomer of MCC shall be made
available by the Employer. Further distribution of power and derivation of
any other voltage shall be in Contractor‟s scope.
b) Termination of incomer and outgoing cables is in scope of contractor.
c) Earthing above ground shall be considered in contractor‟s scope as per
clause no.2.5

3.17.7 PREFERRED MAKE

a) L V Switchgear – L&T
b) L V Switchgear – L&T/ Schneider/ ABB
c) Distribution Boards – L&T/ Legrand/ ABB
d) Moulded Case Circuit Breaker - L&T/ Schneider/ ABB
e) Motor Protection Circuit Breaker – L&T/ Schneider/ ABB
f) Contactors – L&T/ Legrand/ Schneider
g) Current Transformer - Kappa/ Silkans / Pragati / Indcoil / Precise
h) Ammeter and Voltmeter - AE/Rishabh / Conzerve
i) Push buttons - Siemens/Teknic/Vaishno/BCH
j) LED Indicating lamps - Teknic / Mathura / Siemens / Binay
k) MCB – L&T/ Schneider/ ABB
l) Control fuses – SIEMENS / GE
m) Terminal Block – Connectwell / Elmex / Wago
n) Switch-socket – Anchor / Reputed
o) Space Heater – Girish / reputed
p) L T Motor –Siemens
q) L T Cable – KEI/ CCI/ Finolex
r) HFFR wires (including panel wiring) – Finolex/ LAPP/ RR KABEL
s) Local Push button station (LPBS) – L&T/ Teknic/ Schneider/ Mathura
t) Cable Trays – Indiana/ Patny/ Profab/ OBO

3.17.8 Any other make subjected to prior approval of Employer / Project Manager

3.18 COMMISSIONING & GUARANTEE

3.18.1 SCOPE OF WORK
a) Work under this section shall be executed without any additional cost. The
rates quoted in this tender shall be inclusive of the works given in this
section.
b) Contractor shall provide all tools, equipment, metering and testing devices
required for the purpose.
c) On award of work, Contractor shall submit a detailed proposal giving
methods of testing and gauging the performance of the equipment to be
supplied and installed under this contract.

100
 d) All tests shall be made in the presence of the Architect or his
representative or any inspecting authority. At least five working days
notice in writing shall be given to the inspecting parties before performing
any test.
e) Water flow rates of all equipment and in pipe lines through valves shall be
adjusted to design conditions. Complete results of adjustments shall be
recorded and submitted.
f) Contractor shall ensure proper balancing of the hydraulic system and for
the pipes / valves installed in his scope of work by regulating the flow
rates in the pipe line by valve operation. The contractor shall also provide
permanent Tee connection (with plug) in water supply lines for ease of
installing pressure gauge, temperature gauge & rota meters. Contractor
shall also supply all required pressure gauge, temperature gauge for
system commissioning and balancing. The balancing shall be to the
satisfaction of Project Manager / Project Manager.

3.18.2 PRECOMMISSIONNIG

a) On completion of the installation of all pumps, piping, valves, pipe

connections, insulation etc. the Contractor shall proceed as follows:
b) Prior to start-up and hydraulic testing, the Contractor shall clean the entire
installation including all fitments and pipe work and the like after
installation and keep them in a new condition. All pumping systems shall
be flushed and drained at least once through to get rid of contaminating
materials. All pipes shall be rodded to ensure clearance of debris, cleaning
and flushing shall be carried out in sections as the installation becomes
completed.
c) All strainers shall be inspected and cleaned out or replaced.
d) When the entire systems are reasonably clean, a pre-treatment chemical
shall be introduced and circulated for at least 8 hours. Warning signs shall
be provided at all outlets during pre-treatment. The pre-treatment chemical
shall:
e) Remove oil, grease and foreign residue from the pipe work and fittings;
f) Pre-condition the metal surfaces to resist reaction with water or air.
g) Establish an initial protective film;
h) After pre-treatment, the system shall be drained and refilled with fresh
water and left until the system is put into operation.
i) Details and procedures of the pre-treatment shall be submitted to the
Architect for approval.
j) Check all clamps, supports and hangers provided for the pipes.
k) Check all the equipment, piping and valves coming under hot water
system and operate each and every valve on the system to see if the valves
are functioning properly. Thereafter conduct & hydro test of the system as
for (b) above.

101
 l) Fill up pipes with water and apply hydrostatic pressure to the system as
given in the relevant section of the specification. If any leakage is found,
rectify the same and retest the pipes.

3.18.3 STATUTORY AUTHORITIES' TESTS AND INSPECTIONS

a) As and when notified in writing or instructed by the Architect, the

Contractor shall submit shop drawing and attend all tests and inspections
carried out by Local Fire Authorities, Water Authority and other Statutory
Authorities, and shall forthwith execute free of charge any rectification
work ordered by the Architect as a result of such tests and inspections
where these indicate non-compliance with Statutory Regulations. Some of
these tests may take place after the issue of Practical Completion of the
Main Contract and the Contractor shall make all allowances in this
respect.
b) The Contractor shall be responsible for the submission of all necessary
forms and shop drawings to the Statutory Authorities which shall conform
in layout to the latest architectural plans submitted to and kept by these
Authorities.
c) The submission shall comply with the requirements set forth in the
current Codes of Practice and circular letters of the Statutory Authorities.
The shop drawings to be submitted shall be forwarded to the Architect for
checking before submission.
d) The Contractor shall allow for at least two submissions of complete sets of
shop drawings to the Authorities, one to be made within six months after
the award of the Contract but not less than six weeks before the inspection.
The Architect may at his discretion instruct the Contractor for additional
submissions to the Local Authorities whenever necessary.
e) The Contractor shall notify the Architect at least seven days in advance of
his application for local Authority tests and inspections. On receipt of a
confirmed date for test and inspection the Contractor shall inform the
Architect without delay.

3.18.4 FINAL ACCEPTANCE TESTS

a) Following commissioning and inspection of the entire installation, and

prior to issue of the Completion Certificate, the Contractor shall carry out
final acceptance tests in accordance with a programme to be agreed with
the Architect.
b) Should the results of the acceptance tests show that plant, systems and/or
equipment fail to perform to the efficiencies or other performance figures
as given in this Specification, the Contractor shall adjust, modify and if
necessary replace the equipment without further payment in order that the
required performance is obtained.

102
 c) Where acceptance tests are required by the relevant Authorities having
jurisdiction, these tests shall be carried out by the Contractor prior to the
issue of Completion Certificate to the acceptance of the Authorities.

3.18.5 REJECTION OF INSTALLATION / PLANT

a) Any item of plant or system or component which fails to comply with the
requirements of this Specification in any respect whatsoever at any stage
of manufacture, test, erection or on completion at site may be rejected by
the Architect either in whole or in part as he considers
necessary/appropriate. Adjustment and/or modification work as required
by the Architect so as to comply with the Authority's requirements and the
intent of the Specification shall be carried out by the Contractor at his own
expense and to the satisfaction of the Authority/Architect.
b) After works have been accepted, the Contractor may be required to carry
out assist in carrying out additional performance tests as reasonably
required by the Architect/Employer.

3.18.6 WARRANTY AND HANDOVER

The Contractor shall warrant that all plant, materials and equipment supplied and
all workmanship performed by him to be free from defects of whatsoever nature
before handover to the Employer.

3.18.7 HANDING OVER OF DOCUMENTS

All testing and commissioning shall be done by the Contractor to the entire
satisfaction of the Employer‟s site representative and all testing and
commissioning documents shall be handed over to the Employer‟s site
representative. The Contractor shall also hand over all maintenance and operation
manuals, all certificates and all other documentation as per the terms of the
contract to the Employer‟s site representative.

3.18.8 CHECKLIST FOR COMMISSIONING.

3.18.9 Water Supply& Drainage Equipment

a) Operate each and every valve on the system to see if the valves are
functioning properly.
b) Check all clamps, support and hangers provided for the pipes.
c) Check rotation of each motor and correct the same if required.
d) All the pumps shall run continuously for one hour. Record the pressure
and motor current and voltage readings.
e) Check all annunciations by simulating the alarm conditions if any at site.
f) Remove grease trap manhole covers. Check for cleanliness, check for
partitions, and put back the cover.

103
 g) Remove manhole covers on sewer lines, inspect for cleanliness. After they
are found to be clean, pour water into the first manhole and see that all the
lines are clear. Make sure that all the covers are put back after the
inspection.
h) Check gully traps by opening of covers and check that water seal in the
traps are maintained. Check for general cleanliness.
i) Check installation of proper vents and cowls at the roof level for all soil
and waste pipes.
j) Performance test to be carried out and recorded in the following table for
the pumps.

Sr.N Pump Tag No. Model Design Actu P Full load Remarks
o. No. Flow LPS al kg/cm2 Amps
Flow
LPS

1) Domestic
Water Pump
No. 1
2) Domestic
Water Pump
No. 2
3) Flushing Water
Pump No. 1
4) Flushing Water
Pump No. 2

k) (Similar Readings shall be taken for all other pumps)

l) Simulate low level in the domestic water tanks to trip domestic Filter Feed
Pumps. Simulate high level in treated water tanks to trip softener feed
pumps. Simulate low level in treated water tanks to trip treated water
hydro-pneumatic pumps.
m) Submersible Sump Pumps
n) Fill the sump with water, while observing the level.
o) Keep the pump starter switch on „OFF‟ position to check for start of
pump.
p) By keeping the starter switch on „Auto‟ position, both the pumps should
start. As the water level starts receding, one pump should switch off by
itself. The second pump should switch off on further reduction in water
level.
q) Fill the sump with a little water and check both the pumps in „Manual‟
position momentarily.
r) Leave the switches in „Auto‟ position for both the pumps.

104
 3.19 DATA SHEETS
3.19.1 BUTTERFLY VALVES
DATA SHEET A
Blank Spaces to be filled by
SL. NO. BUTTERFLY VALVES UNIT
vendor
ITEM
1.0 GENERAL
1.1. SERVICE
1.2. TAG NOs.
1.3. NO. OF VALVES No. As per BOQ
1.4. DESIGN STANDARD
1.5. VALVE CATEGORY
1.6. DISC
1.7. BODY TYPE Cast Iron
1.8. VALVE SIZE NB 65 mm to 150 mm
1.9. VALVE RATING / CLASS PN 10
FLUID HANDLED WITH ITS SPEC.
1.10.
GRAVITY
COMPANION FLANGE TYPE AND
1.11. ANSI B16.5 Class 150
CLASS

1.12. TYPE OF VALVE OPERATOR 

MAXIMUM FLOW (INDICATE M3/hr, MAX. MIN. OPE

THE RELATED PRESSURE KPa R
ALSO) A
1.13. T
I
N
G
1.14. MAXIMUM FLOW VELOCITY m/s
1.15. DESIGN PRESSURE KPa
1.16. OPERATING PRESSURE KPa
0
1.17. DESIGN TEMPERATURE C
0
1.18. OPERATING TEMPERATURE C
1.19. VALVE LOCATION

105
 DATA SHEET A
Blank Spaces to be filled by
SL. NO. BUTTERFLY VALVES UNIT
vendor
ITEM

MATERIALS OF
4.0
CONSTRUCTION
CAST IRON
4.1  BODY

CAST IRON
3.2.  DISC

3.3. STEM STAINLESS STEEL

3.4. SEAT EPDM
3.5. BODY SEAT RINGS
3.6. DISC SEAL RINGS
3.7. SEAT RETAINING RINGS
3.8. COMPANION FLANGE
5.0 TESTS AND INSPECTION
HYDROSTATIC TEST PRESSURE
4.1. Kg/cm2 15 BAR
FOR BODY
4.2. HYDROSTATIC TEST PRESSURE
FOR DISC Kg/cm2 15 BAR

4.3. DISC STRENGTH TEST

Kg/cm2
PRESSURE
4.4. ACTUATOR PERFORMANCE
Kg/cm2
TEST PRESSURE
4.5. AIR LEAK TEST PRESSURE Kg/cm2
4.6. ELECTRICAL CONTINUITY TEST
4.7. SPARES
6.0 DISC SEAL RINGS
5.1. FLANGE GASKET
5.2. SEAT/SEAL CLAMPING BOLTS
5.3. 'O' RING SEALS OR GLAND

106
 DATA SHEET A
Blank Spaces to be filled by
SL. NO. BUTTERFLY VALVES UNIT
vendor
ITEM
PACKING

5.4.  (REF. NOTE -10)

NOTES :-
1. FOR GENERAL REQUIREMENTS. HOWEVER, IN CASE OF OVERLAPPING
REQUIREMENTS, THOSE OF THE DATA SHEET A, TO BE CONSIDERED AS
THE FINAL ONE.
2. THE VALVE SHALL BE DESIGNED CONSIDERING THE LARGER OF THE
FOLLOWING TORQUE REQUIREMENTS FOR WHICH CALCULATIONS
SHALL BE SUBMITTED:
a) CALCULATED AS PER AWWA-C504-80
b) CALCULATED AS PER THE STANDARD TO WHICH VALVE IS DESIGNED.
3. FOR MANUALLY OPERATED VALVES, TORQUE REQUIRED AT HAND
WHEEL SHALL NOT EXCEED 7 KG.M.
4. MOTOR OPERATED VALVE ACTUATOR SHALL BE RATED TO PROVIDE
AN OUTPUT TORQUE OF ATLEAST 150% OF TORQUE REQUIRED AS PER
NOTE-2 ABOVE UNLESS OTHERWISE NOTED.
5. THE ACTUATOR SHALL BE CAPABLE OF OPERATING IN ANY MOUNTING
ANGLE.
6. THE TRANSMISSION UNIT SHALL BE DESIGNED TO TRANSMIT TWICE THE
VALVE DESIGN TORQUE UNLESS OTHERWISE NOTED.
7. THE ACTUATOR SHALL PROVIDE AN UNSEATING TORQUE OF AT LEAST
50% IN EXCESS OF VALVE SEATING TORQUE AT THE SPECIFIED
VOLTAGE UNLESS OTHERWISE NOTED.
8. SEGMENTAL WELDED CARBON STEEL FLANGE PLATES ABOVE 20 MM
THICKNESS SHALL BE SUBJECTED TO PREHEATING BEFORE WELDING
AND STRESS RELIEVING AFTER WELDING AS PER IS 2825 UNLESS
OTHERWISE SPECIFIED.
9. UNLESS OTHERWISE SPECIFIED IN BOQ , ONE COAT OF ZINC RICH
PRIMER AND TWO COATS OF ENAMEL SHALL BE APPLIED TO ALL
STEEL AND CAST IRON EXPOSED SURFACES. THE MINIMUM THICKNESS
OF COATING SHALL BE 100 MICRONS.
10. THE VENDOR MAY ALSO SUGGEST ANY ADDITIONAL SPARES AND
TOOLS REQUIRED FOR THE SUCCESSFUL OPERATION, START UP AND
MAINTAINENCE OF THE VALVE.
11. IN THE ABSENCE OF ANY TEST RELATED DATA, THE RELEVANT

107
 TESTING STANDARD FOR BUTTERFLY VALVES MAY BE INDICATED.

3.19.2 Y STRAINER

DATA SHEET A
STRAINERS (Y TYPE)
1. TAG NO.
2. QUANTITY REQUIRED As per BOQ
3. LOCATION
4. TYPE Y STRAINER
5. FLUID DOMESTIC AND TREATED WATER
6. FLOW RATE
m3/hr PRESSURE
7. OPERATING
8. OPERATING
barg Ambient
TEMPERATURE
9. DESIGN PRESSURE
C
10. DESIGN barg
11. FLUID TEMPERATURE
VISCOSITY (Cp)

FLUID AT C OP.TEMP.
SP. GRAVITY AT
12.
13. OP. TEMP.
MAX. PERMISSIBLE
PR. DROP
14. SCREEN
UNDER 50% BASKET
CLOGGED
DATA
1. DIA CONDITION
OF 3 MM
2. MIN.PERFORATIONS,
THICKNESS,
mm
3. FREEmmSTRAINING
AREA
15. STEAM JACKET
1. INLET PR. barg, OP. /
DESN.
2. INLET TEMP.  C,
16. OP./DESN.
END CONNECTIONS
1. SIZE, NB mm
DESIGN DATA

2. TYPE
3. DETAILS/
17. COVERSTANDARDS
18. IBR APPROVAL
19. BODY CAST IRON
MATERIA
LS

20. COVER CAST IRON

21. SCREEN BASKET STAINLESS STEEL
22. BOLTS/ STUDS

108
 23. NUTS CARBON STEEL
24. GASKETS Rubber
25. JACKET
JACKET COUPLINGS/
26. FLANGES

ACCESSORIES BY
27. VENDOR:
27.1 FOUNDATION BOLTS
DIFFERENTIAL PRESSURE
27.2
GAUGE
DRAIN/ VENT COCK (SS
27.3
316)
27.4 SUPPORT LEGS
HYDROSTATIC TEST
26. 10.55 Bar
PRESSURE, barg
26.1 SHELL SIDE 20 Bar
26.2 JACKET SIDE
27. VACUUM TEST REQUIRED
PRESSURE DROP TEST
28.
REQUIRED
CLEAN/ 50% CLOGGED
29. INSPECTION:

30.

NOTES:

1. GENERAL REQUIREMENTS:
2. '*‟: BIDDER TO FURNISH INFORMATION.
3 GASKET SHALL BE METAL WIRE-REINFORCED AND
GRAPHITED BOTH SIDES.

109
3.19.3 WAFER CHECK VALVES

DATA SHEET A SHEET : 1 OF

1
WAFER CHECK VALVES
4. FLUID :
1
TAG NO. : FRESH
. SIZ
WATER QUANTITY
E
2 SIZE
:  50 NB 5. DES. PR. :*
RANGE
.
GENERAL

3 6. DES. TEMP. :
RATING : PN 1.0
. AMBIENT R
mm P0 R0 R1
7 2
STANDARD : IS 5312 GRADE: CT
.
8
TYPE : DUAL PLATE, SPRING-LOADED As per BOQ
.
9
ENDS : WAFER TO SUIT ANSI 150 CLASS
.
FLANGES, RF, SERR. FINISH
10
.
11
.
CONSTRUCTION FEATURES

12
.
13
.
14 OTHER
:
.
REQUIREMENTS

15
BODY : CI, IS 210 Gr. FG 260
.
16
PLATE : CARBON STEEL
MATERIALS

.
17
SEAL : NITRILE
.
18
PLATE SEAT : MFR‟S STANDARD
.

110
 19
SPRING : SPRING STEEL
.
20 HINGE PIN &
: SS 304
. STOP PIN
21
.
24
INSPEC

SHELL HYDRO : 15 Bar

.
TION

25
SEAT HYDRO : 10 Bar
TESTS &

.
26 INSPECTION :
.

NOTES: 1. GENERAL REQUIREMENTS :.

111
3.19.4 BALL VALVES

DATA SHEET A SHEET : 1 OF

1
BALL VALVES
1. TAG NO. :
SIZE QUANTITY
GENERA
L

2. SIZE RANGE : < 50 NB

3. RATING :
mm P0 R0 R1 R2
4. GRADE :
5. PORT :
As per BOQ
6. STEM :
7. ENDS : Screwed
8. OPERATION :
CONSTRUCTION FEATURES

ANTISTATIC
9. :
FEATURE
10. FIRE SAFE DESIGN : NA
OTHER
11. :
REQUIREMENTS

SIZE, (in/ mm) :

INS. THK., mm :
FORGED
12. BODY
BRASS
BALL (MIRROR STAINLESS
13. FINISHED) STEEL
STAINLESS
14. STEM
MATERIALS

STEEL
15. SEAT GLASS FILLED
16. SEAL (STEM & BODY) -
17. BOLTS, STUDS & NUTS MILD STEEL
18.
19. SHELL HYDRO :25Bar
ECTI
INSP

20. SEAT HYDRO :16 Bar

ON
TESTS &

21. SEAT AIR :

22. INSPECTION :

112
 3.19.5 TRANSFER PUMPS

Pump DOMESTIC WATER TRANSFER

PUMP (2W+1S)

Make :

Type & Model :

Discharge in LPS / GPM : 5lps

Head (Meters of WC) : 55

Shut off Head (Meters of WC) :

Efficiency (%) : 70

No. of Stages

Suction End I.D. :

Delivery End I.D. :

Details of N.P.S.H. :

Vibration Isolation Detail :

Skid Details :

Operating Weight :

Overall Dimension (MM) :

Mechanical Seal Detail :

Material

Body : c.i

Impeller : ss

113
Type of Impeller

Shaft : SS

Is it suitable for direct coupling :

Motor :

Make :

Model :

Power Requirement (HP / KW) : 6.85 HP

R.P.M. : 2900

Rating :

Over Load Capacity :

Class of Insulation :

Details of Additional protection in winding :

Motor Efficiency :

It it suitable for direct coupling to pump? :

Type of rotary movement :

Method of Starting :

Size and type of cable for connections. :

Number of variable frequency drive :

Detail of VFD :
TRANSFER PUMPS 2

Pump FLUSHING WATER TRANSFER S

PUMP (1W+1S)

Make :

Type & Model :

Discharge in LPS / GPM : 5lps

114
Head (Meters of WC) : 55

Shut off Head (Meters of WC) :

Efficiency (%) : 70

No. of Stages

Suction End I.D. :

Delivery End I.D. :

Details of N.P.S.H. :

Vibration Isolation Detail :

Skid Details :

Operating Weight :

Overall Dimension (MM) :

Mechanical Seal Detail :

Material

Body : C.I

Impeller : SS

Type of Impeller

Shaft : SS

Is it suitable for direct coupling :

Motor :

Make :

Model :

Power Requirement (HP / KW) : 6.85 HP

R.P.M. : 2900

Rating :

115
 Over Load Capacity :

Class of Insulation :

Details of Additional protection in winding :

Motor Efficiency :

It it suitable for direct coupling to pump? :

Type of rotary movement :

Method of Starting :

Size and type of cable for connections. :

Number of variable frequency drive :

Detail of VFD :

3.19.6 FLOAT TYPE LEVEL SWITCHES

1. FLOAT TYPE LEVEL SWITCHES
DATA SHEET A
GENERAL
2. Manufacturer : *
3. Model no.: *
4. FEATURES
5. Type: Magnetic float with guide tube 
Tilt type
6. Accuracy: ± 2 MM 
7. Mounting: Direct 
External chamber
8. GUIDED FLOAT TYPE
9. Switch type: glass encapsulated 
hermetically sealed reed switch
10. Minimum distance between reed switches *
11. No. of floats: single multiple 
Refer followup sheet
12. C-C distance for external chamber 
mounted switches: ………..mm
13. TILT TYPE
14. Switch type: Microswitch encapsulated in
float
15. No. of floats: single multiple

116
 Refer followup sheet
16. ENCLOSURE PROTECTION:
17. Housing : IP-65 IP_ _ 
18. Certification/ approval type: 
Ex d Ex ia NA
19. Housing colour: Grey  Black 
20. Ex-proof to zone: 0 1 2 
Group: I IIA IIB IIC
Temperature class: T1/2/3/4/5/6
21. SUPPLY / SIGNAL
22. Switch contacts: 
SPDT 1 NO
23. Switch contact rating : 
0.2A, 220V DC / 5A , 230VAC
24. MATERIAL:
25. External chamber with drain/ vent 
arrangement:
CS A105 SS 316 PP
26. Float: 316 SS PP Others 
27. Guide tube: 316 SS PP 
28. Bolts & nuts : 
ASTM A 193 Gr.B7 / A194 Gr.2H
29. Gaskets : PTFE OTHERS 
30. Wetted parts: SS 316 PP 
OTHERS
31. Flange: SS 316 PP 
32. Housing: Die cast Aluminium SS 316 
Polyamide
33. Cable for tilt switch:
34. Counter weight for titl type switch:
35.
36. CONNECTION & DIMENSIONS
37. External chamber connection type: 
Upper side - lower side
Upper side - lower bottom
38. External chamber process connection 
size: ½” 1” others
Type : NPT flange SW

39. External chamber instrument flange: 

ANSI class 150 RF flanged (Refer note
3.0)
40. Drain arrangement for external chamber 
Valve Plug
41. Vent plug 

117
 42. Process conncetion for direct mounted: 
ANSI class 150 RF flanged(Refer note
3.0)
43. Cable entry: 1”ET ½ “ NPT 
others
44. ACCESSORIES
45. Still well for direct mounting 
46. Counter weight to keep tilt type switch
cable and float in position
47. Name plate : Removable – SS 
48. Metal tag – SS 
49. Counter flanges 
50. CODES AND STANDARDS
51. Refer note no. 6.0 

52. SPARES
53. Minimum one (1) no. Or 10% of total qty., whichever is higher, for each type and

model no.
54.
55. TESTS
56. Material test / contact rating test / hydro test / calibration test 
57. Valid type test certificate to be provided for enclosure protection . 
58. Vendor to submit test certificates for Employer / engineer‟s review & records 
59. DRAWING
60. The vendor to submit data sheet, dimensional drawing and erection sketch for
review and comments by Employer/ Project Manager.


61. The vendor shall submit all operating and service manuals for the equipment 
supplied for records

NOTES:
1.0 Bidder to submit list of installations and commissions for the make & type of instrument
offered and user‟s certificates.
2.0 Bidder to furnish details (*); required (); not required (-).
3.0 Float size shall be suitable to process conditions and tank height. Accordingly, instrument
flange size shall be selected.
4.0 For qty. Refer to the attached bill of material.

118
NOTES:
5.0 All accessories shall be supplied as specified. In addition, any other accessories required
shall be supplied without any price implication to make the measurement complete to
match with process requirement.
6.0 Bidder shall indicate all applicable codes and standards.

3.39.6 SOLENOID VALVE

1. DATA SHEET A 35. Protection For Rust Prevention

GENERAL
2. Manufacturer 36 Painting Standard : As Per IS-6005,
1970
3. Model No. 37 Painting Standard : As Per IS-6005,
1970
4. Service 38 ACCESSORIES
5. PROCESS DATA 39 Name Plate : Required
6. Fluid 40 Metalling enclosure for connecting
flying leads: Required
7. Pipe size 41 CODES AND STANDARDS
8. Operating Pressure : kg/sQcm 42 ASME, ASTM, IEEE, IBR
9. Operating Temperature : °C 43 Weather Proof : IS 13947 PART I
10. Operating Flow Ex. Proof : IS 2148 / BS EN 50014 /
BS EN 50020
11. 44 TEST
12. FEATURES 45 Performance; Required
13. Shut Off Class (Leakage) 46 Hydro Test : Required
14. Type : Pilot Direct 47 Seat Leakage Test : Required
15. Body Rating : ANSI Class 300 48
CV Test : Certificate to be furnished

16. Duty : Continuous Intermittent 49 Coil Insulation Test : Required

17. No. of Ports / No. of Ways : 3/2 5/2 50 Test Certificate From PESO :
Required for all exproof
solenoid valves
18. Power Supply : 230 V AC 110 VAC
24 VDC
19. Style Of Coil : Moulded
20. Coil Insulation : Class F for high temp. as
per IEC 60085/IS 1271
21. MATERIAL OF CONSTRUCTION

119
22. Body Material : Bronze SS 316

23. Seat Material : SS 316 Teflon

24. Plunger Material : SS316

25. Packing Material
26. ENCLOSURE PROTECTION
27. Weather Proof To : IP 67 & 68
28. Ex-Proof To: Zone 1 ZONE 2
Group IIA IIB IIC
Temp.Class : T1 T2 T3 T4 T5
T6
29. Intrinsic safe certified
30. CONNECTION AND DIMENSIONS
31. Process Connection Type : NPT BSP

32. Size
33. Cable Entry Size : 1” ET
34. PAINTING

Notes:-

1. * - Bidder to furnish details.

2. All accessories shall be supplied as applicable.
3. The bidder shall indicate all applicable codes and standards
The solenoid coil shall operate the valve even when the supply voltage drops down by 15% or
4.
goes up by 10%.
The coil shall be wired to a terminal block located inside the housing. Flying lead wires of the
5. coil are not acceptable.the material of housing shall be metallic unless otherwise
indicated in data sheet.
Each solenoid valve body shall be subjected to pneumatic pressure test by air / nitrogen with test
6. pressure not less than 1.5 times the maximum working pressure (rated) of the valve.
There shall not be any visible leakage during the test
Each solenoid valve shall be subjected to seat leakage test by air / nitrogen with test pressure
7. equal to maximum working pressure (rated) of the valve for one minute. There shall not
be any seat leakage during this test.
The coil shall be low power consumption type. Generally the power consumption of coil shall be
8.
less than 5 W.

120
3.19.7 ELECTRICAL TECHNICAL DATA SHEETS

For MCC +PDBs+MLDBs/SLDBs/DBs ( To be filled by the bidders)

S.No. Description Recommended Specification Confirmation by

the
Bidders

1 Type of Panel a. MCC non drawout type

compartmentalized.

b. Panels non drawout type,

non compartmentalized

2 Type of Mounting Free standing Floor Mounted

3 Fault kA 50kA -1 Sec for MCC

4 Thickness of CRCA sheets

a Structural members 3mm

b Covers and doors 2mm

c Base channel MCC - ISMC 100

d Gland plate 3mm

5a. Painting/ Process Synthetic Enamel Paint

121
 As per seven tank process

Oven baked.

b Paint shade;

a. Inside RAL – 7032

b. Outside RAL - 7032

6 Details of busbars Electrolytic grade Copper of

specified rating for details
see constructional features
mentioned in specifications

7 Cable Entry For MCC & other Panels

Top or Bottom depending upon

location of Panel.

8 Enclosure For MCC – IP -52 with louvers for

Ventilation.
Protection/

Ventilation

9 Control Wiring/ Insulated 660Volts Cu wire.

Power Wiring

a. Voltage Circuit 1.5 sq mm

b. Current Circuit 2.5 sq mm

c. Minimum size of Power wiring 16 sq mm

122
 CKt

10 Maximum Operating Height 2100

11 Mounting height of Range 350mm to 1900mm

Relays/Meters

Control Switches

3.19.8 CONSTRUCTIONAL FEATURES FOR MCC

S.No. Description Recommended Specification Confirmation by

the
Bidders

1 MCC

a. Busbar Chamber 400mm ht

b. Metering Chamber 400mm ht

c. Incoming Compartment 1000mm vide Module

Single Tier

123
d. Overall Height 2100 mm

e. Overall Depth 1300 & 900 mm

f. Overall Length ( To be indicated by the bidder)

g. Construction IP-52 with louvers for

ventilation

h. Current Density 1.25 Amp / Sq.mm

i. Main Bus 1.75 Amp / Sq.mm

ii. Branch Bus Rating 75% of aggregate Switches

connected.

1.25 Amp / Sq.mm Density

iii. Neutral Bus Half of the size of phase bus

iv. Earth Bus Half of the size of phase bus

j. Incoming and outgoing feeders. As per SLD

124
3.20 LIST OF APPROVED MAKES FOR PLUMBING AND SANITARY WORKS
NOTE:
- All materials and products shall conform to the relevant standards and shall be of
approved make and design. A list of manufacturers/ vendors is given separately
herein below for guidance. The Engineer shall give the approval of a manufacturer/
vendor/ only after review of the sample/ specimen. In case the same is not available in
the market or in case of change in trade name, equivalent makes/ re-designated
manufacturer then an equivalent approved make shall be used with the approval of
Employer/ Engineer. The complete system and installation shall also be in conformity
with applicable Codes & Standards and Tender specifications.
- Only “First” class quality materials shall be used.
- Employer reserves the right to choose any of the approved make / vendors as per this
list.
- In case of products not indicated in this list, bis marked products shall be preferred.
- Specification of manufacturer‟s item shall be checked against tender item /
specifications before selecting any product or brand name. In case of any discrepancy,
tender item/ specifications shall prevail, and any such brand of item shall not be used
which is not conforming to tender specifications even if it is listed in this list.
- For use of material from a bis listed/ certified manufacturer, the contractor shall
furnish a copy of the BIS certificate to Employer before procuring the material.
- In case non-availability of any item/ material among approved manufacturers/ brands
at a particular site/ region, alternate manufacturers/ brands conforming to BIS/ BS etc.
shall be used subject to approval by Employer.
- In case of non-availability of any manufacturer among approved manufacturers at a
particular site/ region, alternate manufacturer‟s name shall be proposed along-with
required credentials for Employer‟s approval.
- In case of any item/ product neither covered in this list nor having A BIS
specifications, the contractor shall submit the proposed item/ product along-with
technical details/ specifications (as per bid), test certificates etc. And other credentials
of the manufacturer for Employers approval.

125
 LIST OF APPROVED MAKES FOR PRODUCTS AND MATERIALS FOR
PLUMBING AND SANITORY WORKS ARE INDICATED IN THE TABLE
BELOW. HOWEVER, ANY OTHER MAKE WHICH IS EQUIVALENT AND
MEETING THE TENDER SPECIFICATIONS ARE ALSO ACCEPTABLEWITH
PRIOR APPROVAL OF THE ENGINEER

S.No. Details of Materials / Equipment Manufacturer’s Name

1. a. Vitreous China Sanitaryware Hindustan

Parryware /or

Approved Local

2. W.C Seat Covers Admiral

Tara or

Approved Local

3. a. Low level Flushing cisterns Commander

Duralite or

Approved Local

b. WC Connectors Multiwik

Viega or

Approved Local

4. Bath Tub and Shower Tray Aquaplus

Parryware or

Approved Local

126
5. Stainless Steel Sink Cobra or

Jayna

Nirali

Approved Local

6. Cistern Commandor or Approved

Local

Champion

Parryware

7. CP Brass Fittings Parryware

or Approved local

8. Flow Control Devices Jaquar

RST

or Approved Local

9. Storage Type Geyser Bajaj

Venus

or Approved Local

10. Floor Drain Fixture, Rain Water Outlets ACO

GMGR

Neer

or Approved Local

127
11. Urinal Trap Chilly

Neer

or Approved Local

12. ULTRA LOW FLOW FIXTURES- Hindware

(Flush valves, Faucets, Bib taps) Parryware

Low Flow C.P Fittings or Approved Local

13. Water Cooler Aquaguard

Blue star

or Approved Local

14. C.P. Grating for Floor Trap Chilly

GMGR

Neer

or Approved Local

16. GI pipes fittings Crescent Engg Corp.

Jalandhar

KS Engg

RM Engg works,
ahmedabad

Zoloto or Approved Local

17. GI/MS Pipe Protection Wrapping & IWL - Pypkote

Coating
Neotape

128
 Rustech – Coatek

STP Ltd. or Approved

Local

18. Pipe clamp & supports Diamond

Easyflex

Intellotech or Approved
Local

19. Pipe Hangers Hitech

OM fasteners

or Approved Local

20. RO UNIT Aqua Guard

Kent

Konark

or Approved Local

21. UPVC Pipe Finolex

Jain

Kisan

Prince

22. CPVC pipes & fittings Ajay

Ashirwad

129
 Astral

Prince

23. Teflon Tape Approved local

24. Toilet Accessories Akoi

Parko or Approved local

25. GM / Forged Brass Ball Valves Jayhiwa

Leader

Zoloto or Approved local

26. Gate Valve / Sluice Valves Advance

Kirloskar

Jainsons

SANT

Zoloto

27. Butterfly Valve Zoloto

Jayhiwa

Pipeline Products or
Approved local

28. Check Valve – WaferType Kirloskar

Jayhiwa

130
 Zoloto or Approved local

29. Check Valve – Dual Plate Normex

Sant

Pipeline Products or
Approved local

30. Cast Iron Non Return valve Leader

Zoloto

Pipeline Products or
Approved local

31. Check Valve Forged Screwed Leader

Pipeline Products

RB

Zoloto

32. Pressure Reducing Valve RB

OR

Zoloto
33. Solenoid Valve Avcon

Uflow

Danfoss or local approveds

34. Thermostatic mixing valve Danfoss

Overtrop

35. Air Release Valve OR

Pipeline Products

Zoloto

131
36. Ball Float Valve Prayag

Zoloto

Leader or local

37. NRV – Ball type – Sewage application Danfoss or Approved local

Silverspark
Normex

38. HDPE Tanks Sintex or Approved local

Ashish

39. Air Vent Inlet Valve Jainsons

SKS

Studor
40. FRP/GRP- SMC water tank Devi Polymers pvt. Ltd.

Approved local /Binani

41. FRP/GRP storage tanks Sintex or Approved local

42. Y Strainer CI Leader or Approved local

Pipe line products

Zoloto

43. Storm Water Drainage & Sewage Aquasub Engineering

Sump Pumps (Submersible)
HBD

132
 Kirloskar

KSB

44. Transfer Pumps Aquasub Engineering

CRI Pumps

HBD

Kirloskar

Lubi/Local

45. Self-Priming Pumps Aquasub Engineering

CRI Pumps

Johnson

Kirloskar

Lubi/Local

46. Borewell Pump Aquasub Engineering

CRI Pumps

Grundfos

Kirloskar

47. Anti Vibration Mounting & Flexible Easyflex

Connections
Resistoflex

48. Pressure Gauge Fiebig

H Guru

133
49. Water Meter (Mechanical Type) Capstan or Approved
local

Kranti

Kent

50. Level Controller & Indicator (Water) Pumptrol

or Approved local

RM Engg.

Works, Ahmedabad

51. Paints Asian Paints

Berger

ICI

Shalimar Paints

52. MH / Water Tank Plastic Steps KGM or Approved local

Patel

Pranali Industries

53. Insulation for Hot Water Pipes Armacell

or Approved local
Armaflex

K-Flex

Thermaflex

54 Electric Hot Water Generator / Heat A.O. Smith

Pump
Bajaj

Venus

134
55. Solar Heating A.O Smith

Vijay Solar

Overtrap

Honeywell

56. Grease Trap/Separator ACO

Kessels

Wade

57. Welding Rods Ador

Cosmos

Prima (S)

Super Bond (S)

58. Fastener Fisher

Hilti

59. Fire Sealant Birla 3 M, Hilti

Promat

135
 60. Level Indicator HELLY, PUMPTROL

TECHNIKA,
TECHTROL

61. Temperature Sensor Forbes Marshall

Danfoss

61. Level Switch SBEM

Wika
RK DUTT

Chemtrol
3.21 APPROVED MAKES/ MANUFACTURERS( Electrical Equipments):
NOTE:
- All materials and products shall conform to the relevant standards and shall be of
approved make and design. A list of manufacturers/ vendors is given separately
herein below for guidance. The Engineer shall give the approval of a manufacturer/
vendor/ only after review of the sample/ specimen. In case the same is not available in
the market or in case of change in trade name, equivalent makes/ re-designated
manufacturer then an equivalent approved make shall be used with the approval of
Employer/ Engineer. The complete system and installation shall also be in conformity
with applicable Codes & Standards and Tender specifications.
- Only “First” class quality materials shall be used.
- Employer reserves the right to choose any of the approved make / vendors as per this
list.
- In case of products not indicated in this list, bis marked products shall be preferred.
- Specification of manufacturer‟s item shall be checked against tender item /
specifications before selecting any product or brand name. In case of any discrepancy,
tender item/ specifications shall prevail, and any such brand of item shall not be used
which is not conforming to tender specifications even if it is listed in this list.
- For use of material from a bis listed/ certified manufacturer, the contractor shall
furnish a copy of the BIS certificate to Employer before procuring the material.
- In case non-availability of any item/ material among approved manufacturers/ brands
at a particular site/ region, alternate manufacturers/ brands conforming to BIS/ BS etc.
shall be used subject to approval by Employer.
- In case of non-availability of any manufacturer among approved manufacturers at a
particular site/ region, alternate manufacturer‟s name shall be proposed along-with
required credentials for Employer‟s approval.
- In case of any item/ product neither covered in this list nor having A BIS
specifications, the contractor shall submit the proposed item/ product along-with
technical details/ specifications (as per bid), test certificates etc. And other credentials
of the manufacturer for Employers approval.
136
 LIST OF APPROVED MAKES FOR PRODUCTS AND MATERIALS FOR
PLUMBING AND SANITORY RELATED ELECTRICAL WORKS ARE
INDICATED IN THE TABLE BELOW. HOWEVER, ANY OTHER MAKE
WHICH IS EQUIVALENT AND MEETING THE TENDER SPECIFICATIONS
ARE ALSO ACCEPTABLEWITH PRIOR APPROVAL OF THE ENGINEER

SL DESCRIPTION VENDOR/MANUFACTURER/MAKE
N
O

1 Protective relays (Numerical ABB

Type)
Siemens

GE

SEL (Schweitzer Engineering Laboratories)

Alstom

2 Protective relays ABB

(Electromechanical
Type) Siemens

GE

Schneider Electric (formerly Areva/EE)

3 Auxiliary Relay Schneider Electric (formerly Areva/EE)

ABB

Siemens

VA Tech

L&T

4 Electronic circuit Relay OEN

Omron

Allen Bradley

137
 PLA

5 Control and Relay Panel ABB

Siemens

Easun Reyrolle

Alstom

Schneider Electric

6 Instrument Transformers Automatic Electric

(CT/PT)
Crompton Greaves

Indcoil

Kappa

Precise

Pragati

Gilbert and Maxwell

Silkaans

Jyoti

ECS

Schneider Electric

ABB

Siemens

7 Switchgear/Switchboard L.V.- Siemens

Drawout/Fixed Type
(PCC/MCC/PMCC/M L&T
LDB/MPDB/
MOVDB/APFC) Schneider Electric

ABB

8 Air circuit breakers L&T

Siemens

138
 Schneider Electric (M&G)

ABB

9 MCCB‟s L&T

Siemens

Schneider Electric (M&G)

ABB

10 Switch Disconnector Fuse Unit Siemens

(SDF) And Switch
Disconnector Isolator Technoelectric

Schneider Electric

L&T

11 Change-over switch Havells (euroload)

C&S

Schneider Electric

GE Power

Kraus & Naimer

Siemens

BCH

L&T

12 VVVF Drives / Electronic Siemens

Softstarter
Allen Bradley (Rockwell Automation)

Yaskawa

Schneider Electric

ABB

Danfoss

139
13 LV capacitors (APP) Universal Cables

ABB

Malde

Madhav

Epcos

Aswani

Schneider Electric

L&T

14 Series Reactors For Capacitors Manohar Brothers

WHEPL

Epcos

15 AC Power Contactor Siemens

ABB

L&T

BCH

Schneider Electric (Telemecanique)

16 DC Power Contactor BCH

BHEL

Siemens

L&T

Schneider Electric

17 Auxiliary contactors Siemens

L&T

Schneider Electric (Telemecanique)

140
18 Electronic / Microprocessor Siemens
based overload relay
ABB

Schneider Electric

19 Bi-metal / Overload Relay Siemens

Schneider Electric

L&T

20 Thermister relay Alstom/ Minilec/ Insta controls

21 Single Phasing Preventer Siemens

Minilec

Alstom

Schneider Electric

L&T

22 Time switch GIC

Theben

Siemens

Schneider Electric

Legrand

23 Timers GIC

Theben

BCH

Siemens

Electronic Automation Pvt Ltd.

Minilec

L&T

141
 Legrand

Schneider Electric

24 Time Delay Relay Schneider Electric

ABB

Siemens

BCH

L&T

Omron

PLA

25 Motors Siemens

Bharat Bijlee

Crompton Greaves

Marathon Electric Motors (India) Ltd.

(Formerly Alstom Ltd)

BHEL

ABB

Kirloskar

26 Battery Charger & DCDB Hitachi

Caldyne Automatics

Chhabi Electricals

Mass-tech Controls

HBL Power Systems

Automatic Electric

Amara Raja

Universal Instruments

142
27 Luminaire Philips

Zumtobel

Crompton Greaves

Bajaj

GE

28 Lamps Philips

GE

Osram

Sylvania

LVD

Neptune, USA

29 Ballast Philips

Crompton Greaves

Bajaj

ATCO

30 LT Power Cables/ Earthing Universal Cables Ltd.

Cable
NICCO

KEC International Ltd

Cable Corporation Of India Ltd

Finolex

INCAB

Polycab

LAPP

RR Kabel

143
31 LT Control Cables LAPP

Polycab

NICCO

Universal Cables Ltd.

KEC International Ltd

Finolex

INCAB

KEI

Cable Corporation Of India Ltd

32 HFFR wires (including panel Finolex

wiring)
Polycab

LAPP

RR Kabel

33 Non-insulated Copper Earthing Gupta Industrial Corporation (Vasai, Palghar)

conductors
Bharat Wires & Ropes

Diamond Cables

34 Distribution Boards (other than Siemens

MLDB, MPDB,
MOVDB) / Panels / C&S
Enclosures / JB /
Marshalling Panel Schneider Electric

Rittal

President

Enclotek

Eldon

Hensel

Legrand

144
 Manshu Comtel

Pentair

ABB

BCH

35 MCB, RCCB, RCBO / MCB Legrand

Isolators
Siemens

Schneider Electric

Klockner Moeller

ABB

36 MPCB Siemens

Schneider Electric

Moeller

ABB

L&T

37 Alarm Annunciators (solid Digicont

state type with LED
illumination) / Facia Industrial Instruments & Controls
Annunciator
Procon Inst. (P) Ltd

MTL India Pvt. Ltd.

Rochester Instruments System Ltd.

IDECIZUMI

Minilec

IICP

Proton Electronics

Alstom

Yashmun

145
 ICA

Ronan (Waree)

38 Decorative switches, sockets Honeywell (MK Electric)

and metal boxes
(single plate Anchor (Panasonic)
arrangement)
Havells (Crabtree)

39 Modular switch & socket Anchor (Panasonic)

(wraparound) (twin
plate arrangement) Anchor (Roma / Ave)

Honeywell (MK Electric)

Legrand

Havells (Crabtree)

Schneider Electric (Clipsal)

Siemens

ABB

Gewiss

40 Ceiling fan Usha

Crompton Greaves

Bajaj

Orient

Khaitan

Almonard

41 Wall mounting fan Almonard

GEC

Crompton

Bajaj

Orient

146
 Usha

42 Exhaust Fan / Ventilation Fan Nadi

Usha

Almonard

Bajaj

Crompton Greaves

43 Air Circulators/Man Coolers Almonard

(Pedestal/Wall
Mounted) Bajaj

Crompton Greaves

44 Cable termination/jointing kits Raychem (Tyco Electronics / RPG)

3M(Cold Shrink/Push-on)

ABB Kabeldon

45 Control / selector switch Kraus & Naimer

Kaycee

GE Power controls

L&T

Siemens

ABB

Schneider Electric

46 Indicating Lamps (Multi-chip Binay

LED)
Teknic Controls

Vaishno

Siemens

L&T

147
 Schneider Electric

Concord

BCH

47 Terminal Block / Connectors Wago / Connectwell / Pheonix / Elmex

48 Control transformer Indcoil

Precise

Silkaans

NEC

Gauss Electricals

49 Semiconductor Fuse Siemens

Schneider Electric (Ferraz Shawmut)

Eaton (Cooper Bussmann)

GE

50 HRC fuse (Power & Control) Siemens

L&T

GE

Eaton (Cooper Bussmann)

Technoelectric

Schneider Electric (Ferraz Shawmut)

51 Pushbuttons Siemens

Schneider Electric (Telemecanique)

Teknic Controls

L&T

Concord

148
 BCH

Vaishno Electricals

52 Push button station Siemens

Schneider Electric

R Stahl

Hensel

Bals

Gewiss

53 Non metallic enclosures Rittal

(including Industrial
Receptacles) Hensel

SCAME

Menekkes

Bals

Siemens

Schneider Electric

BCH

PCE

Legrand

Gewiss

54 Digital Meter – Ammeter & Schneider Electric (Conzerv)

Voltmeter
AE

Rishabh

Schneider Electric (Power Measurement/

ION)

Circutor

Siemens

149
 Masibus

55 Electromechanical – Ammeter Automatic Electric

& Voltmeter
MECO

IMP

Rishabh

56 Load Manager / Multi Schneider Electric (Conzerv / (Power

Function Meter / kWh Measurement / ION)

Circutor

Rishabh

Schneider Electric

Alpha (ABB)

Schlumberger

SEMS (Secure)

Electro Industries / GaugeTech

57 Power quality analyser A-eberle

Schneider Electric (Power Measurement/

ION)

Schneider Electric (Conzerv)

Chino – Laxsons

Yokogawa

Rishabh

Fluke

Hioki

58 Cable lugs Dowells

Comet

3D (Billets Elektro Werke Pvt.Ltd)

150
59 Cable Glands (safe area - Comet
double seal cone grip
type) Jainson

Braco

Baliga

R. Stahl

Crouse Hinds

Siemens

Hex (Brass Copper & Alloy(I))

Cosmos

60 Polyamide Cable Glands Lapp

Hensel

Gewiss

Fibox

61 Lightning Arrestors WS

Jayshree

Elpro

Oblum

Crompton Greaves

62 Surge Suppressors OBO

Emerson

Furse

Dehn+Sohne

Erico

Pepperl+Fuchs

MTL

151
 Schneider Electric

ABB

Weid Muller

Siemens

Phoenix Contact

63 Uninterrupted Power Supply Emerson Network Power (India) Pvt. Ltd. (

(UPS) Liebert / Chloride)

Schneider Electric (MGE / Gutor / APC /

Invensys)

Aplab

Fuji Electric , Japan

Hitachi

Eaton

Riello-PCI

Socomec

ABB (Newave)

64 Floor trunking system (GI OBO

trays, troughs & pull
boxes) and GI Cable Honeywell
trays
Legrand

Indiana

Profab

Patny

Sadhana

Sterlite

Reliance

Jenco/Pentax Ferro Incorporate

152
65 Furniture trunking system / Legrand
Cable management
System Schneider Electric

Rittal

Panduit

Honeywell

Eubiq

66 UPVC Conduit/JB/flexible Precision

conduit/tees/
Bevels,elbow & Polycab
accessories/fittings
Sudhakar

AKG

67 GI Conduit / Pipes JK Tube Company (AKG)

BEC Industries

Zenith

SAIL

TATA Steel

Jindal

68 MS Conduit JK Tube Company (AKG)

BEC Industries

Jindal

TATA Steel

SAIL

69 Casing Capping Precision

Circle ARK

Mody

153
70 Lighting Controller / Lighting Lutron
Management System
Zumtobel

Philips

Tridonic Atco

71 Lead Acid Battery (Plante / Exide

Tubular)
HBL Power Systems Ltd.

Amara Raja Batteries Ltd.

Hoppecke

72 SMF/VRLA battery Exide

HBL Power Systems Ltd

Amara Raja Batteries Ltd.

Hoppecke

73 Ni – Cd Battery HBL Power Systems Ltd.

Hoppecke

Amco Saft

74 High mast lighting system Philips

Bajaj

Crompton Greaves

BP Projects

Valmont

75 SCADA / EMS ABB

Siemens

Alstom

Schneider Electric

154
 Electro Industries / GaugeTech

Rishabh

76 Fire Barriers / Sealing Brattberg

Roxtec

Signum

Navell

Multikil

77 Water barriers/sealing system Roxtec

Rayflate (Tyco Electronics)

78 Decontactor BCH

79 Insulating mats Electromat

Dozz

Raychem RPG

80 Emergency Light / Installite / Prolite

Conversion module /
Battery Pack Legrand

Philips

Tridonic Atco

Zumtobel

81 Choke (for VVVFD) Siemens

ABB

Danfoss

Allen Bradley (Rockwell Automation)

Yaskawa

155
82 Power Supply Unit Siemens

MTL

Aplab

Pheonix

Cosel

83 PLC Allen Bradley

Siemens

Schneider Electric

84 Voltage / Power / Current / ABB

Frequency / Energy
Transducer AE

Siemens

Schneider Electric

Rishabh

Masibus

85 Encoders Hubner

Honeywell

Turck

86 Limit Switch BCH

Honeywell

Siemens

Jay Balaji

Wago

87 Aviation Obstruction Light Binay

(multiple LED type)

156
88 Diesel Engines Cummins

Caterpillar

MTU

Mitsubishi

Wartsila

Rolls Royce

89 Alternators for DG Sets Cummins (Stamford / AvK)

Leroy Somer

BHEL

90 Digital Multimeter for Beckmann

Operation &
Maintenance Fluke

AVO

91 Clip-On Ammeter for HCK, Germany

Operation &
Maintenance Kyoritsu Electrical , Japan

157
TECHNICAL SPECIFICATION

FOR

FIRE PROTECTION SYSTEM

158
 FIRE PROTECTION WORKS

4.1 TECHNICAL SPECIFICATION FIRE PROTECTION SYSTEM

4.1.1 EQUIPMENT & SERVICES TO BE PROVIDED BY THE CONTRACTOR

4.1.1.1 This specification covers the general requirements of design, preparation of detailed
drawings, supply of material, manufacture, testing, inspection at BIDDER‟S works,
packing, forwarding, transportation, transit insurance, delivery at site, erection /
installation, testing, commissioning at site and carrying out performance / acceptance
tests of the equipment, materials and services as per enclosed data sheets and other
documents for fire protection system (FPS).
4.1.1.2 The scope of work is as listed below.
Sprinkler system, Hydrant system and Portable Fire Extinguishers shall be provided
for various floors as per architectural floor plans. Bidder shall note that in areas where
gap between false ceiling & ceiling slab exceeds 800 mm, sprinklers shall be
provided.
4.1.1.3 Tentative layout drawings for fire water pump house and hydrant systems have been
prepared by the PROJECT MANAGER and enclosed with this enquiry. However the
following shall be in the scope of bidder.
a) Preparation and submission of detailed engineering drawings based on these
specifications and latest base drawings.
b) Performing and submitting Hydraulic calculations for the entire fireProtection
system including sprinkler and hydrant system.
c) Drawing(s) showing layout of portable extinguishers along with necessary
calculations.
d) Preparation of any specific fabrication drawings, as required.
e) Obtaining approval of the system from client‟s insurance company, local
authority(ies) having jurisdiction (Fire officer, Factory Inspector, etc.) and
approving agency appointed by client, including taking out necessary number of
prints of drawings, submission to approving agency, co-coordinating site visits,
making any minor modification in drawings for the purpose, etc.
f) Prepare and submit as-built drawings as per Document and drawing submission &
distribution schedule.
g) The specification covers Details of pumping and pipe mains for the water based
systems. Main fire water pumps, standby pumps, jockey pumps along with their
prime movers viz., electric motors and diesel engines.
h) Piping inside and around pump house including suction and delivery piping,
delivery header, recirculation piping.
i) All the valves and specialties in above piping.
j) Supporting arrangements needed (indoor & outdoor) for the piping, valves and
instrumentation mentioned above.
k) Hume pipes are as per standard practice to be provided wherever road crossings
are shown.
l) Wrapping & coating for underground piping.

159
 m) Excavation and back filling required for underground piping / outdoor supporting
arrangement.
n) Supply and application of painting for piping, fitting, valves, equipment, hose
cabinets and structural steel and auxiliary steel for supports.
o) It is not the intent to specify completely herein all details of design and
construction of equipment or materials to be supplied or of services to be
rendered.
p) However, the equipment, materials and services shall conform in all respects to
high standards of engineering design, workmanship and be capable of
performing in continuous commercial operation in a manner acceptable to Client /
Project Manager who will interpret the meaning of drawings and specifications
and shall have the power to reject any work or material which in his judgement
are not in full accordance therewith.
q) The equipment to be supplied and erected under this specification are detailed in
BOQ and these shall be in accordance with Specification and data sheets and the
relevant data sheet A of data sheets section.
r) Any item which may not have been specifically mentioned herein but are needed
to complete the equipment / system shall also be treated as included and the same
shall also be furnished and erected, unless otherwise specifically excluded as
indicated.

4.1.1.4 The Bidder‟s scope also includes the following:

a) Auxiliary steel / supporting steel for supporting the equipment, piping as well as
related drilling, welding work, painting of supports etc.
b) All kinds of supports as necessary for piping.
c) All anchor bolts, nuts, washers and inserts to be embedded in concrete for the
equipment and piping.
d) Construction of valve chamber in case of underground pipes.
e) Hydro testing & Flushing (All necessary equipments, connections & valves shall
be in CONTRACTOR‟S scope.)

4.1.1.5 For routing piping, cabling etc. breaking / making of opening in wall, etc. shall be
carried out by Contractor at no extra cost.

4.1.1.6 For pipes of fire water system that enter the buildings, the following will be in scope
of contractor: If the pipe has to cross the metal cladding, then a correct size opening
shall be made in the cladding and after the pipe is installed, the opening shall be
sealed both on inside and outside by using proper sealants as approved by engineer-
in-charge. Where pipe has to cross brick / block work wall, then a correct size
opening shall be made in the wall, an appropriate sleeve installed and after the fire
water pipe is installed, the opening between fire water pipe and sleeve shall be sealed
both on inside and outside by using proper sealants as approved by engineer-in-
charge.

4.1.2 SPECIFIC REQUIREMENTS / INSTRUCTION TO BIDDERS

160
4.1.3.1 All equipment supplied shall have capacities not less than those specified in the data
sheets and necessary test certificates shall be furnished in this regard. Approved
makes and type of equipment/ components shall be supplied. The make, type
reference of the equipment is subject to EMPLOYER‟s approval.
4.1.3.2 Grouting of all equipment and supports, supply of grounding material such as cement,
sand, necessary form work etc. is Bidder‟s responsibility.
4.1.3.3 No Separate payment will be made for necessary structural supports of piping.
4.1.3.4 The quantities of piping & valves, specialties etc. indicated in Schedule of quantities
are indicative for the purpose of Bidder‟s guidance and shall not be binding to limit
the scope of Contractor‟s work. In case there is any variation (plus or minus) in the
quantities actually supplied and installed from the quoted quantities, the price of the
same shall be adjusted based on the unit rates furnished by the BIDDER.
4.1.3.5 Bidder shall note that for piping, quantities of fittings like elbows, reducers,
fabricated reducers / miters, compression fittings, flanges, nipples etc. are not defined.
The price for supply, fabrication and erection of necessary fittings shall be included in
the unit rates for respective pipe sizes. The rates for flanges, and hardware like bolts,
nuts, washers and gaskets shall be included in prices quoted for pipes, equipment,
valves and specialties as applicable.
4.1.3.6 No separate prices are called for painting. Price for supply and application of painting
shall be included in the unit prices for piping, valves and equipment, structural steel
work as applicable.
4.1.3.7 For pipes, measurement shall be corner to corner after deducting length of valves,
specialties, in-line instruments.
4.1.3.8 All charges for inspection, testing, radiography, dye penetrate testing, flushing,
cleaning, hydro/air testing, purging with inert gases, commissioning, including
consumables required for same shall be included in the unit rate for erection of
piping/valves/equipment.
4.1.3.9 Minor civil works like wall opening, chipping of foundation, grouting of
foundations shall be carried out at no extra cost.
4.1.3.10 In addition to the scope mentioned in Clause 4.1.1.2 above, the
CONTRACTOR shall supply and erect all required temporary pipes, fittings, flanges,
valves and specialties and hangers and supports for testing and cleaning operations, as
a part of the erection scope of contract for each of the systems listed above. The
BIDDER shall consider this requirement while quoting unit prices for erection.
4.1.3.11 The construction of the fire protection system requires all CONTRACTORS
to adhere to good daily housekeeping practices. During construction the
CONTRACTOR shall every day, keep all work and storage areas used by them free
from accumulation of waste materials. Scrap/ rubbish shall be removed from the site
to the satisfaction of the client. The CONTRACTOR shall maintain a crew to carry
out this function without any additional payment.
4.1.3.12 The contractor shall prepare and submit to the EMPLOYER for approval,
final piping bill of materials as actually erected for purpose of reconciliation.
4.1.3.13 The surplus material with the CONTRACTOR for all materials brought by
him shall be taken back by the CONTRACTOR except surplus from those materials
for which the EMPLOYER has given, in writing, clearance for procurement.
4.1.3.14 All the pipes shall conform to the relevant piping standards. The pipes shall be
joined using butt welding to ANSI B 16.25.

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4.1.3.15 Slings/ wire ropes and other lifting, hoisting or pulling slings used for lifting
various loads shall be invariably tested by a test load before carrying out actual
erection.
4.1.3.16 The Vendor shall ensure that other utilities/items and aesthetics are not
damaged or disturbed due to the installation activities.
4.1.3.17 Caps over concealed sprinklers shall be fitted only after painting of ceiling (by
others) is completed.
4.1.3.18 Sprinklers shall be masked off prior to painting. Any painted sprinkler or
sprinkler coated with plaster of Paris is to be replaced by CONTRACTOR at no cost
to the EMPLOYER.
4.1.3.19 Method of Testing System: The following tests shall be carried out for
ensuring that the system and various components meet the system specifications

Hydrant piping  To withstand min. hydro-test at the pressure 1.5 times

the max. working pressure i.e. 8.8 x1.5 =13.2 kg/cm2g
for two hours (as per clause no. 7.5.6 of TAC manual)
 Leak test: system to be tested at maximum operating
pressure for functional test at operating pressure for 2
hours after fixing all components.

Fire water pump Shall be capable of delivering not less than 150 % of rated
capacity at a head of not less than 65 % of the rated head

Diesel Engine Shall be capable of operating continuously on full load at the

site elevation for a period of six hours.

Wrapper coating Holiday testing

on underground
pipes

Other components As per data sheet / requirements specified.

4.1.3 BIDDER’S PROPOSAL

4.1.4.1 To enable thorough and fast scrutiny of the BIDDER‟s proposal, BIDDER‟s are
advised to respond all their technical data in the enquiry by clearly marking out their
response, wherever they want to provide additional data and / or they deviate from the
specified requirements. In case of full compliance, the enquiry specification and data
sheets will remain unaltered. Each data sheets shall be certified by the BIDDER. This
requirement is very important. Non compliance of this by the BIDDER may result in
their bid being rejected.
4.1.4.2 Bidder shall ensure and cover all his eligible employees deputed on site under ESI act
and Provident Fund Act. The contractor shall be liable to honour all labour laws as
applicable in the state, also in respect of payment of minimum wages, payment of
Provident Fund and ESI contribution, labour licence and any such acts which are not
explicitly mentioned in the document but prevailing during the tenure of contract. The
contractor should have his separate code number for compliance under ESI act and

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 Provident Fund Act, so as to cover all his eligible employees under the act in the said
code number. The contractor shall comply with the provisions of the act, on month to
month basis and shall keep the appropriate record required under the act as well as
shall submit the copy of compliance to the Employer regularly.
4.1.4.3 BIDDER is advised to quote for the complete scope and partial response will not be
entertained. In case of few items which do not directly fall under BIDDER‟s
manufacturing range and / or not available from indigenous source, BIDDER should
take the responsibility upon them to arrange to procure them and supply to ensure that
their proposal is complete in all respects.
4.1.4.4 Ignorance of the site shall not be accepted as basis for any claim for compensation.
The submission of the tender by the BIDDER will be construed as evidence that such
an examination was made and any later claims / disputes in regard to price quoted
shall not be entertained or considered. Bidders may visit the site, if necessary, after
getting permission of client.

4.1.4 CODES AND STANDARDS

4.1.5.1 All equipment, systems and works covered under this specification shall comply with
all currently applicable statutes, regulations, standards and safety codes in the locality
where the equipment will be installed. All equipment and systems shall comply in all
respects with requirements of codes and standards as indicated in data sheets of this
specification.
4.1.5.2 Other national standards established to be equivalent or superior to the codes and
standards specified are also acceptable. The BIDDER shall furnish English translation
of all standards specified in this specification.
4.1.5.3 In the event of any conflict between the codes and standards referred to in the
specification and the requirements of this specification, the more stringent of this
requirement shall govern.
4.1.5.4 All codes and standards referred to in this specification are latest editions of
respective codes and standards.

4.1.5 MAINTENANCE REQUIREMENTS

4.1.6.1 In order to carry out preventive maintenance, it should be possible to readily
disassemble, repair, and reassemble the equipment system in the shortest period and
to attend to any defect by a minimum disassembly.
4.1.6.2 The BIDDER shall confirm that space shown for the equipment is adequate from
point of view of access, easy maintenance and for day to day operation.
a) All system must have convenient maintenance characteristics including
b) Minimum disturbance to production during preventive maintenance.
c) Easy access to replacement part which can be installed by personnel with
minimum skill.

4.1.6 GUARANTEES AND PERFORMANCE REQUIREMENTS

4.1.7.1 GENERAL
The fire protection system shall perform satisfactorily to meet the guarantee
requirements specified to the entire satisfaction of the CLIENT / ENGINEER and
statutory requirements.

4.1.7.2 NOISE AND VIBRATION

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 a) Amplitude of vibration at bearing of rotating equipment shall conform to ISO:
10816-1.
b) Vibration isolators of proven design shall be furnished by the BIDDER for
preventing the transmission of vibration from the equipment (fire water
pumps, etc.) to the other neighbouring equipment and structure.

4.1.7 PAINTING

4.1.8.1 Painting in the immediate vicinity of any electrical and rotating equipment and / or
pipe in service shall not be performed without the prior written approval of the
EMPLOYER for the specific structure, equipment, or pipe to be painted.
4.1.8.2 The CONTRACTOR‟s scaffolding shall be erected, maintained and dismantled
without damage to structures, machinery, equipment or obstruction to work of other
CONTRACTORs.
4.1.8.3 All surfaces such as light gauge / glasses, required for clear visual observation shall
be cleaned after paint application.
4.1.8.4 Special care shall be taken to avoid any paints from dropping on the machined
moving parts of equipment, name plates or indicator dials of instruments and control
valves. Prior to paint application or spraying paint removable adhesive tape shall be
used to cover these.
4.1.8.5 On final completion of all work, the CONTRACTOR shall leave the entire premises
within the site of his operation clean and free from all rubbish resulting from his
painting operation and shall remove any paint or other blemishes caused by him on
adjacent walls, windows, equipment and finished surface.
4.1.8.6 All piping shall be painted after hydro test only.
4.1.8.7 The iron and steel surfaces shall be thoroughly cleaned of all rust, scale, grease or oil
by manual or power tools and then primer coat shall be applied.
4.1.8.8 The EMPLOYER reserves the right to inspect the cleaning down and painting
operations at any stage and if required by EMPLOYER/ ENGINEER unsatisfactory
surface preparation or paint application shall be emended at CONTRACTOR‟s
expense.
4.1.8.9 On job site, no painting shall be carried out in a dust laden atmosphere or under
unsuitable weather conditions viz. when raining or when metal surfaces are damp or
when condensation is likely to affect the paint film before it is dry.
4.1.8.10 All the exposed surfaces of equipment and piping shall be painted with 1 coat of zinc
chromate primer and 2 coats of synthetic enamel paint. Shade of finish paint shall be
as per IS:5 shade 538. Minimum thickness (DFT) of paint shall be as under:-
a. Primer - 1 coat of Zinc Chromate primer with minimum dry film thickness (DFT) 25
microns per coat.
b. Finish - 2 coat of synthetic enamel paint with minimum dry film thickness (DFT) 25
microns per coat. Total DFT 50 microns minimum.

4.1.8 SYSTEM DESCRIPTION

4.1.9.1 Hydrant System

The system shall be designed to operate automatically on operation of any of the
hydrant valve(s). The system shall be always pressurized and will operate by a set of
pumps and related instrumentation and controls. The operation of pumps shall be
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 sequential. The jockey pump shall start and stop to maintain header pressure. In case
of operation of hydrant(s), the jockey pump would be unable to maintain the pressure
and the pressure drops further. At a lower predetermined pressure the motor driven
pump starts. In case motor driven pump fails to start, the pressure continues falling.
At a further lower predetermined pressure, the diesel engine driven standby pump
shall operate. Stopping of hydrant system pumps shall be manual
4.1.9.2 Sprinkler System
The system shall be designed to operate automatically on breaking of any of the
sprinkler bulbs. The operation of sprinklers in a particular zone would be indicated on
the panel through instruments/appurtenance provided on the alarm valve. The system
shall be always pressurised and will operate by a set of pumps and related
instrumentation and controls. The operation of pumps shall be sequential. The jockey
pump shall start and stop to maintain header pressure. In case of operation of
sprinklers, the jockey pump would be unable to maintain the pressure and the
pressure drops further. At a lower predetermined pressure the motor driven sprinkler
system pump starts. In case motor driven pump fails to start, the pressure continues
falling. At a further lower predetermined pressure, the diesel engine driven standby
pump shall operate. Stopping of pump shall be manual.
4.1.9.3 Fire Water Pump House and Underground Fire Water Tank
a) Fire Water Reservoir shall be of RCC underground type construction in two
equal compartments along with an adjacent underground fire water pump
house so that the pumps will be operating under positive suction head.
Effective capacity required for exclusive use by fire protection system is 200
cubic meters.
b) Following Fire Water Pumps shall be provided in the underground pump
house.
Name Quantity Parameter

Electric Motor driven Main Pump

01 171 m3/hr @ 8.8 kg/cm2(g)*
- Horizontal Centrifugal type
Diesel Engine driven Stand by
Fire Pump - Horizontal 01 171 m3/hr @ 8.8 kg/cm2(g)*
Centrifugal type
Electric Motor Jockey Pump – 10.8 m3/hr @ 8.8 kg/cm2(g)
01
Horizontal Centrifugal type *

Pump Power requirement shall be finalised by the contractor.

The jockey pump shall be used for make-up of leakages. The start-stop of jockey
pump and start of fire water pumps shall be automatic by sensing of falling header
pressure by individual pressure switches.
A pressure switch shall be provided on header for sensing header pressure low.
A pressure gauge shall be provided at discharge of each pump.
The system shall be pressurised at 8 kg/cm2(g). Pump shall be installed with pressure
switches in the common delivery header for automatic starting in the following
tentative sequence:

Sr. No. Description Set Pressure

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 (in kg/cm2g)
01. Jockey pump – 1 start * 6
02. Jockey pump – 1 stop * 7
03. Main pump-start 5
04. Standby Pump- start 4
 * The above settings are indicative and actual parameters will be finalised in the
detail engineering phase. In addition to above Signals, Pump “Running” & “Fail To
Start” signal shall be provided & necessary Pressure switches shall be envisaged.
 Pumps shall be capable of furnishing not less than 150% of rated capacity at a head of
not less than 65% of the rated head. The shut-off head shall not exceed 120% of rated
head.
4.1.9.4 Portable Fire Extinguishers
Portable fire extinguishers for the proposed facilities are included in this package.
Portable fire extinguishers shall be provided as per TAC. All the extinguishers should
have ISI mark. Certificates to this effect shall be furnished by CONTRACTOR. Spare
quantity of 10% of all types shall be provided.

4.1.9 SUMMARY OF DATA TO BE FURNISHED ALONG WITH BID

The BIDDER shall ensure the following documentation are prepared and submitted
to EMPLOYER along with the Bid:
4.1.10.1 TECHNICAL BID
a) All data sheet from of the tender specification shall be duly filled in.
b) Performance curves/rating charts used for selection of equipment for all the
systems shall be furnished along with the bid, with the duty points duly marked
on them.
c) All sheets of bill of quantities duly filled in, signed and stamped.
d) Electrical load list indicating rating and quantity. Bidder is not allowed to change
the motor rating in the event of order placement
4.1.10.2 DETAILED ENGINEERING DOCUMENTS AFTER LOI
a) The detailed engineering documents, hydrant piping layout drawings, Pump house
Piping layout drawings etc., Piping calculation and datasheets for the execution of
the job.
b) Final data sheets.
c) Any drawing detailed fabrication drawing which may be necessary for ring
bending / fabrication etc.
d) Any drawing which may be required to be modified / generated to suit the site
condition / obtaining TAC approval.
e) General arrangement drawings for hydrants, pumps, diesel tank valves &
specialties.
4.1.10.3 FINAL DOCUMENTS
a) Operation and maintenance manuals.
b) Quality assurance documentation specific for the project.
c) Final as built documentation folder containing all drawings and technical data
sheets for future reference.

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4.1.10 SCHEDULE OF INSPECTION / TESTING AT SITE (TO BE WITNESSED BY
CLIENT)
4.1.12.1 The schedule of tests indicated below is indicative and not exhaustive.
CONTRACTOR to carry out any other tests at site as per directions of CLIENT.

Sl No. Name of the System/Equipment Tests to be carried out at site

a) Pumps Performance Test

Noise level and vibration level

All rotating equipment
b) measurement

c) Power consumption For all equipment

d) Pump control panel and logic Operation test

Hydrostatic leak test, Wrapper coating

e) Piping (Sample)
thickness, Radiography

f) Fire Hydrant (Sample) Operation test

g) Sprinkler Operation and performance test

h) Alarm Valve / Installation Control Valve Operation Test

i) Fire Extinguisher Operation Test

4.2 FIRE PROTECTION SYSTEM-ELECTRICAL REQUIREMENTS

4.2.1 SCOPE OF WORK
4.2.1.1. Power and Control cabling from MCC to Fire Protection motors including cable
carrier system.
4.2.1.2. Local Push button station
4.2.1.3. Earthing system above ground
4.2.1.4. Structural steel for supporting the panels, LPBS, Cable trays etc.
4.2.2 ELECTRICAL PANELS
4.2.1.1. The Contractor‟s scope includes 1 No. MCC for Fire Protection System as per
Appendix - 1 of this section.
4.2.1.2. 415 Volts, 50 Hz, TPN supply at the incomer of MCC will be made available by the
Employer. Further distribution of power and derivation of any other voltage shall be
in Contractor‟s scope.
4.2.1.3. MCC incomer shall be suitable for termination of 1RX3.5CX120 sqmm, AL, XLPE
The Contractor‟s scope includes 1 No. MCC for Fire Protection System as per
Appendix - 1 of this section.

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4.2.1.4. All potential free contacts (Feedback & command from PLC) shall be wired upto
Marshalling compartment of MCC.
4.2.3 LOCAL PUSH BUTTON STATIONS (LPBS)
4.2.3.1. LPBS for motors shall be provided by contractor. Necessary supporting structural
steel for the same is in Contractor‟s scope.
4.2.3.2. LPBS shall be metal enclosed, weather proof, dust and vermin-proof, suitable for
mounting on wall or structures. The enclosure shall be sheet steel, 2 mm thickness
and shall have degree of protection not less than IP55. The enclosure shall be painted
with one coat of epoxy primer and two coats of Epoxy Light Gray paint – 631 shade
as per IS-5.
4.2.3.3. LPBS for shall be provided with 1no. recessed type start push button and 1No. Palm
push, mushroom head type stop push button.
4.2.3.4. All push buttons shall be fitted with two (2) NO and two (2) NC contacts, rated for
10 A at 240V AC.
4.2.3.5. LPBS shall be suitable for bottom cable entry with stopping plugs.
4.2.3.6. Internal wiring shall be done with copper conductor HFFR wires shall be neatly done.
4.2.3.7. All spare contacts shall be wired upto terminal block.
4.2.3.8. Distance between cable gland plate and terminal block shall be minimum 75mm for
ease of termination.
4.2.3.9. Two (2) Nos. earthing terminals shall be provided for external earthing. Earthing
continuity bonds shall be provided.
4.2.4 CABLING SYSTEM
4.2.4.1. For MCC, Power supply will be made available at incomer with the help of 1.1 kV,
XLPE Power Cables by others. Further Power and control cabling from MCC to
motors shall be in the in scope of Contractor. Incoming Cable sizes will be indicated
to successful bidder during execution based on total load of each plant.
4.2.4.2. FPS MCC shall be installed in Pump House.
4.2.4.3. MCC shall be provided with Top Cable entry. Anchor Fasteners, Bolts and other
necessary supporting structure required for Panel installation shall be provided by
bidder.
4.2.4.4. Contractor shall furnish Cabling layout & Cable Schedule for each Area.
4.2.4.5. For overhead cable trays, foundation (if required) for cable tray supporting structure
will also be provided by Bidder.
LV Power Cables shall be 1.1 kV grade stranded copper conductor (up to 6 sq. mm)
and stranded aluminium conductor (above 6 sq. mm) multi core, XLPE insulated,
extruded PVC inner sheathed, GI wire / strip armoured, and extruded FRLS PVC
outer sheathed, as per IS:7098 (Part- 1).
4.2.4.6. Control Cables shall be 1.1 kV grade stranded copper conductor (of minimum
2.5sq.mm.), XLPE insulated, extruded PVC inner sheathed, GI wire / strip armoured,
extruded FRLS PVC outer sheathed as per IS:7098 (Part-1).
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4.2.4.7. Minimum 1 core shall be kept spare in control cable.
4.2.4.8. Cable trays shall be Hot dipped Galvanised Iron (85 micron galvanising) with
accessories such as coupling plates (with minimum 8 nos. holes), bends, tees,
reducers, coupling nut-bolts etc. of following width. All the hardwares used for cable
tray jointing, cable supporting & clamping shall be of SS304 material.
4.2.4.9. Nylon ties shall not be used for clamping cables, GI strip with SS304 hardware shall
be used.
a) While sizing of Cables, Bidder shall consider voltage drop of 1.0% (max.) from
MCC to Motor.

b) Cable sizes indicated in data sheets of low voltage induction motor are for
General Guidelines only. Contractor shall provide cable sizing calculation based
on design criteria mentioned above.
4.2.5 EARTHING SYSTEM
4.2.5.1. Earthing below ground shall be by others. Earthing above ground i.e. equipment
earthing upto earthing bus shall be in the scope of Bidder.
4.2.5.2. Earthing shall be of GI.
4.2.5.3. Earthing connection at equipment shall be of bolted type.
4.2.5.4. 1 Run of 50x10mm GI Strip shall be provided by contractor along Cable Tray and
shall be connected at suitable point to Earth Grid.
4.2.5.5. Bidder shall furnish the Earthing layout along with calculations (below as well as
above ground).
4.2.6 LV MOTORS
4.2.6.1. Motors shall be suitable for 415 V, 3 phase, 50 Hz supply, squirrel cage type.
4.2.6.2. Motors shall be squirrel cage type, energy efficient (IE-3 class as per IS-12615, 2011)
squirrel cage induction motors having TEFC, IP-55 enclosure (including terminal
boxes and bearing housing) with Class-F insulation (and temperature rise limited to
Class B) conforming to IS 325.
4.2.6.3. Motors shall be energy efficient (IE-3) type.
4.2.6.4. Motors will be with Direct On Line starter (DOL).
4.2.6.5. For other details, refer specification No. Data sheets A1 of low voltage induction
motor.
4.2.6.6. Bidder shall follow below mentioned values of Efficiency as per ECBC.

Motor Size (kW) Efficiency (%)

2 Pole 4 Pole

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 Motor Size (kW) Efficiency (%)

2 Pole 4 Pole

1.1 (1.5 hp) 82.2 83.8

1.5 (2 hp) 84.1 85

2.2 (3 hp) 85.6 86.4

3.0 (4 hp) 86.7 87.4

4.0 (5.5 hp) 87.6 88.3

5.5 (7.5 hp) 88.5 89.2

7.5 (10 hp) 89.5 90.1

11.0 (15 hp) 90.6 91

15.0 (20 hp) 91.3 91.8

18.5 (25 hp) 91.8 92.2

22.0 (30 hp) 92.2 92.6

30.0 (40 hp) 92.9 93.2

37.0 (50 hp) 93.3 93.6

45.0 (60 hp) 93.7 93.9

55.0 (75 hp) 94 94.2

75.0 (100 hp) 94.6 94.7

4.2.6.7. For preferred makes refer Appendix-2 of this section.

4.2.7 TERMINAL POINTS (BATTERY LIMIT)
4.2.7.1. 415 Volts, 50 Hz, TPN supply at the incomer of MCC shall be made available by the
Employer. Further distribution of power and derivation of any other voltage shall be
in Contractor‟s scope.
4.2.7.2. Termination of incomer and outgoing cables is in scope of contractor.
4.2.7.3. Earthing above ground shall be considered in contractor‟s scope as per clause no.
4.2.5
4.2.7.4. APPENDIX - 1

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 FPS MCC (Loc: Pump House)

Motor Rating
Sl. No. Name of the equipment Feeder Type
(kW)

1) Incomer MCCB 400A

STAR/DELTA
Fire Protection Main Pump 70
2) STARTER

Fire Protection Jockey Pump DOL 10

3)
MCCB+63A
4) Socket in MCC 63A
Socket

Note – kW Rating & no. of feeders indicated here are preliminary & shall be confirmed by the bidder.

4.3 FIRE PROTECTION SYSTEM-INSTRUMENTATION AND CONTROL (I&C)

SYSTEM REQUIREMENTS

4.3.1 EQUIPMENT & SERVICES TO BE PROVIDED BY THE BIDDER

4.3.1.1. This specification covers the general requirements for design, preparation of detailed
drawings, supply of material, manufacture, testing, inspection at BIDDER‟S works,
packing, forwarding, transportation, transit insurance, delivery at site,
erection/installation, testing, commissioning at site and carrying out performance /
acceptance tests of the Instrumentation & Control System for Fire Protection System
as per specifications in this section, enclosed data sheets, drawings and other
documents.
4.3.1.2. The following shall be in the scope of the BIDDER:
4.3.1.3. Supply, erection & commissioning of instruments as per P&ID for following systems:

a) Hydrant System

b) Sprinkler system

c) The instruments shown on P & ID are of minimum requirements. However

BIDDER shall provide all instruments required for proper functioning of the
systems.
4.3.1.4. Supply, erection & testing, commissioning of Fire Protection Panel and completely
wired Pressure switches to Fire Protection Panel. Panel shall be located in Pump
house along with all required accessories as per specification. The cabling required up
to Fire Protection panel from instruments is in the BIDDER‟s scope
4.3.1.5. Contractor shall supply & lay the following cables:

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 a) All cables between the field instruments, junction boxes, control panel, MCC &
any other equipment with termination & cable gland at both ends along with all
cable laying accessories.

b) Power supply cables as required for the instruments & panels. 230 V AC power
supply shall be made available by Bidder. Bidder shall supply, lay & terminate
the power supply cables from that point to the respective system panels for I&C
system. Power supply cables for further distribution of power supply within the
panel & from panel to field shall be provided by Bidder.

c) Cable trays / GI /PVC conduits for all the above cabling. The cable trays in the
outdoor areas shall be provided with covers.
4.3.1.6. All erection hardware including structural steel for erection of all field instruments,
cable trays/ GI / PVAC conduits, panels etc. shall be provided by the BIDDER.
BIDDER shall supply all necessary erection hardware required for proper installation
of the instruments
4.3.1.7. Earthing for all field instruments, panels, PDBs etc. shall be in the scope of
contractor.
4.3.1.8. Bidder's scope of work shall include complete loop checking of all measurement &
command chains.
4.3.1.9. Integration & commissioning of the complete system.
4.3.1.10. Minor civil work such as wall opening & sealing it back after laying of cable
trays / conduits, pedestals for stanchions, grouting, anchor fasteners for supporting
etc. are included in scope of bidder
4.3.1.11. Site Acceptance tests (SAT) to meet the design specifications & functional
requirements as specified.
4.3.1.12. Assumptions to cover lack of information are not allowed. Bidder is obliged
to obtain reliable information from EMPLOYER/ PROJECT MANAGER.
4.3.1.13. The compliance with this specification does not relieve the Bidder from his
responsibility towards contractual obligations with regard to completeness,
satisfactory operation and easy maintenance of the unit
4.3.1.14. Supply & erection of GI / PVC conduits as required for cabling.
4.3.1.15. The BIDDER‟s scope of work shall include trial runs, start up, commissioning
and process trials of systems covered in this specification.
4.3.2 DESIGN CRITERIA
4.3.2.1. All instruments shall be suitable for use in hot, humid, tropical & dusty climate.
4.3.2.2. Field mounted electrical and electronic instruments shall be weatherproof to IP-65.
All instruments of submersible type if any shall be protected to IP-68.
4.3.2.3. Wherever the service is hazardous, the field transmitters shall be intrinsically safe.
For switches, solenoid valve & junction boxes suitable ex-proof enclosure shall be

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 provided in hazardous areas. For intrinsically safe instruments suitable barriers shall
be provided in relay control cabinet by BIDDER.
4.3.2.4. All panels, control desks & enclosures shall comply with the requirements of
protection classes as indicated below
In-door Air-conditioned (A.C.) areas IP 20
In-door Non A.C. areas IP 42
Outdoor areas IP 65
4.3.2.5. The field junction boxes for indoor application with IP55 and outdoor JB with IP65
shall be provided.
4.3.2.6. All wetted parts shall be of minimum SS 316. However, based on the process
application, suitable superior material shall be provided to match the process.
4.3.2.7. All instruments and control devices located on control panels shall be of miniaturised
design, suitable for modular flush mounting on control panels with front draw out
facility and flexible plug-in connections at the rear.
4.3.2.8. The I&C system shall be designed by selecting high-grade components of proven
quality and proper design of system electronics. The system shall be highly reliable
with high-integrity and high MTBF system.
4.3.2.9. All instruments, control systems and accessories furnished under this specification
shall be from the latest proven product range of a qualified manufacturer whose
successful performance has been established by a considerable record of satisfactory
operation in utility power stations.
4.3.2.10. The normal working range of all indicating instruments shall be between 30%
and 80% of the full range.
4.3.2.11. For pressure switches and temperature switches, the set points shall fall within
30% to 70% of the scale range selected.
4.3.2.12. For level measurement, the maximum of the range will cover the overflow
point or six inches from the top of the tank and the minimum of the range will be six
inches above the bottom of the tank. Also, the gauge glasses will be stacked with
overlap to cover permissive, alarm and trip levels.
4.3.2.13. The performance of all instruments shall be unaffected for the variation in
voltage and frequency of the power supply.
4.3.2.14. Provision shall be made for external adjustment of span and zero for all
instruments for calibration.
4.3.2.15. All the hardware/software shall be latest and field proven as available in the
market.
4.3.2.16. All requirements of auxiliary equipment for instruments and control
devices including thermo wells, resistance elements and transmitters, special
wiring and piping accessories, air filter and pressure regulators, condensation
pots and all other special devices required for installation in instrument piping and
wiring system shall be furnished complete as required for each individual element,
instrument or system unless specifically stated otherwise in this specification.

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 4.3.2.17. Tag numbering philosophy would be uniform for the entire plant. There
would be a single, unique tag for a given equipment / signal.
4.3.2.18. All parts subject to high pressure, temperature or other severe duty shall be of
materials and construction suitable for the service conditions and long operating life.
4.3.2.19. Components of instruments, control devices, accessories, piping etc. which
contact with steam, condensate or boiler feed water shall be manufactured from
copper free materials which do not react with media at operating parameters.
4.3.2.20. Instruments for location in outdoor/indoor/air-conditioned areas shall be
designed to suit the environmental conditions and shall be suitable for continuous
operation in the operating environment without any loss of function or departure from
the specification requirements covered under this specification.
4.3.2.21. The power supply for the instrumentation & control system shall be 24 V DC,
unless otherwise specified.
4.3.2.22. IBR certification wherever applicable shall be provided with the instruments.
4.3.2.23. For interlock and protections dedicated switches shall be provided. All trip
condition shall be preceded by pre warning.
4.3.2.24. 230 V AC power distribution board (PDB) / UPS distribution board in the
control rooms.
4.3.2.25. Earthing pits.
4.3.3 SPECIFIC REQUIREMENTS / INSTRUCTION TO BIDDERS
4.3.4.1. This is a unit rate contract. Price shall be quoted as per the specifications in section.
The quantities of cables, conduits, trays etc. is estimated based on the Plot plan
drawing. Bidders are advised to go through the tender document carefully and
suggested that clarifications, if any, are obtained from Department before submission
of their quotation.
4.3.4.2. The construction of this facility requires that, all BIDDERS adhere to good daily
housekeeping practices. During construction the BIDDER shall every day, keep all
work and storage areas used by them free from accumulation of waste materials.
Scrap / rubbish shall be removed from the site to the satisfaction of the EMPLOYER.
The BIDDER shall maintain a crew to carry out this function without any additional
payment.
4.3.4.3. It is not the intent to specify completely herein all details of design and construction
of equipment or materials to be supplied or of services to be rendered.
4.3.4.4. However, the equipment, materials and services shall conform in all respects to high
standards of engineering design, workmanship and be capable of performing in
continuous commercial operation in a manner acceptable to EMPLOYER who will
interpret the meaning of drawings and specifications and shall have the power to
reject any work or material which in his judgement are not in full accordance
therewith.
4.3.4.5. Any item which may not have been specifically mentioned herein but are needed to
complete the equipment / system shall also be treated as included and the same shall
also be furnished and erected, unless otherwise specifically excluded as indicated.

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 4.3.4.6. To enable thorough and fast scrutiny of the BIDDER's offer, BIDDERS are advised
to respond all their technical data in the enquiry by clearly marking out their
response, wherever they want to provide additional data and / or they deviate from the
specified requirements. In case of full compliance, the enquiry specification and data
sheets will remain unaltered. Each data sheet & write up in specification shall be
signed and stamped by the BIDDER. This requirement is very important. Non
compliance of this by the BIDDER may result in their bid being rejected.
4.3.4.7. BIDDER is advised to quote for the complete scope and partial response will not be
entertained. In case of few items which do not directly fall under BIDDER‟s
manufacturing range and / or not available from indigenous source, BIDDER should
take the responsibility upon themselves to arrange to procure them and supply to
ensure that their offer is complete in all respects.
4.3.4 CODES AND STANDARDS
4.3.5.1. All equipment, systems and works covered under this specification shall comply with
all currently applicable statutes, regulations, standards and safety codes in the locality
where the equipment will be installed.
4.3.5.2. In particular, the following standards are applicable (latest editions)

175
ANSI : American National Standards Institute

1.1.1. Control Valve Seat Leakage classification.

ASME : American Society for Mechanical Engineers

BS : British Standards

BS-5308 Part-I Specification for Polyethylene insulated cables.

DIN-43760 Temperature Vs Resistance curves for RTD.

IEC : International Electro technical Commission

IEC 79 Electrical Apparatus for Explosive Gas atmosphere

IEC-332 Test on bunched wires or cables.

IEC 529 Classification of degree of protection provided by

enclosures

IEC 584-2 Thermocouple Tolerances

IEC 751 Industrial RTD Sensors.

IEC 801 Electromagnetic compatibility for industrial for industrial

Process measurement and control.

ISA : Instrument Society of America

S-5.2 Binary Logic Diagrams for Process Operations.

S-7.3 Quality standard for instrument air

S-75.01 Flow equations for Control Valve Sizing

ISO : International Organization for Standardization.

ISO-5167 Measurement Of fluid flow in closed conduits

NEC : National Electric Code

NEMA : National Electrical Manufacturer’s Association

ICS-6 Enclosures for industrial control system

IS:13947. Low voltage switchgear and control gear : General rules

Part-1

176
 IEC 326. Printed Circuit Boards
4.3.5.3. Other national standards established to be equivalent or superior to the codes and
standards specified are also acceptable. The BIDDER shall furnish English translation
of all those standards apart from those mentioned in this specification.
4.3.5.4. In the event of any conflict between the codes and standards referred to in the
specification and the requirements of this specification, the more stringent of these
requirements shall govern.
4.3.5.5. Unless indicated otherwise, all codes and standards referred to in this enquiry
specification shall be understood to be the latest version on the date of offer made by
the Bidder.
4.3.5 MAINTENANCE REQUIREMENTS
4.3.6.1. In order to carry out preventive maintenance, it should be possible to readily
disassemble, repair, reassemble the I&C equipment in the shortest period and to
attend to any defect by a minimum disassembly.
4.3.6.2. All system must have convenient maintenance characteristics including :

a) Minimum disturbance to production during preventive maintenance.

b) Easy access to replacement part which can be installed by personnel with

minimum skill.
4.3.6 I&C SYSTEM CONFIGURATION
4.3.7.1. SPRINKLER SYSTEM
a) Instruments shall be provided for the system as per P&ID & data sheets in as per
specification.

b) Alarm from these instruments shall be annunciate in Window Annunciator located

in Fire Protection Panel.
4.3.7.2. HYDRANT SYSTEM
a) Instruments shall be provided for the system as per P&ID & data sheets in
specification.

b) Alarm from these instruments shall be annunciate in window Annunciator located

in Fire Protection Panel.
4.3.7.3. JUNCTION BOX
a) All the cables shall be wired to Fire Protection Panel through Junction Boxes.
4.3.7.4. FIRE PROTECTION SYSTEM CONTROL PANEL
a) A relay based Fire Protection Panel shall be provided for local operation and
monitoring at fire water pump house. The panel shall house the logic of operation
and Annunciation of Fire water pumps. Auto manual switches and push buttons
177
 will be provided on panel for local operation of pumps. The annunciator shall be
microprocessor based, split type with alarm windows mounted on front door and
electronic components inside the panel. Potential free contacts shall be wired up
to the terminals inside fire protection panel for each of the alarm. The control
supply for the panel shall be 24V DC. The panel will be provided with 230V AC
from reliable supply from UPS, AC to DC converter in redundant mode will be
provided in the panel.
4.3.7.5. The operation in auto & manual modes shall be as below:
a) Auto mode

 In the auto mode, the pumps shall be started / stopped as per the table given in
P&ID.

b) Jockey Pumps

 The jockey pump shall start/stop automatically based on the pressure in the
delivery header P&ID. Alarms shall be provided for indication „trip‟ & „failed to
operate‟ status of jockey pump.

c) Main Fire Water Pumps

 The main fire water pumps shall start at the pressures in the hydrant header as
given in P&ID. If the main fire water pump fails to start, the system pressure will
fall further. When the reaches header as given in P&ID, the standby fire water
pump shall start automatically.

 The main & standby engine driven fire water pumps shall be stopped manually by
pushbuttons on the MCC even in the auto mode.

 Alarm shall be generated at delivery header pressure as given in P&ID to alert the
operator to stop the fire water pump.

 Alarms shall be provided for indication of running, trip & failed to operate status
of each fire water pump (main & engine driven) and trip & failed to operate status
of jockey pump. The potential free contact from pressure switches provided in the
discharge of each pump shall be used for indication of „Pump running.

 Provision for Potential Free contacts shall be provided in fire Protection Panel for
wiring the Pump trip signal of Fire water Pumps to DDC (If any).

d) Manual mode

 In the manual mode, the fire water pumps & jockey pumps shall be
started/stopped using pushbuttons provided on the MCC.

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 4.3.7.6. The control voltage shall be 24 VDC. The power supply (230 V AC) shall be
made available in the panel by the bidder from the MCC.
4.3.7.7. 2 nos of level switch shall be considered for Fire Water storage tank which
will generate potential free contact for Hi & Low level alarm in relay based Fire
Protection Panel.
4.3.7.8. Level indicator or Gauge shall be considered for fire water storage tank for
local monitor purpose.
4.3.7.9. The cables to be considered are armored cables.
4.3.7.10. Cables inside Pump house shall be laid over perforated trays.

4.3.7 SPECIFICATION FOR THE ALL THE FIELD INSTRUMENTS SHALL BE AS

GIVEN BELOW
4.3.8.1. Pressure Gauges

Sr.No Description Employer‟s requirement

1 Type : Direct Reading

2 Casing : SS 304

3 Glass : Toughened borosilicate shatterproof

4 Dial size : 150 mm

5 Wetted Parts : SS 316

(including
accessories)

6 2-valve manifold : SS 316

7 Diaphragm seal : SS 316 (with suitable coating of material if

required)

8 Pointer : Aluminium

9 Movement & socket : SS 316

10 Accuracy : + 1.0 % of full scale

11 Process Connection : Bidder to State

12 Over range : 25% above maximum pressure

protection

13 Accessories :  Syphon for services above 75oC

 Snubber for pump discharge applications
 Chemical diaphragm for corrosive fluid

179
 lines (acid, alkali etc.), in discharge of
sludge transfer pumps & in oil.
 2-valve manifold (2-valve manifold &
snubber is not be required for diaphragm
seal application.)
 SS name plate.

4.3.8.2. Pressure Switch

Sr.No Description Employer‟s requirement

1 Type : Non-indicating type

2 Casing : Aluminium casing

3 Wetted Parts : SS 316

(including
accessories)

4 Repeatability : + 1.0 % of full scale reading

5 Micro switch contacts : 2 Nos. SPDT contacts rated 5A at 240V AC.

6 Over range protection : 25% above maximum pressure

7 Accessories : Syphons for services above 75oC, snubbers for

pump discharge applications and chemical
diaphragm for corrosive & oil services, 2-valve
manifold and SS name plate

4.3.8.3. Solenoid Valve

Sr.No Description Employer‟s requirement

1 Type : Direct operated (rated for insulation class

“F”)

2 Power supply : 24V DC

3 Size : Full port

4 Material of : Body – Brass

Construction
Internals - SS 304

5 Accessories : SS Nameplate, Free wheeling diode is

required across the solenoid

6 Applications : Three (3) way solenoid valve shall be

provided single acting spring return cylinder
for pneumatically operated on-off valves.

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 7 Notes: Terminal blocks and Manual actuator shall be provided in the
solenoid valves.

4.3.8.4. Level Gauge / Indicator – Float & Cord

Sr. No. Description Qty. Employer‟s requirement

GENERAL

1. Manufacturer

2. Model No.

FEATURE

3. Calibrated scale board Required

4. Colour of numerals Black

5. Accuracy + 10 mm

6. Enclosure IP 65 or equal

7. Mounting Top

8. Height of numerals 40 mm high minor

marking at every 100
mm; 70 mm high major
marking at every 1000
mm

MATERIAL OF
CONSTRUCTION

9. Float SS 316

10. Float cable SS 316

11. Anchor SS 316

12. Spring assembly CS with cadmium plating

13. Board Aluminum epoxy painted

14. Guide wires SS 316

15. Elbows Aluminum epoxy painted

16. Flanges SS 316

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 CONNECTION &
DIMENSIONS

17. Type Flanged

18. Flange size 4”

19. Flange rating #150 S. O. RF

20. Name plate/ metal tag Fixed SS304

Installation hardware Required

4.3.8.5. Float Switch

Sr. No. Description

1. Manufacturer : *
2. Model no. : *
3.
4. FEATURES
5. Calibrated scale board
6. Colour of numerals :
7. Height of numerals :
8. Accuracy : +/- 5 mm +/- 10 mm
9. Range :
10.

11. MATERIAL OF CONSTRUCTION

12. Float : SS 316
13. Float cable : SS 316
14. Anchor : SS 316
15. Spring assembly : spring steel
CS with cadmium plating
16. Board : Aluminum epoxy painted
Aluminum polyurethane painted
17. Guide wires (refer note 4 & 5) :
SS 316

18. Elbows : : Cast Aluminum

Aluminum epoxy painted
Aluminum polyurethane painted
19. Pulley: SS316 Aluminum

182
 20. Pipe enclosing float cable: GI SS 316
21. CONNECTIONS & DIMENSIONS
22. Type : flanged
23. Flange size :
24. Flange rating
25.
26. ACCESSORIES (REFER NOTE 3)
27. Mounting brackets
28. Name plate / metal tag
29. Gaskets, bolts, nuts
30. All installation hardware
31.
32. CODES & STANDARDS
33. Refer note - 2
34.
35. TESTS
36. Performance :
37. Calibration :
38. Hydro test for the float :

DRAWINGS/DOCUMENTS
1. Vendor shall submit data sheets, catalogue and erection sketch for review and comments by
Employer/Project Manager.
2. Vendor shall submit instruction manual for records.

TEST CERTIFICATES
1. Vendor shall submit all routine test certificates for Employer/Project Manager‟s review.

NOTES :
1.0 *: bidder to state / furnish details; : required; – not required.
2.0 The bidder shall indicate all applicable codes & standards.
3.0 All accessories shall be supplied as applicable.
4.0 Sufficient float & guide wire to be supplied on single length to cut at site as per requirement.
5.0 Option of counter weight instead of anchoring of guide wire at bottom is decided based on site condition
of the Tanks
6.0 Refer follow-up sheets for service and application details.

4.3.8.6. Junction Boxes

Sr. Description Qty. Employer‟s

requirement
No.
183
Sr. Description Qty. Employer‟s
requirement
No.

GENERAL

1. Manufacturer

2. Model No.

FEATURE

3. Mounting Wall/ column

4. No. of terminals 32 (2x16)

5. Terminal type Screwed

6. Terminal size Suitable for 2.5 sq.

mm. wire

7. Mounting plate Required

8. Cable entry Bottom

9. Gland plate Removable

10. Door Single lockable door

with gasket

11. Lock & key Required

12. Sheet thickness 3 mm

13. Painting Inside: glossy white;

Outside: RAL 7032

14. Protection class Weather proof to IP

65

MATERIAL OF
CONSTRUCTION

15. Enclosure MS with epoxy

painting

16. Gasket Neoprene

17. Cable entry sealing Fire proof compound

18. Name plate/ metal tag Fixed SS304

184
 Sr. Description Qty. Employer‟s
requirement
No.

19. Installation hardware Required

4.3.8.7. Power Supply

230 V AC power supply for the I&C system shall be available from UPS. All field
instruments/ valves shall operate on 24 V DC power supply. Two-wire field
instruments shall be system powered (24 VDC) from the control system. The
distribution of power in field, if required for the instruments/valves, shall be through
a designated field mounted junction box (with fused terminals).
4.3.8.8. Instrumentation and Control Cables

(a) All instrument cables for control and indication shall be flame retardant, Low smoke
(FRLS) and tested in accordance with IEC 60332 Part 3 and Cable design shall be as
per EN 50288-7.

(b) The basic specification of the conventional cables shall be as follows:

Conductor material - Tinned copper, with minimum 7 strands

Conductor size - 1.0 mm2 for signal cable as minimum.

1.5 mm2 for control cable as minimum

1.5 mm² for power cables as minimum

Other sizes based on the load requirement

Core / Pair - 1 Pair, 2 Pair, 6 Pair, 12 Pair for signal

1 Triad, 8 Triad for RTD signals

2 Cores, 3 Cores (Power), 6 Cores, 12 Cores, 24 Cores, 36

Cores for control cable

Insulation - Polyethylene

Voltage grade - 660 / 1100 V

Inner sheath - PVC, black

Screening - Aluminium Mylar tape

Coverage - 100%, Overlap 25%

Drain wire Tinned- Copper, 0.5 mm2

Armouring/ Braided - GI wire /strips

185
 Outer sheath - FRLS PVC for 90ºC

Blue (IS), Grey (Non IS / Exd), Black (Power)

(c) Cables for earthing

1100 V, FRLS, PVC insulated, Green color, stranded copper cable.

(d) All multipair & multicore cables shall be provided with 20% (of used pairs/cores)
spare pairs & cores for future use.
4.3.8.9. CABLE TRAYS AND CABLE GLANDS

(a) Cables Glands

Cable entries in field instruments & panel shall be using cable glands. The cable
glands shall be of double compression type with high quality neoprene gaskets. Cable
glands shall be of brass with nickel plating.

(b) Cable trays

Cable trays shall be perforated of hot dipped galvanized steel. I&C cables (24 V DC)
and power cables (230 V AC) shall be routed through different cable trays to avoid
electromagnetic interference. Minimum
300 mm distance shall be maintained between I&C cables /24 V DC power supply
cables and 415 V AC/ 230 V AC power cables. The thickness of the cable trays shall
be 2mm while that of the tray covers shall be 1.5mm
4.3.8.10. FIRE PROOF SEALING OF CABLE PENETRATION
Cables/ cable tray openings in walls and floors or through pipe sleeves from one area
to another or one elevation to another will be sealed by a fireproof sealing compound.
The fire-proof sealing compound will effectively prevent the spread of fire from the
flaming to non-flaming side, in the event of fire.
4.3.8.11. WIRING
All inter cubical and internal wiring for all panels/ junction boxes/ power distribution
boards shall be carried out with 1100V grade, stranded tinned copper conductors with
insulation. The minimum size of the stranded copper conductor used for the panel
wiring shall be 1.0 mm2 for analog signals and 1.5 mm2 for 24 V DC control
commands. For power supply, the conductor size shall be provided as per the load
rating (min. 2.5 sq. mm for 230 V AC and 1.5 sq.mm. for 24 V DC). Control &
Power wiring shall be segregated and routed in PVC troughs. Different colour wires
shall be used for different voltages.

Engraved core identification plastic ferrules, marked to correspond with the panel-
wiring diagram shall be fitted at both ends of each wire. Cross ferruling shall be done.
186
 For termination of cables emanating/entering the panels & junction boxes etc.
Terminal blocks shall be provided. For 24 V DC power distribution to panels/
junction boxes, terminal blocks shall be provided for cables emanating/entering the
panels.

For 230 V AC PDBs & sub-PDBs, normal terminal blocks are acceptable.

All spare contacts and spare terminals of the panel mounted equipment and devices
shall be wired to the terminal strips.
4.3.8.12. CABLE TERMINATIONS
Suitable termination accessories shall be provided for terminating on the terminal

strips in junction boxes, consoles, panels, power distribution boards etc. All necessary
cable terminating accessories such as removable gland plates,

compression glands, supporting clamps and brackets, wiring troughs and gutters, etc.
shall be included in the BIDDER‟s scope of supply. Cable entry into the junction
boxes, consoles, panels, power distribution boards etc. shall be using double
compression Nickel plated brass.

Disconnect type terminals with fuses with visual indication of fuse down shall be
provided at each digital input & output terminal.

Disconnect type terminals shall be provided for all inputs/ outputs to isolate field
input and output for maintenance purpose.
4.3.8.13. RELAYS
All industrial relays used shall have 2 NO + 2 NC contacts.

Whenever relays are used (if applicable) to interface process input/outputs, 20%
additional relays shall be provided. In addition, 20% spare space shall be provided in
panels/junction box to install 20% additional relays or other items in future.
4.3.8.14. LABELS
All front mounted equipment, as well as equipment mounted inside the
panels/junction boxes shall be provided with individual labels with equipment
designation engraved. These shall be phenolic overlays (1.6 mm thick) with black
background and white lettering and shall be fixed to the panel by stainless steel
screws (counter sunk). The panels/junction boxes shall also be provided at the top
with a label engraved with the designation. Lettering for panel/control desk/junction
box designation shall be 6 mm. The minimum lettering size for instrument/device
labels shall be 3mm. The lettering on the labels shall be subject to EMPLOYER'S
approval. Labels of internally mounted equipment shall be clearly visible.

187
 4.3.8.15. EARTHING
Each panel, junction box & power distribution board shall be provided with a safety
ground bus & system ground bus made of copper securely fixed along the inside base
of the panels. These buses shall be typically of 25 mm wide and 6 mm thick of
copper. The safety ground bus shall be properly secured to the plant safety earthing.
All metallic cases/frames of relays, instruments, other panel mounted equipment shall
be connected to the safety ground bus and shields & drain wires of signal/control
cables shall be connected to the system ground bus by independent copper wires of
not less than 2.5 sq. mm. The system ground bus shall be electrically isolated from
AC mains earthing bus. The insulation colour code for earthing wires shall be green
with yellow bands.

4.3.8 TENDER EVALUATION

The BIDDER shall comply with all systems / parameters wherever they are specified
in data sheets of specification. No credit will be given during tender evaluation, if
parameters better than those specified are offered by the BIDDER.

4.3.9 SUMMARY OF DATA TO BE FURNISHED ALONG WITH BID AND AFTER

PLACEMENT OF ORDER
The BIDDER shall ensure the following documentation are prepared and submitted
to EMPLOYER for his review / record.
4.3.10.1. Technical Bid
a) Specification, each data sheet & write-up in specification shall be signed / filled
and stamped by the BIDDER indicating compliance to the specifications.

b) The following drawings/ documents shall be submitted:

 Dimensional Drawings of Junction boxes, Window annunciator panel along

with BOQ.

 Instrument list indicating, Make, Model No., Service, Type of Instrument.

 Engineering activity and manufacturing schedule giving activity wise breakup

to meet the delivery schedule.
4.3.10.2. Final Documents

188
 a) Operation and maintenance manuals.

b) Quality assurance documentation specific for the project.

c) Final as built documentation folder containing all items for future reference.

4.3.10 DATA AND DRAWINGS BY BIDDER (AFTER THE AWARD OF CONTRACT)

The BIDDER shall submit the following drawings / documents after award of
contract. BIDDER shall adhere to the delivery schedule as submitted along with the
BID. BIDDER shall also refer to data sheets in Data sheets for list of deliverables to
be submitted for various instruments/ panels.

Sl. No. Details

(a) PERT/Bar chart for the design, manufacturing, erection,

commissioning, trial operation and performance testing of the
system offered.

(b) System Functional Write-up.

(c) Unpriced purchase order copy for various bought out /sub
contracted equipment / services.

(d) Letter from Sub BIDDER(s) showing order acceptance and

adherence to project schedule.

(e) Junction Box list with data sheets, Internal G.A. drawings,
internal wiring drawings & BOQ, quantity & model no. of all
instruments/ items mounted in the junction boxes.

Window annunciator panel list with data sheets, Internal G.A.

drawings, internal wiring drawings & BOQ, quantity & model
no. of all instruments/ items mounted in the junction box.

(f) Heat load and Power consumption for all I&C loads.

(g) Instrument list with tag numbers, Makes and Model nos.,
Service, Type of instrument.

(h) Data sheets & catalogues for all instruments (including panel
mounted instruments), installation sketches along with erection
bill of quantities for all field mounted instruments and loop
diagrams.

189
 Sl. No. Details

(a) Data Sheets & catalogues for I&C cables & power cables.

(b) QAPs for all items like field & panel mounted instruments,
valves, panels, junction boxes, cables etc.

(c) Earthing diagrams.

(d) Cable Schedules and Interconnection cable schedules.

(e) „As Built‟ drawings.

(f) Instruction manual for installation and start-up.

(g) System operation and maintenance manual.

4.3.11 TESTING, INSTALLATION, COMMISSIONING AND ACCEPTANCE

4.3.12.1. General

On the basis of guidelines specified in this specification Bidder shall submit their own
testing, installation, commissioning and acceptance procedure. The procedure shall
include purpose of test, test definition, results expected and acceptance criteria.
4.3.12.2. Site Acceptance Tests (SAT)
Full integrated site acceptance test shall be performed before hand over of total
system to the EMPLOYER. The test shall demonstrate functionality of the entire
I&C system supplied & erected by the BIDDER. The BIDDER shall provide all
personnel, test facilities, equipment and tools etc. for the same. All test instruments
shall have calibration certificates from approved test house, valid for minimum 6
months. A test procedure is required for approval 2 weeks prior to the schedule start.
4.3.12.3. Instrumentation Testing Requirements
a) Tests on cable

 Check details are in accordance with the specification.

 Check for physical damage.

 Megger test between each core and armour/sheath.

 Continuity check including screen continuity

 Terminations in the Panels/ junction boxes/ battery with battery charger

supplied & erected by the BIDDER.
b) It shall be ensured that erection of junction boxes are as per approved layout
drawings. Checking for tagging/identifications of all the panels /junction
boxes shall be done. Checks for continuity and termination of all power signal
190
 & control cables as per approved drawings shall be carried out. All the panels
& junction boxes supplied & erected by the BIDDER shall be checked at site
by carrying out the following tests:

 Visual & Mechanical testing.

 Power up tests on battery with battery charger, checking input & output
voltages

 Checks on incoming voltage and power distribution in the various panels

& junction boxes by switching on MCCBs/MCBs one after the other.

 Power up tests on the DC power supply system, checking input & output
voltage

 Tests on electrical installation

 Checking of closing, tripping, supervision and interlocking of control

devices.

 Checking operation of all alarm circuits.

c) Instrument Calibration.

 The services of factory trained instrumentation technicians, tools and

equipment for field calibration of each instrument to its specified accuracy
in accordance with the manufacturer‟s specifications and instructions for
calibration shall be provided.

 Each instrument shall be calibrated at 0 percent, 25 percent, 50 percent, 75

percent and 100 percent of span using test instruments to simulate inputs
and read outputs that are rated to an accuracy of at least 4 times greater
than the specified accuracy of the instrument being calibrated.

 Such test instruments shall have accuracies traceable to the National

Bureau of Standards as applicable.

 A written report on each instrument in the format required by the

Employer shall be provided to the Employer certifying that it has been
calibrated to its published specified accuracy. This report shall include a
listing of the published specified accuracy and permissible tolerance at
each point of calibration. The report shall be certified by the Engineer.
d) System Validation

 The services of factory trained and field experienced instrumentation

engineer(s) shall be provided to validate each system and verify that it is
operational and performing its intended functions as per specifications.
191
  Each system shall be validated by simulating inputs at the first element in
loop (i.e. sensor) of 10 %, 50 % and 90 % of span, or on/off and verifying
loop output devices (i.e. indicator, alarm etc.).

 During system validation, provisional settings shall be made on levels,

pressure, temperature, alarms etc.

 Correct operation of controllers shall be verified by observing that the

final control element moves in the proper direction to correct the process
variable as compared to the set point.

 All logic sequences shall be verified to operate in accordance with the

specifications.

 All defects and malfunctions disclosed by tests shall be corrected

immediately. New parts and materials shall be used as required and
approved and tests shall be repeated.

 A report certifying completion of validation of each instrument system

indicating the errors observed during the validation and any provisional
settings made to devices shall be provided. The report shall be made in the
format required by the Employer and shall be certified by the Employer
when he approves it.
e) Final Operational Testing and Acceptance.

 Upon completion of instrument calibration and system validation, all

systems shall be tested under process conditions.

 The testing shall include, but not limited to all specified operational
modes, taking process variables to their limits (simulated or process) to
verify all alarms, failures, interlocks and operational interlocks between
systems and/or mechanical equipment.

 Any defects or malfunctions shall be immediately corrected using

approved methods and materials and the tests shall then be repeated.

 Upon completion of final operational testing, a report shall be submitted,

indicating that the total control system provided meets all the functional
requirements specified herein. This report shall be made in the format
required by the Employer. The Employer shall certify this report when he
approves it and it shall constitute final acceptance of the control system.
4.3.12.4. Commissioning
a) Commissioning Procedure shall be carried out in a methodical sequence as
follows

192
  Start-up,

 Initial running,

 Operability adjustment,

 Stable operation

 Final adjustment
b) The BIDDER shall check the operating conditions of the Plant by constantly
monitoring operating data.
c) The BIDDER shall specify for each discrete part of the Plant the operational
data to be recorded and the manner in which the data is to be taken.
d) All the operating data shall be recorded, evaluated and submitted to the
Employer.
4.3.12 SPARE PHILOSOPHY
4.3.13.1. Spare shall include spare parts, special tools and tackles, including tool box, as
required for pre-commissioning & commissioning, start-up and interim operation,
day-to-day maintenance, any premature failures for the facilities and first one
years operation.
a) Start-up and Commissioning spares
b) Mandatory spares
c) One-year operational spares
d) Special tools and equipments (if required)
4.3.13.2. Following spare philosophy shall be followed for field instrument:
a) Local gauges, instruments, switches, lamps etc. – 10% of each type/model or
1 No. minimum whichever is higher
b) All electronic items/ transmitters – 10% of each type/model or 1 No.
minimum whichever is higher
4.3.13.3. Following spare philosophy shall be followed for the control system:
a) For relays and passive components in panel, minimum 20% spare components
shall be provided.
b) In addition, 20% spare space shall be provided in panels/junction box /
cabinets to install relays or other items in future.

4.4 DATASHEETS

4.4.1 DATA SHEETS FOR HORIZONTAL CENTRIFUGAL PUMPS

4.4.1.1. DATA SHEET A

1. Designation: Refer Table-1 25. Drive transmission :

193
 Direct / Gear / Pulley

2. Number Required : Refer Table-1 26. Seal : Gland Packing /

General

3. Tag Numbers : - Refer Table-1 Mechanical Seal

4. Location : Indoor / Outdoor Single / Double

5. Operation : Continuous / 27. Pump Driver : [Refer Table-1]

Intermittent As And When Required Motor As Per Data Sheets Of Low

construction features(continued)
Voltage Induction Motor

6. Steam Turbine As

7. Liquid Pumped :Fire Water Diesel Engine As Per Specification

8. Temperature : Ambient By Employer / Vendor

9. Specific Gravity : 1 28. Nozzle orientation:

10. Viscosity: Kg/M/S Side Suction-Side Discharge /

11. % Solid By Weight : NIL End-Suction Top-Discharge Back

Pull-Out Type
Design Data

12. Maximum Size Of Solid : mm Top Suction-Top Discharge

13. Design Capacity : Refer Table-1 29. Flange drilling standard :

14. Minimum Suction Head : 0 Mlc ANSI B 16.5, 150#

15. Maximum Suction Head : Mlc 30. Flange Face : FF

16. minimum discharge head: 31.

17. Differential Head : Refer Table-1 32. Casing :CI IS 210 GR. FG 260

18.NPSH Available: Flooded Suction 33. Impeller : Bronze To Is 318 Gr 2

19.Design Code : IS:5120 (Refer Note- 34. Shaft :AISI 410 ASTM A 276
materials of construction

4)

20. Type Of Pump : : Refer Table-1 35. Shaft sleeve : ASTM A 276 GR.
410 hardended and tempered
Construction Features

36.Casing Ring : bronze to IS 318 GR 2

21.Impeller: open/semiopen/closed 37. Impeller Ring :NA

22. volute :As Per Mfr‟s Standard 38. Stuffing Box Packing :Graphite

Single / double / diffuser 39. Base plate : CS IS 2062 GR. A

23. Shaft : coupled / monoblock 40. Companion Flanges :For Size

24. Coupling : flexible/spacer 150 ASTMA 105; 150 IS 2062-

194
 1992
41. Companion flanges with nuts, 57.

spares and maintenance

Bolts, Gaskets : Yes/No 58.

tools and tacles

42. Common Base Plate : Yes/No 58.1
43. Foundation Bolts : Yes/No 58.2

44. Coupling : Yes/No 58.3

45. Coupling Guard With Bolts : Yes 58.4

46. Drip Tray : yes/no 59. Capacity :

47. lantern ring : yes/no + (-) nil refer table-1
3

performance guarantee
m /hr
48. Bearing temperature gauges :
Accessories

60. Differential head :

+ (-) nil refer table-1

yes/no mlc
49. Priming tank with accessories : 61.Power Consumption :
yes/no +NIL (-) (*)
kw
Capacity : M3 62. power consumption :
Cost Loading And Penalty

50. Foot Valve : Yes/No rs. /

kw
Size And Number : mm NB And 63.
51. Strainer: Yes/No 64.
52. Suction Pressure Gauge : Yes/No 65.
53. Discharge Pressure Gauge:Yes/No 66.
Tests And Inspection

54. motor starter : yes/no

55. Recommended Spares : yes/no (see note 1)

56.Painting : Epoxy / Synthetic 67. Hydrotest Duration :

enamel yes/no 68.

195
 TABLE-1

DETAIL OF PUMPS

SL. NO.
IN
DESCRIPTION UNITS PUMP-1 PUMP-2 PUMP-3
DATA
SHEET
Fire water main Fire water stand
Jockey pump
1.0 Designation pump by pump
[refer note-5]
[refer note-2] [refer note-2]
2.0 Tag Numbers - P-1 P-2 P-3

3.0 Number Required Nos. 1 1 1

4.0 Design Capacity M3/Hr 171 171 10.8

5.0 Differential Head Mwc 88 88 88

-- Maximum Speed Rpm 1500 1500 2900

End-Suction
End-Suction Top- End-Suction Top-
Top-Discharge
6.0 TYPE OF PUMP Discharge Back Discharge Back
Back Pull-Out
Pull-Out Type Pull-Out Type
Type
Drive Data/ Prim
7.0 Motor Diesel Engine Motor
Mover
NOTES
1. Additional tests indicated as 'B' in shops inspection requiremets shall also be carried out when it is
applicable.
2. pumps shall be capable of furnishing not less than 150% of the rated capacity at a head not less
than 65% of the rated head. the shut-off head shall not exceed 120%of the rated head
3. * value / capacity to be indicated by bidder
4. negative tolerance on capacity, head & efficiency is not acceptable.
5. for vertical inline jockey pumps moc shall be as follows:-
base/adaptor -grey cast iron, impeller / intermediate chamber -AISI-304, shaft-AISI-316
4.4.1.2. SCOPE
This specification covers the general design, materials, construction features,
manufacture, shop inspection and testing at manufacturer‟s works and delivery at site
of Horizontal Centrifugal Pumps.
4.4.1.3. CODES AND STANDARDS
The design, materials, construction, manufacture, inspection, testing and performance
of horizontal centrifugal pumps shall comply with all currently applicable statutes,
regulations and safety codes in the locality where the equipment is to be installed.
The equipment shall also conform to latest applicable Indian or equivalent standards.
Other international standards are also acceptable, if these are established to be equal

196
 or superior to the listed standards. Nothing in this specification shall be construed to
relieve the VENDOR of this responsibility.
4.4.1.4. DESIGN REQUIREMENTS
a) Pumps of a particular category shall be identical and shall be suitable for parallel
operation with equal load division. Components of identical pumps shall be inter-
changeable.
b) Flow rate versus head curve shall have stable and continuously rising
characteristics towards the shut-off head. In case of unstable (drooping)
characteristics the duty point shall be well away from the unstable region.
Besides the actual flow rate versus head curve, curves for minimum and
maximum impeller diameters shall also be shown.
c) The shut-off head shall be at least 110% of the differential head.
d) The required NPSH at duty point shall be at least one (1) metre less than the
available NPSH.
e) The rating of the pump driver shall be the larger of the following:
 The maximum power required by the pump from zero discharge to
run-out discharge at site climatic conditions.
 110% of the power required at the duty point at site climatic conditions.
f) The corrosion allowance for pressure parts shall be 3 mm.
g) Pumps shall run smooth without undue noise and vibration. Noise level produced
individually or collectively shall not exceed 85 dB (A) measured at a distance of
1.86 metres from the source in any direction. The overall vibration level shall be
as per zones A and B of ISO 10816-1
h) In case of fire water pumps, pumps and drivers with all the accessories shall meet
the requirements of Tariff Advisory Committee (TAC) or any other standard as
called for in data sheet A. Pump type shall be as accepted by TAC accredited
Agency.
4.4.1.5. CONSTRUCTION FEATURES
a) In addition to static balancing, impeller and balancing drum shall be balanced
dynamically at or near the operating speed.
b) Pump shall be provided with renewable type casing ring. Pump having capacity
1,000 M3/Hr and above shall be provided with impeller ring in addition to casing
ring. The hardness of impeller ring shall be 50 BHN higher than that of casing
ring.
c) Pump casing shall be provided with drain and vent connection with plugged or
valve connection.
d) Bearing shall be oil-lubricated or grease-lubricated and shall have a life of 40,000
hours of working. In case of oil-lubricated bearing, constant oil leveller with
magnetic drain plug shall be provided.
e) Replaceable shaft sleeves shall be provided to protect the shaft where it passes
through stuffing box.
197
 f) Stuffing box shall be of such design that it can be repacked without removing any
part other than the gland and lantern ring.
g) Mechanical seals shall be provided if called for in data sheet - A. If required, a
flushing line shall be furnished, complete with strainer and orifice, from the pump
discharge to the sealing face. When pumping liquid is not suitable for this
purpose, a flushing connection shall be provided so that it can be connected to an
external source. Auxiliary piping and plan shall be in accordance with appendix -
D of API 610.
h) The allowable loads on the pump nozzles shall be at least twice the values listed
in the relevant tables of API 610 without reference to any other criterion. The
base plate shall be designed to cater to the above increased loads.
i) In addition to accessories listed in data sheet A, any other accessories required for
safe and efficient operation of pump shall be provided.
j) All incidental piping and valves required for sealing, lubrication and cooling for
stuffing box packing and/or bearing of pump shall be furnished by the VENDOR.
k) Leakage from the pump shall be led to the nearest surface drain by OTHERS.
Pump VENDOR shall provide necessary arrangement like drip tray, base plate
drain connection etc.
l) All pumps, except for back-pull out type, shall be provided with flexible coupling.
Back-pull out type pumps shall be provided with spacer type coupling.
m) Coupling guard made of expanded metal and bolted to the base plate shall be
furnished for all coupled pumps.
n) In addition to accessories listed in data sheet A, any other accessories required for
safe and efficient operation of pump shall be provided.
o) All incidental piping and valves required for sealing, lubrication and cooling for
stuffing box packing and/or bearing of pump shall be furnished by the VENDOR.
p) Leakage from the pump shall be led to the nearest surface drain by OTHERS.
Pump VENDOR shall provide necessary arrangement like drip tray, base plate
drain connection etc.
4.4.1.6. TESTS AND INSPECTION
a) Hydrotest pressure on casing shall be 1.5 times maximum discharge head or twice
differential head whichever is higher. (Maximum discharge head = shut-off head
+ maximum suction head). Unless otherwise stated in data sheet A, the
hydrostatic tests on the casing shall be conducted for a minimum duration of 30
minutes.
b) The pumps shall be tested as per IS 5120, at rated speed at MANUFACTURER's
works to measure capacity, total head, efficiency and power. The negative
tolerance on efficiency shall be limited to 2.5% and not 5% as indicated in IS
5120. These tests shall form the basis for acceptance of pumps except for
vibration and noise. The pumps shall be tested over the range covering from shut-
off head to the maximum flow. The duration of the test shall be minimum one (1)
hour. Minimum five (5) readings approximately equidistant shall be taken for
plotting the performance curves.
198
 c) After installation, the pumps shall be subjected to testing at site also. If the site
performance is found not to meet the requirements regarding vibration and
noise as specified, the equipment shall be rectified or replaced by the
VENDOR, at no extra cost to the EMPLOYER.
4.4.1.7. PERFORMANCE GUARANTEE
a) Performance parameters to be guaranteed by the VENDOR and tolerances
permitted shall be as indicated in specification and/or data sheet A. BIDDER shall
confirm acceptance of these by indicating values in data sheet B. Pump or any
portion thereof is liable for rejection, if it fails to give any of the guaranteed
performance parameters.
4.4.2 DATA SHEETS FOR DIESEL ENGINE AND ACCESSORIES
4.4.2.1. DATA SHEET A

1.0 GENERAL
Make and model No.

2.0 Nos. Required 1

3.0 Mode of operation Continuous Duty

Type

4.0 Diesel engine type Radiator cooled

DESIGN DATA

5.0 Site Conditions

(a) Maximum ambient temperature C 37

(b) Relative humidity at maximum ambient % 80

temperature

(c) Altitude above mean seal level Meters 3 M above MSL

(d) Air temperature at the inlet of charge air C *

cooler

6.0 Design Fuel Oil

6.1 Designation High Speed Diesel

6.2 Standard IS 1460-2005

6.3 Maximum engine speed RPM To Suit Fire Pump

6.4 Type of drive between diesel engine and driven Direct/gear/belts/other

equipment s

6.5 Maximum noise level db ( A ) 85 at 1.0 M from

199
 Eqpt. Outline

6.6 Engine Air Data ( Primary) *

7.0 SECONDARY COOLING WATER Not Required

DATA

7.1 Designation

7.2 Pressure at EMPLOYER‟s terminal point Kg/cm2 (g

)

7.3 Temperature at EMPLOYER‟s terminal point C

(max.)

7.4 Total hardness ppm

7.5 Turbidity ppm

7.6 Chlorides (as CaCO3) ppm

8.0 Engine starting system

9.0 Period for taking load from start impulse Seconds

SCOPE OF SUPPLY

10.0 Diesel engine Yes

11.0 Driven equipment Yes

12.0 Control panel Yes

13.0 Fuel Oil system

13.1 Day tank Yes

13.2 Fan for Radiator Yes

13.3 Hand operated transfer pump No

13.4 Flexible hose on suction and discharge of hand No

operated transfer pump

13.5 AC motor driven priming pump with clock *

timer

13.6 *
Thermostatic heater

200
13.7 1 X 100 % Duplex filter or 2 x 100 % Simplex *
filters

13.8 *
Interconnecting fuel oil piping between engine,
duplex filters and day tank with necessary
valves, fittings and other specialities

13.9 Interconnecting piping from transfer pump to

day tanks and suction piping for transfer pumps
together with necessary valves, fittings and
other specialities.

14.0 Air cooled Radiator System

14.1 Engine driven circulating Fan Yes

14.2 Heat exchanger secondary cooling water cooled No

14.3 Air cooled radiator Yes

14.4 Complete jacket water interconnecting piping No

with valves, fittings etc.

14.5 Engine driven fan with guard Yes

14.6 Air duct No

15.0 Secondary Cooling Water System

15.1 Complete interconnecting raw water piping No

with valves, fittings and specialities

16.0 Engine Starting System - Electrical

16.1 Starter motor Yes

16.2 Starter battery and battery charger Yes(2×100%

batteries)

17.0 Engine Exhaust Gas System

17.1 Silencer Yes

201
17.2 Complete exhaust gas piping with lagging, Yes – To be led with
fittings, supports, expansion joints (i.e. bellows hood & bird mesh
) etc. outside Raw/Fire
water Pump house
building with min. 1
mtr. above the bldg.

18.0 Instrumentation as per write up Yes

19.0 Base frame for engine and driven equipment Yes

20.0 Holding down bolts and foundation bolts Yes

21.0 Coupling between engine and driven equipment Yes

22.0 Clutch between engine and driven equipment No

with engaging assembly

23.0 Coupling guard for coupling between engine No

and driven equipment

24.0 Painting at shop Yes

25.0 Maintenance tools and tackles for entire plant Yes

Construction Features

26.0 Fuel oil day tank capacity ( Cylindrical ) Min. 6 hrs of engine
rating

27.0 Air compressors Not applicable

28.0 Starting battery type Lead

acid/alkali/other/ not
applicable/ VRLA
maintenance free

29.0 Type of base frame for engine and drive Mild Steel
equipment

Tests

30.0 Shop testing of fully assembled engine Required

31.0 Final testing of complete diesel engine set plant Required/not required
at site prior to take over by the EMPLOYER

Codes And Standards & Start Up And Essential

Spares

32.0 ISO 3046

Refer note 1
202
 Notes:

1. The following spare parts which will be adequate to the requirement of one engine shall
be supplied with the engine (only one common set for the quantity of engines mentioned
in specifications):

a) Two sets of fuel filters, elements and seals.

b) Two sets of lubricating oil filters, elements and seals.

c) Two sets of belts (where used).

d) One complete set of engine-joints, gaskets and hoses,

e) Two injector nozzles.

f) One complete set of piston rings – for all cylinders of the engine.

g) One inlet valve and one exhaust valve.

2. Starter battery for manual and automatic start of engine (one for each) and one common
2- rate trickle charger & the same should be capable to charge two batteries
simultaneously. Battery capacity shall be adequate for ten consecutive starts without
recharging with a cold engine under full compression.

3. The capacity of the diesel engine shall be as per IS 12469 for fire water pumping
requirements. Necessary calculations along with pump curves shall be submitted to
establish the same.

4. * - Bidder to fill

5. Fuel Oil Day Tank capacity mentioned in cl. No. 3.2 of Data sheets document shall be
read as 6 hrs.
4.4.2.2. SCOPE

This specification covers the design, manufacture, construction features, erection

supervision, delivery to site, commissioning, and performance testing of diesel engine
along with accessories.
4.4.2.3. CODES & STANDARDS

The design, manufacture and performance of Diesel engine shall comply with all
currently applicable statutes, regulations and safety codes in the locality where the
Equipment will be installed. The equipment shall also conform to the latest
applicable Indian/British/USA / ISO Standards. Nothing in this specification shall be
construed to relieve the VENDOR of this responsibility. In particular, the equipment
shall conform to the latest editions of the standards followed.
4.4.2.4. DESIGN REQUIREMENTS

203
a) DIESEL ENGINE

 The diesel engine shall be radiator cooled and shall be furnished with at least
the minimum equipment according to standard practice. The power rating,
required auxiliaries, guarantees of fuel consumption, parallel operation,
governor performance and torsional vibration shall be in accordance with ISO:
3046.

 The engine shall be provided with an exhaust gas turbocharger having a

charge air cooler, integral intake air filter and silencer.

b) FUEL OIL SYSTEM

 An overhead „Day‟ tank of about 10hours rated capacity or capacity which

meets the Petroleum rules which ever is less shall be installed. The „Day‟ tank
shall be provided with a suitable electrical sensing device to signal „low‟ oil
level in the tank. A mechanical oil level indicator shall also be provided to
indicate low and high levels. This tank shall in particular, conform to the
requirements of IS:803 and API:650. A hand operated / motor operated
transfer fuel pump with hoses / piping and other accessories shall be provided
to transfer fuel oil to the day tank.

 Thermostatically controlled heaters shall be provided for heating the fuel oil,
if ambient conditions warrant the same.

c) LUBE OIL SYSTEM

 Automatic pressure lubrication shall be provided by engine driven gear type

pump. The system should be complete with an oil cooler and 1 x 100 %
duplex fine-mesh filters or through 2 x 100% capacity individual filters.
Differential pressure gauge across the filters or pressure gauges on either side
of the filters shall be provided to monitor the cleanliness of the filters.

 The oil cooler shall be either air or water cooled and shall be equipped with
the necessary bypass to bypass the cooler during start up until the oil
temperature reaches the pre requisite value.

 Thermostatically controlled heaters shall be provided for heating the lube oil,
if ambient conditions warrant the same.

 A DC motor driven standby lube oil pump shall be provided, if specified, to

supply lube oil to the engine and turbo-charger on failure of the engine driven
oil pump and/or during coasting down period of the engine.

 An AC motor driven intermittent operation pre lube oil pump shall be

provided. This pump in conjunction with a suitable clock timer shall supply
204
 lube oil intermittently to the engine when the engine is not in operation to
keep the system primed with lube oil for remote and quick starting at any
instant. A suitable pressure relieve valve protective device shall also be
provided.

 For the charge air cooler and lube oil cooler, the air flow to the charge-air
cooler shall be thermostatically controlled.

d) ENGINE STARTING SYSTEM

 Starting of the diesel engine shall be either by compressed air or by electric

starting system as specified in Data Sheet-A.

 Electric Starting System

 The electric starting system shall comprise of starter motor, starter batteries
and battery charger and all the required instruments and accessories. If
automatic starting is specified in Data Sheet, facility shall also be provided for
manual starting of the engine. Necessary auto / manual selector switch shall
be provided on the diesel engine control panel. Suitable hydro meter shall be
provided for testing the specific gravity of the battery electrolyte. A voltmeter
should be provided and installed so that the voltage of the batteries may be
ascertained.

e) AIR INTAKE AND EXHAUST SYSTEM

 The VENDOR shall provide an air intake filter and silencer (if required). Air
will be taken from the diesel engine room.

 The exhaust shall consist of an exhaust driven turbocharger with lagged

piping interconnecting cylinder head outlets with the turbocharger inlet.
Exhaust manifold shall be of fabricated steel and it shall be suitably lagged.
Exhaust gas from the turbocharger shall be led through an exhaust gas
silencer. The exhaust gas silencer, necessary pipes, adapters, etc. shall be
provided by the VENDOR

 The exhaust gas pipe shall be led to the atmosphere at a minimum of 3 meters
above the building where the diesel engine is installed. The exhaust pipe shall
be insulted for personal protection upto a safe height.

f) GOVERNING SYSTEM

 The governor shall be Woodward type EGB-10 or approved equal. The

governor characteristics shall comply with the requirements of „Class A 1-
governing‟ of ISO 3046.

205
  The governor shall have the following features :

 The governor shall be provided with an electrically operated speeder gear for
remote adjustment of generator frequency, suitable for operation on DC
voltage indicated in Data Sheet-A.

 An overspeed trip mechanism shall be provided to automatically shut off fuel

in case the set speed reaches about 110% of rated speed. The values at which
the mechanism trips the engine shall be adjustable.

 An engine mounted emergency stop push button shall be provided which,

when operated will trip the engine.

g) CONTROL SYSTEM FOR DIESEL ENGINE

 Unless otherwise specified in Data Sheet-A, tripping of the diesel set for a
normal shut down will be done manually, by means of push buttons.

 It should be possible to shut down the diesel engine either through the local
push button on the diesel control panel or through the remote push button. The
trip impulse should directly go to the engine shut down device without
passing through the local/remote selector switch.

 The diesel engine shall be tripped automatically under the following abnormal
conditions :

 Over speed of diesel engine set as sensed by over speed trip device.

 Low lubricating oil pressure after engine has attained 90% speed.

 Incomplete start after a preset time

 DC control supply failure

 Emergency stop

 Generator fault

 Any other tripping condition required for the safe operation of the engine.

h) CONTROL PANELS

 Suitable control panel comprising of necessary auxiliary relays, pushbuttons,

DC voltmeters, DC ammeters, DC motor starter, control switches, etc. with
complete panel internal wiring shall be provided by the VENDOR. Once the
start push button is pressed or starting impulse is given (in the case of
automatic starting), complete starting sequence shall be automatically

206
 disengage and stop after the engine picks up speed. When the engine stops all
the controls shall automatically be reset to its normal starting operation.

 Annunciators shall be supplied by the VENDOR and mounted on each diesel

control panel to give visual and audible indication for the following
conditions.

 High lubricating oil temperature

 Low lubricating oil pressure and trip of the engine.

 Fuel oil day tank level low

 Engine overspeed and trip

 Failure to start

 Standby lube oil pump in operation (if provided)

 Lubricating oil priming pump (if provided) in operation

 Fuel oil priming pump(if provided) in operation

 Low DC voltage

 Starting air pressure low (alternatively, if provided)

 DC control supply failure

 Four (4) Nos. spare windows shall be provided

 Each annunciator system shall be provided with :

 One push button for acknowledging the audible alarm(visual indication shall
persist)

 One push button for resetting the visual indication after the fault has been
cleared.

 One push button for testing the illuminated transparencies.

 On the occurrence of a fault the audible alarm shall sound and the appropriate
window shall light up. The audible alarm will be silenced by pressing the
„acknowledge‟ push button. The visual indication shall, however, persist until
the relevant fault contact has reset after which the visual indication can be
reset by the „rest‟ push button.

 After acknowledgement of one trouble by the „acknowledge‟ push button, the

alarm circuit shall be ready to operate for another fault.
207
  The VENDOR shall provide all the sensing devices at the diesel engine for the
above alarms and accessory relays at the control panel. These shall be
suitable for operation on ungrounded DC system. The DC supply will be
made available at the control panel by the EMPLOYER. Suitable name plates
shall be provided for each window.

i) MOTORS

Drive motors shall conform to the companion specification data sheets of low voltage
induction motor.

j) POWER AND CONTROL CABLES

The VENDOR shall include in his scope of supply all auxiliary wiring between the
diesel engine and control panels.

k) INSTRUMENTS FOR ENGINE

The following instrumentation shall be provided:

Dial type thermometers shall be provided as follows :

 Lube oil outlet temperature from bearing.

 Lube oil temperature at lube oil cooler inlet/outlet

 Pressure gauges shall be provided as follows :

 At the discharge of all auxiliary pumps provided with the diesel engine.

 At the lube oil cooler outlet

 On air receiver

Differential pressure gauges across lube oil and fuel oil filters or separate pressure
gauges on either side of the filter.

Pressure switches shall be provided for automatic starting of the DC motor driven
standby lube oil pump on low lube oil pressure.

Pressure switches shall be provided for lube oil system to give on alarm if the
pressure falls below a preset value and subsequently trip the unit when the minimum
safe pressure limit has been reached.

A thermostat shall be provided at the lube oil outlet from engine bearing for alarm on
high oil temperature.

Tachogenerator Primary sensing devices, control valves, controller etc. for :

208
  Lube oil temperature and pressure

 Fuel oil day tank low level

Leads from all the sensing devices and instruments to which the EMPLOYER‟s
cables (from the engine to the diesel control panel) will be connected shall be neatly
brought to terminal blocks.

The terminal block shall be properly identified.

l) PIPING, VALVES AND FITTINGS

All necessary interconnecting piping, valves and fittings, supports, filters and
strainers shall be provided for lube oil, fuel oil and starting air systems. Terminal
points shall be as indicated in specifications. The piping shall be designed, fabricated
and tested in accordance with ANSI. B 31.1- Pressure piping code or approved
equivalent.
4.4.2.5. ITEMS OF GUARANTEED PERFORMANCE

The following items of performance shall be guaranteed by the VENDOR in respect

of the diesel engine units and the auxiliaries, when operating under the specified site
conditions.

 Net electrical output at engine shaft

 Fuel oil consumption at full load

 Lubricating oil consumption at full load

 10% overload for one hour without overheating or showing signs of undue
stress and within specified frequency variation.

 Vibration and noise levels

 Governor response, overspeed trip and overspeed capability.

The VENDOR shall indicate the standards according to which tolerances on the
performance figures will be applicable.
4.4.2.6. SHOP TESTS

The VENDOR shall perform all the following shop tests to ensure that the equipment
conforms to the specifications and meets the performance guarantees.

a) Tests on the diesel engine shall include, but not be limited to, the following :

 One (1) hour at 50 % load

 One (1) hour at 75 % load

209
  Four (4) hours at full load followed by one (1) hour continuous load of 110%.

 Specific fuel oil consumption measurement at various loads.

 Vibration levels

 Noise levels

b) The Vendor shall perform hydraulic tests at 1.5 times the design pressure on all
pressure parts.

c) Readings shall be recorded at intervals of 15 minutes during the test period of diesel
engine. The Vendor shall provide necessary calibrated instruments for the
measurement of pressures, temperatures and flow of fuel oil, lubricating oil, jacket
water etc, The tests shall be performed in accordance with ISO 3046.

d) The VENDOR shall clearly indicate if he is not in a position to carry out any of the
above tests.

e) Copies of the test certificates and record of tests shall be submitted to the
EMPLOYER for approval.

f) In the event, the VENDOR cannot perform any or all of the tests mentioned above or
the EMPLOYER cannot witness such shop tests if performed by the VENDOR, the
VENDOR shall perform all the tests mentioned above at the site subject to
EMPLOYER‟S acceptance after installation and during commissioning.
4.4.2.7. PAINTING

a) Machined and finished surfaces shall be protected against formation of rust and
corrosion by application of suitable rust inhibitors.

b) All steel surfaces which are to be painted shall be thoroughly cleaned, degreased and
given one shop coat of primer, prior to assembly.

c) All castings shall be sand blasted, degreased and cleaned before painting.
4.4.2.8. COMMISSIONING

The VENDOR shall perform the following tests at site, but not limited to the
following to the satisfaction of the EMPLOYER :

210
 a) Specific Fuel Oil Consumption test

b) Lube Oil Consumption test

c) Vibration

d) Noise level

e) Automatic starting up

f) Governor response

4.4.3 DATA SHEET FOR HYDRANT VALVE

DATA SHEET A
17. Hand wheel: cs as per is 1030 or
1. Type: Single headed-63 mm size conf
CI
to IS 5290 type a with / without as per IS 210
stand post of 80 mm nb 18. Seat washer:
2. Type: double headed- conf to is:5290 rubber as per IS 937 or leather
type b / two valves as above as per is 581
19. Gland packing: asbestos free
3. Lug type: pull out / twist
thread
4. Flange drilling standard: ANSI as per IS 4687 /
Materials of construction (contd.)

B16.5 / is:_ _ _ _ / 20. Spring: phosphor bronze wire

General

5. Companion flange at stand post as per is 7608 for cu alloy hydrant

required: yes/no Valve or SS wire as per IS 6528 for
6. Size: 63 mm al alloy/ SS hydrant valve
7. Scope includes stand post - yes/no 21. Blank cap: ABS plastics
8. Standpost size: 80 mm/ 100 mm 22. Stand post: same as firewater pipe
9. Water: ordinary/ sea water 23. Companion flange at stand post:
10. Hydrant valve shall bear ISI mark Astm a 105
11. 24.
12. 25.
13. 26.
14. Valve body, bonnet, stop valve, 27.
construction
Materials of

Checknut and instantaneous female 28.

Outlet 29.
14.1 leaded tin bronze as per gr ltb2 30.
ntin
Pai

of is 318 or 31. Valve top except face of flange

g

211
 14.2 al alloy as per designation and instantaneous outlet:
PO FIRE RED, shade no. 536 of
4225, 4450, 4600 of is 617 or
IS 5
14.3 SS as per grade 1/4 of IS 3444 32. Hand wheel: black as per IS 2932

Spares and maintenance

15. Valve spindle: brass rod as per is 33.

tools and tackles

319 or is 320 for body of leaded tin 34.
bronze or SS as per IS 6603 for body 34.1
of al or ss 34.2

16. 34.3

35. Test pressure for: 41.

2
35.1 Water tightness: 14 kg/cm g 42.
2
35.2 Valve body and gland: 21 kg/cm g 43.

Approved sub-vendors
36. Flow test: 900 lpm @ 7.0 kg/cm2g 44.
Tests and inspection

37. As per shop inspection and testsand/or 45.

46.
as per specification and tac regulations 47.
(note 1) 48.
38. 49.
39. 60.
40. 51.

Note
1. Additional tests indicated as 'b' in shops inpection requiremets shall also be carried out when
it is applicable.
2. Hydrant valve shall be ISI marked.

4.4.4 DATA SHEET FOR BRANCH PIPES AND NOZZLES

DATA SHEET A
Spares and maintenance

1. Standard: IS 903 13.

tools and tackles
General

2. 14.
3. 14.1
4. 14.2
Materia

constru

5.1 cu alloy as per sand castings: 14.3

ction
ls of

Gr ltb2 of is 318 or gr htb1 of is 304 14.4

212
 Die casting: gr 3 of is 292 14.5
Hot forgings: is 291 15. Test pressure: 21 kg/cm2g
16. As per shop inspection and

Tests and inspection

Gravity die castings: is 1264
tests
- or -
5.2 al alloy as per die castings:
Designations 4450, 4600 of is 617 17.
-or- 18.
5.3 SS as per grade 1 - or- 4 of IS 3444 19.
20.
6. Washer: type b of IS 937 21.

Approved sub-vendors
7. Nozzle spanner: gr 35c4 or 40c8 of 22.
IS 1570 (Part 2/Section 1) – with 23.
Plating of chromium or zinc 24.
9. Branch pipe inlet size: 63 mm 25.
Dimensions

10. Nozzle bore: 20 / 25 / 30 26.

11. 27.
12. 28.
Notes
1. The branch pipe with nozzle shall be isi marked.

4.4.5 DATA SHEET FOR FIRE HOSES WITH COUPLING

DATA SHEET A
1. Hose:IS 636 -type a or type b or is:8423 7. Diameter: 63 mm
is: 14933 - type a or type b or is:4927 8. Length for: (type of hydrant)
Dimensions

8.1 (internal / fire escape): 7.5 m /15

Standards

2. Delivery coupling:
m (note 2)
instantaneous spring lock type 8.2 (external hydrant): 15 m
as per IS 903 (note 1) 9.
3. 10.
4. Hose: controlled percolating fire hose
Spares

11.
construction
Materials of

pipe
5. Delivery couplings: 11.1
5.1 cu alloy as per sand castings: 11.2
213
 gr ltb2 of is 318 or gr htb1 of is 304 11.3
die castings: gr 3 of is 292 11.4
12. Hose proof pressure: 21.4 or 35
hot forgings: dcb 1 of is 291
kg/cm2(g)

Tests and inspection

13. Hose burst. Pressure: 35.7 or 50
gravity die castings: is 1264
kg/cm2(g)
14. Coupling hydrotest: 21
- or -
kg/cm2(g)
15. As per shop inspection and tests
5.2 al alloy as per die castings:
and/or
is designations of 4450, 4600 of is 617
and TAC guidelines (see note 3)

Approved sub-
- or - 16.

vendors
5.3 SS as per IS 3444 grade 1 / grade 4 17.
18.
6. 19.
Notes
1. Each hose shall have one male half coupling at one end and one female half coupling
at the other end. The couplings shall be joined with hosepipe as per the procedure
detailed in tac fire protection manual.
2. For tg hall, boiler house and mill bays of a power plant and basements 15 m long hoses
shall be used.
3. The fire hose as well as coupling shall be isi marked.
4. Additional tests indicated as 'B' in shops inspection requirements shall also be carried
out when it is applicable.
.

4.4.6 DATA SHEET FOR FIRE HOSES CABINETS

DATA SHEET A1
1. wall / floor mounted hose Support legs complete with
Construction features (contd.)

Cabinets suitable for 2 nos.63 mm Foundation bolts, nuts etc.:

Dia x 15 m / 7.5 m long hoses and Yes / no
Accessories : (note 1,2) 12. Painting for gi crca moc: (note 10)
General

( refer data sheet A2 ) 12.1 External (spray paint):

2. Wall / floor mounted hose A. One coat of red oxide primer
Cabinets suitable for 2 nos.63 mm B. Two coats of synthetic enamel
Diax15 m / 7.5 m long hoses,
Finesh paint PO RED shade 538 as
accessories

214
 And hose reel as per is 884 : per IS-5.
Size: _____ h x ______ w x _____
12.2 Internal (spray paint):
d in mm.
(note 1, 2) a. One coat of red oxide primer
3. Special hose cabinet:- B. Two coats of synthetic enamel
finesh paint. Shade white
13.
size: _____ h x ______ w x 14.

Spares & maintenance

_____ d in mm.

tools & tackles

(note 1, 2) 14.1

4. canopy required: yes / no

( also see note-3)
5.

As per shop inspection and tests and /

6. Material of construction of 15.
or
Tests and inspection

Cabinet body : frp / GI CRCA

IS 277 & base metal conforming (note 11)
To IS 513 16.
7. Thickness of body if material of 17.
Construction features

Construction is GI CRCA : 16/18/20

18.
SWG
Grade of zinc coating 200 as per IS
19.
sub-vendors

277
8. Thickness of glass panel: 3mm 20.
Hammer with chain: 1 set chrome
9. 21.
plated
10. Lock with duplicate set of keys 22.
Approved

For each cabinet:

23.
yes
11. Mounting clamps, structural 24.
Notes

1. Following accessories shall be made available inside the hose box after installation at site
a. 2 nos. 63 mm dia x 15 m / 7.5m long hoses with coupling
b. 1 no. Branch pipe
c. 1 no. Nozzle
d. 1 no. Nozzle spanner

215
2. Floor mounted hose cabinets shall be provided with minimum 1 m high structural support
legs.

3. Canopy is required for hose cabinets to be located outdoors.

4. Scope of supply with hose cabinets shall not include hoses, hose reels, branch pipes and
nozzles.

5. The word “FIRE”, in 150 mm letter size in red, shall be painted on the cabinet glass.

6. The cabinet shall be provided with clamps for holding branch pipe, nozzle and hose reel
where applicable.

7. Provision to keep one key and one hammer in glass covered recess on the side of the
cabinet shall be made.

8. The cabinet shall be supplied with a small container having a set of spare rubber rings
packed in french chalk.

9. Making of pockets in the wall, grouting of bolts, finishing the wall as before, and
mounting of cabinets on to the wall or the structural supports shall be in contractor‟s
scope.

10. Colour shade scheme for FRP hose box shall be same as that mentioned for GI CRCA
MOC – however the colour shall be uv resistant fade proof integral type suitable for
external atmosphere.

11. Additional tests indicated as 'b' in shops inpection requiremets shall also be carried out
when it is applicable.

216
1.1.2. DATA SHEET A2

4.4.7 DATA SHEET FOR FIRE HOSES REELS

DATA SHEET A
1. Standards: 11. Pipe with fittings: ms as per
Contd.

IS 1239 (part 1 and part 2) or ss

1.1 Hose reel : IS 884 or bs-en 671-1
General

304
on features
Constructi

1.2 Nozzle : IS 8090 or bs-en 671-1 12. Hose length : 30 m

Stop valve : as per IS 778 or ball
1.3 13. Hose id : 19/32 mm
valve
217
 As per bs 5159 15. Nozzle id : 6.35 mm maximum
2. Type : swinging (180o) wall 16.
Mounting / suitable for 17.

Spares and maintenance tools and

Mounting in hose cabinet 18.
18.
3. Hose reel connected to
1

tackles
18.
Permanent water supply: yes
2
Flow through nozzle : minimum 18.
4.
24 lpm 3
Hub : al alloy conforming to a-8 18.
5.
wp of 4
Is 617 or CS sheet as per IS 513 or 19
Hydrostatic pressure 21 kg/cm2
al .
Sheet as per is 737 or galvanised
Or 18 kg/ cm2 for 5 minutes.
steel
20 As per shop inspection and
Tests and inspection

Or glass filled polypropylene

. testsand/
Sides: CS sheet as per IS 513 or al
6.
sheet
As per is 737 or al alloy
Materials of constrution

And tac guidelines.

conforming
To a-8 wp of is 617 or carbon steel
Polyester powder coated
7. Wall bracket: CS as per IS 513
Or ci as per is 210
21
8. Swivel joint : Leaded Tin
.
22
Approved subvendors

Bronze gr ltb2 of IS 318

.
Hose reel tubing : Reinforced 23
9.
Rubber .
24
As per IS 444 or EN - 694
.
25
10. Nozzle: gunmetal or nylon or
.
Acrolonitrile butadiene styrene (abs)

218
4.4.8 DATA SHEETS FOR PORTABLE FIRE EXTINGUISHERS
DATA SHEET A
Quantity (As per BOQ)

Spare refills

Remarks
Type

Sl. Tac guide Floo Wal Colou Trolle

Capacity Standard
No. lines r l mn y
Mounted
1.

Total
water bucket
Sand/

9 lit Yes

2.1 2.0 kg IS 15683 Yes/no

2.2 3.0 kg Yes/no
2.3 4.5 kg IS 15683 Yes
Carbon dioxide

2.4 6.5 kg Yes/no

2.5 9.0 kg Yes/no
2.6 22.5 kg Yes/no
2.7 6 to 7 kg  2
Yes/no
nos.
2.8
2.9
3.1 9.0 lit Yes --
3.2 50.0 lit Yes/no -- -- --
3.3 150.0 lit Yes/no -- -- --
Chemical foam

3.4
3.5
3.6
3.7
3.8
3.9

4.1 9.0 lit IS 15683 Yes

Mechanical foam

4.2 135.0 lit IS 14951 Yes/no

4.3
4.4
4.5

219
 Quantity (As per BOQ)

Spare refills

Remarks
Sl. Type Tac guide Floo Wal Colou Trolle
Capacity Standard
No. lines r l mn y
Mounted
4.6

Total
4.7
4.8
5.1 9.0 lit Yes/no --
Soda acid

5.2 50.0 lit Yes/no -- -- --

5.3
5.4

6.1 0.5 kg Yes/no --

Abc type dry chemical powder with map-90 powder

6.2 1.0 kg Yes/no --

6.3 2.0 kg Yes/no --
6.4 6.0 kg IS 15683 Yes --
6.5 9.0 kg IS 15683 Yes --
6.6 1.0 kg Yes/no --
6.7 2.0 kg Yes/no --
6.8 5.0 kg Yes/no --
6.9 10.0 kg Yes/no --
6.10 25.0 kg IS 10658 Yes -- -- --
6.11 50.0 kg Yes/no -- -- --
612 75.0 kg Yes/no -- -- --
6.13
6.14
7.1 1.25 kg IS 11108 Yes/no -- --
7.2 2.5 kg IS 11108 Yes/no -- --
7.3 4.0 kg IS 11108 Yes/no -- --
Halon 1211

7.4 5.0 kg IS 11108 Yes/no -- --

7.5 6.5 kg IS 11108 Yes/no -- --
7.6
7.7
7.8
7.9

220
 Quantity (As per BOQ)

Spare refills

Remarks
Sl. Type Tac guide Floo Wal Colou Trolle
Capacity Standard
No. lines r l mn y
Mounted
8.1 9.0 lit IS 15683 Yes --

Total
(gas cartridge)

8.2
Water

8.3
8.4
8.5
Spares and maintenance tools and

9. 11.
10. 12.

Approved sub-vendors
10.1 13.
tackles

10.2 14.
10.3 15.
10.4 16.
10.5 17.
10.6 18.
notes
1. All items conforming to is shall be isi marked.
2. Tests and inspection shall be as per shop inspection and testsand/ applicable indian standards and tac
regulations. Additional tests indicated as 'b' in shops inpection requiremets shall also be carried out
when it is applicable.

3. Mounting clamps and structural support legs complete with nuts and bolts etc. Shall be provided by
the vendor for floor, wall and column mounted portable fire extingushers.

4.4.9 VALVES AND SPECIALITIES GENERAL REQUIREMENTS

4.4.9.1. SCOPE

The following paragraphs describe general requirements for valves and specialities. Only the
applicable paragraphs for the type of valve or speciality are to be considered along with data
sheet-A. These apply unless specified otherwise in data sheet-A.
4.4.9.2. CODES AND STANDARDS

Valves and specialities shall be generally as per the following standards:

ANSI B16.1 : Cast Iron Valve Ratings

221
 ASME B16.34 : Ratings of Valves-Flanged, Threaded and Welding Ends

API 594 : Wafer and Wafer - Lug Check Valves

API 600 : Steel Flanged and Butt Welding End Gate Valves

API 602 : Steel Gate Valves, Threaded and Socket Welding Ends

API 609 : Butterfly Valves

BS 1414 : Steel Gate Valves, Flanged and Butt Welding Ends

BS 1868 : Steel Check Valves, Flanged and Butt Welding Ends

BS 1873 : Steel Globe Valves, Flanged and Butt Welding Ends

BS 5156 : Diaphragm Valves

BS 5351 : Steel Ball Valves

BS 5352 : Steel Gate, Globe and Check Valves, 50 mm and Smaller

IS 778 : Bronze Valves

MSS-SP 67 : Butterfly Valves

4.4.9.3. GEAR OPERATORS

Gear operators shall be provided on the following basis:

222
4.4.9.4. GATE AND GLOBE VALVES

Up to and including ANSI 300 class - 350 mm and larger

600 class and higher - 200 mm and larger

4.4.9.5. OTHER VALVES

Plug and ball - 150 mm and larger

Butterfly - 200 mm and larger

Gear operators shall be suitable for a differential pressure corresponding to the

maximum valve rating at room temperature.

All gear operators shall be of the enclosed type.

4.4.9.6. INTEGRAL BYPASS

Gate valves shall be provided with integral bypass valve, as per MSS-SP 45, as
follows:

Classes 150 and 300 - 350 mm and larger

Class 600 and higher - 200 mm and larger

Type of bypass valve shall generally be the same as the main valve. Bypass pipe shall
be at least schedule 80 and material of construction of bypass valve and pipe shall be
compatible with the main valve.
4.4.9.7. VALVE STEMS

Valve stems shall be of wrought materials. Castings are not acceptable.

4.4.9.8. BACKSEAT

All gate, globe and piston valves shall be provided with back seating arrangement to
facilitate replacement of gland packing with the valve in service.
4.4.9.9. CHECK VALVES

Check valves of sizes 350 mm and larger shall be provided with features to prevent
slamming and hammering. These can be in the form of springs or external dash pot.
4.4.9.10. HARDNESS
13% chromium steel seat surfaces shall have a minimum hardness of 250 BHN and a
differential hardness of 50 BHN.
4.4.9.11. NAME PLATES
The details on name plates shall be as per MSS-SP 25.
4.4.9.12. TAG PLATES
223
 Tag plates shall be of stainless steel type 304 or aluminium.
4.4.9.13. TESTING
Strength and leak tests shall be as per any of the standards MSS-SP-61, API 598 or
BS EN 12266-1 and 2 at the test pressures indicated in data sheet-A. Stainless steel
valves shall be tested using potable water.
4.4.9.14. NDT REQUIREMENTS
All cast steel valves shall be subject to radiography in all accessible areas, as defined
in ASME B16.34, on the following basis:

(a) Class 600 and higher - All sizes

(b) Class 300 - Sizes 450 mm and larger

(c) Class 150 - Sizes 600 mm and larger

All cast steel valves of class 600 and higher shall also be subject to magnetic particle
or liquid penetrant examination as per ASME B16.34.

All cast steel valves of class 300 shall have radiography quality castings irrespective
of size.

Acceptable levels of defects shall be as per ASME B16.34.

4.4.9.15. FACE-TO-FACE OR END-TO-END DIMENSIONS
Face-to-face dimensions of flanged-end valves and end-to-end dimensions of butt
welding-end valves shall be as per ASME B16.10.

For valves not covered by ASME B16.10, the dimensions shall be as per applicable
valve standards.
4.4.9.16. PREPARATION FOR DESPATCH
COATING

All carbon steel and cast iron exposed surfaces shall be given one coat of primer and
two coats of aluminium finish paint after release has been given for painting and
before despatch. Machined surfaces shall be coated with an easily removable rust
protective except that this is not applicable for austenitic stainless steel components.

END PROTECTION

After completion of the requirements of para 14.1, body end ports, flange faces and
welding ends shall be covered with suitable close fitting protectors to protect the
machined ends and prevent ingress of dirt and moisture.

DISC
224
 The disc shall be closed before despatch except in the case of soft-seated valves
where the disc shall be backed off to relieve the pressure on the seal.

PACKING

Valves and specialities shall be so packed as to minimise the possibility of damage

during storage or transit. The packing shall be suitable for tropical conditions.

4.4.9.17. DATA SHEET-A (GATE VALVE)

1. Tag no.: Later Quantity (As per
Size
2. Size range:  50 NB BOQ)
General

3. Rating: PN 1.6
4. Grade: CT Mm P0 R0 R1 R2
5. Fluid : Fire water
8. Stem : rising- outside screw & yoke
Ends : Flanged, FF SERR conc. Finish as per
9.
ANSI B 16.5
11
bonnet : bolted
Construction features

.
12
wedge : solid
.
13
operator : handwheel
.
14
seat : body -renewable
.
: wedge-integral
15
Other requirements :
.
Conforming to IS 14846

16 Cast iron to IS: 210 GR. FG

Body/ bonnet :
. 260
17 Cast iron to IS: 210 GR. FG
Wedge :
. 260
18 13 % CR steel as per IS
Stem :
. 6603
19 Gun metal as per IS 318 ltb
Materials

Body seat ring :

. 2
20 Gun metal as per IS 318 ltb
Wedge facing ring :
. 2
21
Gland packing : Jute & hemp
.
22
Gasket : Rubber as per IS 638 type b
.
23
Bolts & nuts : Cs as per IS 1363 cl 4.6 / 4.0
.
225
 24 Cast iron to IS: 210 gr. Fg
handwheel :
. 260
25 Kg/ sq. Cm. Duration 5
Shell hydro : 24
Tests & inspection
. mins.
26 Kg/ sq. Cm. Duration 2
Seat hydro : 16
. mins.
27
.
28 Inspection :as per shop inspection and tests.
.
Notes: 1. General requirements: as per valves and specialities general requirements
2. Additional tests indicated as 'B' in shops inpection requiremets shall also be carried
out when it is applicable.

4.4.9.18. DATA SHEET-A (WAFER CHECK VALVES)

1 4. Fluid : fresh
Tag no. :
. water Quantity(As per
Size
2 BOQ)
Size range :  50 NB 5. Des. Pr. :*
General

.
3
Rating : PN 1.6 6. Des. Temp. : ambient
. R R
Mm P0 R0
7 1 2
Standard : API 594 Grade: CT
.
8
Type : Dual plate, spring-loaded
.
9
Ends : Wafer to suit ANSI 150 Class
.
Flanges, RF, SERR. Finish
10
Construction features

.
11
.
12
.
13
.
14
Other requirements :
.

15
Body : CI, IS 210 GR. FG 260
.
Materials

16
Plate : Carbon steel
.
17
Seal : Nitrile
.
226
 18
Plate seat : Mfr‟s standard
.
19
Spring : Spring steel
.
20
Hinge pin & stop pin : SS 304
.
21
.
24
Shell hydro : 24 Barg
.
Tests & inspection

25
Seat hydro : 16 Barg
.
26 Inspection :
.

Notes: 1. General requirements: as per valves and specialities general requirements

2. Additional tests indicated as 'B' in shops inpection requiremets shall also be carried
out when it is applicable.

4.4.9.19. DATA SHEET-A (BALL VALVES)

1. Tag no. : -- Quantity (As per
Size
General

2. Size range : < 40 NB BOQ)

3. Rating : 800 class R R
Mm P0 R1
4. Grade : -- 0 2
5. Port : std port
6. Stem : --
7. Ends : Screwed
8. Operation :  100 mm (4" ) - lever
Construction features

9. Antistatic feature : Not required

10
fire safe design (API 607) : Not required
.
11
other requirements : Two piece construction
.

Size, (in/ mm)

:
Ins. Thk., mm
:
12
Material

Body : ASTM A 105

.
s

13
Ball (mirror finished) : SS 304
.

227
 14
Stem : SS 304
.
15
Seat : --
.
16
Seal (stem & body) : -do-
.
17 ASTM A 193 GR. B7/
Bolts, studs & nuts :
. ASTM A 194 GR. 2H
18
.
19
Shell hydro : 25 Barg
Tests & inspection

.
20
Seat hydro : 16 Barg
.
21
Seat air : 6 Barg
.
22 Inspection :as per shop inspection and testsand if applicable
.

Notes: 1. General requirements: as per valves and specialities general requirements

2. Additional tests indicated as 'B' in shops inpection requiremets shall also be carried out
when it is applicable.

4.4.9.20. DATA SHEET-A (Y STRAINER)

1. Tag no. Later
2. Quantity required As per BOQ
3. Location As per P & ID
4. Type Y type
5. Fluid Fire water
6. Flow rate m3/hr As per detailed engineering
7. Operating pressure barg 11
8. Operating temperature  c Ambient
9. Design pressure barg 16
10. Design temperature c 50
Design data

11. Fluid viscosity (cp) at op.temp. 1

12. Fluid sp. Gravity at op. Temp. 1
13. Max. Permissible pr. Drop 0.5 bar(g) – for strainers on pump suction line
Under 50% clogged condition 1 bar(g) – for strainers on other locations
14. Screen basket data *
1. Dia of perforations, mm *
2. Min. Thickness, mm *
3. Free straining area Four times pipe cross sectional area min
15. Steam jacket No
1. Inlet pr. Barg, op. / desn. -
2. Inlet temp.  c, op./desn. -
16. End connections RF
1. Size, NB mm As per drawings
2. Type Flanged
228
 3. Details/ standards ANSI B 16.5,150 #
17. Cover Bolted
18. IBR approval No
19. Body Is:2062/IS:1239(pt-1)/IS:3589
20. Cover IS:2062
21. Screen basket SS 304
Materials

22. Bolts/ studs ASTM A 193 B7

23. Nuts ASTM A 194 2H
24. Gaskets ARAMID FIBRE
25. Jacket NA
26. Jacket couplings/ flanges NA
27. Accessories by vendor:
27.1Foundation bolts No
27.2Differential pressure gauge No
27.3Drain/ vent cock (ss 316) Yes
ests & inspection

27.4Support legs No
26. Hydrostatic test pressure, barg
26.1Shell side 1.5 x design press.
26.2Jacket side Not applicable
27. Vacuum test required No
28. Pressure drop test required
Clean/ 50% clogged Yes
29. Inspection: as per a) shop inspection and testsand

30.
Notes: 1. General requirements: as per valves and specialities general requirements
2. Additional tests indicated as 'b' in shops inpection requiremets shall also be carried
out when it is applicable.

3. '*‟: Bidder to furnish information.

4.4.9.21. DATA SHEET-A (BUTTERFLY VALVE)

Sl.
Item Unit
No.
1.0 General
1.1. Service Fire Protection
1.2. Tag nos. -
1.3. No. Of valves No. As Per BOQ
1.4. Design standard IS 13095/BS5155
1.5. Valve category -
1.6. Disc Concentric / offset -double / triple
1.7. Body type Lug / wafer / flanged-short / long
229
Sl.
Item Unit
No.
pattern
1.8. Valve size NB As per BOQ
1.9. Valve rating / class PN 16
1.10. Fluid handled with its spec. Gravity Water – 1.0
1.11. Companion flange type and class Class 125/ 150

 Manual-lever / gear/handwheel
1.12. Type of valve operator / chain wheel / electric / pneumatic /
hydraulic /

Maximum flow (indicate the related M3/hr,

1.13. pressure also) Kpa
1.14. Maximum flow velocity M/s 3.0
1.15. Design pressure Bar
1.16. Operating pressure Bar
0
1.17. Design temperature c
0
1.18. Operating temperature c 4 °c to 40 °c
1.19. Valve location Indoor / outdoor
1.20. Maximum differential pressure
1.21. Shut off class / requirements
1.22. Valve flange face Flat face / raised face
1.23. Type of mating flange
1.24. Drilling standard IS 1538 table 4 & 6
1.25. Surface finish
1.26. Preferred face to face dimension Mm As per std./
Phase
1.27. Power supply
,v, hz,
1.28. Air / hydraulic supply pressure Bar
1.29. Valve opening / closing time Secs
1.30. Fail safe position of actuator Valve to close / valve to open
1.31. Shut off applicability
1.32. Frequency of valve operation
1.33. Valve shaft orientation
Fire tested Yes / No. (if “yes” specify the std.
1.34. To which it should conform)

1.35. Electric continuity between shaft / Yes / no

230
 Sl.
Item Unit
No.
body / disc
Motor spec. (for motorised actuator
1.36.
only)
Application of valve for dead – end
1.37.
service
Application of valve for bi-directional Yes / no.
1.38.
service.
2. Accessories
2.1. Floor stand
Companion flange with bolts, nuts &
2.2.
gaskets
2.3. Lifting lugs
2.4. Tapped holes in lug
2.5. Extension spindle
2.6. Torque & limit switch mechanism
2.7. End limit switches
2.8. Adjustable seat
2.9. Reduction gear unit
2.10. Locking device
2.11. Valve position indicator
Yes / no (if „yes‟ specify lining
2.12. Body lining
matl.) Epdm
2.13. Auxilliary hand wheel Yes / no
2.14. Blow out proof stem Yes / no
3. Additional requirement
3.1. Painting(refer note-9)
Seismic qualification of valve required Yes / No.
If yes, indicate the document no. For
response spectrum or equivalent data
3.2.
which the vendor has to refer

3.3. Any other requirement

4. Materials of construction
Cast iron - IS 210 gr. FG 220
4.1.  Body

231
 Sl.
Item Unit
No.
Ductile iron – IS 1865 GR. 450/10
4.2.  Disc

4.3. Stem SS AISI 431

4.4. Seat
4.5. Body seat rings SS 410
4.6. Disc seal rings EPDM
4.7. Seat retaining rings SS AISI 304
4.8. Companion flange ASME B 16.5
5. Tests and inspection
Additional tests indicated as 'b' in
shops inpection requiremets shall also
5.1. be carried out when it is applicable.

5.2. Hydrostatic test pressure for body Kg/c

m2
5.3. Hydrostatic test pressure for disc Kg/c
m2
5.4. Disc strength test pressure Kg/c
m2
5.5. actuator performance test pressure Kg/c
m2
5.6. Air leak test pressure Kg/c
m2
5.7. Yes / no (if „yes‟ indicate relevant
Electrical continuity test
std.)
6. Spares
6.1. Disc seal rings
6.2. Flange gasket
6.3. Seat/seal clamping bolts
6.4. 'O' ring seals or gland packing

NOTES:-
1. For general requirements refer valve and specialities. However, in case of
overlapping requirements, those of the data sheet a, to be considered as the final
one.
2. The valve shall be designed considering the larger of the following torque
requirements for which calculations shall be submitted:
c) Calculated as per AWWA-C504-80
d) Calculated as per the standard to which valve is designed.
232
 3. For manually operated valves, torque required at hand wheel shall not exceed 7
kg.m.
4. Motor operated valve actuator shall be rated to provide an output torque of atleast
150% of torque required as per note-2 above unless otherwise noted.
5. The actuator shall be capable of operating in any mounting angle.
6. The transmission unit shall be designed to transmit twice the valve design torque
unless otherwise noted.
7. The actuator shall provide an unseating torque of at least 50% in excess of valve
seating torque at the specified voltage unless otherwise noted.
8. Segmental welded carbon steel flange plates above 20 mm thickness shall be
subjected to preheating before welding and stress relieving after welding as per is
2825 unless otherwise specified.
9. Unless otherwise specified in specification, one coat of zinc rich primer and two
coats of enamel shall be applied to all steel and cast iron exposed surfaces. The
minimum thickness of coating shall be 100 microns.
10. The vendor may also suggest any additional spares and tools required for the
successful operation, start up and maintainence of the valve.
11. In the absence of any test related data, the relevant testing standard for butterfly
valves may be indicated.
4.4.9.22. AIR RELEASE VALVE
Air release valve shall be 15mm screwed inlet Brass single acting type and shall be
fixed on all high points in the system (wet riser) with ball valves or as shown on
drawings, suitable for pressure not less than 15 Kg/Sq.cm

4.4.10 FIRE PROTECTION SYSTEM PIPING MATERIAL SPECIFICATION

(GRADE CT)

Service : fire water (fresh water)

Corr. All.
Temp. º f / º c 50 1.5
Design

Inch/ mm

Pr. Psig/ kg/ Rf, conc.serr.

8.8 flange facing
cm2 g (note -1)
Inch
Nom. Pipe size < 150 200 250 300 350 400
mm
Inch
Outside dia. 219 273 324 356 406
mm
Inch Heavy
Thickness 6 6 6 6 8
mm Cl
Inch
Nom. Pipe size
mm
233
 Inch
Outside dia.
mm
Inch
Thickness
mm
< 40 - SW TO ANSI B16.11
Line joint
> 50 - BW TO ANSI B16.25
Nominal
pipe
Size Material Dimensional
Item Remarks
range Specification Standard
Inch /
mm
IS 1239 ERW, BLACK, < 40 - PE, >
< 150 IS 1239 PT.1
PT.1 50 - BE
Pipes
IS 3589 GR.
> 200 IS 3589 ERW / EFW, BLACK, BE
FE 410
ASTM A234
50 to 150 ANSI B16.9 SCH40, SMLS ( NOTE -2 )
B.w. fittings

Elbows, caps, GR. WPB

reducers ,tees

Stub ends
ANSI
S.w.fittings < 40 ASTM A105 3000CL
B16.11
Included angle =300,
Fabricated reducers > 200 Same as pipe
Site fabricated
15 0 , 30 0 , 30 0, 15 0,
Mitres > 200 Same as pipe R=1.5 d
Site fabricated
Branch connections All Same as pipe Use stub-in type
ANSI B
< 150 ASTM A105 So , 150 CL
16.5
200 to IS 2062 GR. ANSI B
Flanges So , 150 CL
300 A 16.5
IS 2062 GR. ANSI B So , 150 cl, light weight (note -
>350
A 16.5 3)
ANSI B
< 150 ASTM A105 150 cl
16.5
200 to ANSI B
Blind flanges IS 2062 GR. A 150 cl
300 16.5
ANSI B
>350 IS 2062 GR. A 150 cl, light weight (note -3)
16.5
IS 1364 CL
All IS 1367
Machine / stud bolts 4.6

234
 NOMINA
L PIPE MATERIAL DIMENSION
ITEM SIZE SPECIFICA AL REMARKS
RANGE TION STANDARD
inch / mm
HEAVY ALL IS 1367 IS 1364 CL4
HEX.
NUTS
3mm THICK RING , SELF
GASKET BLACK ANSI B16.21 CENTERING TYPE
ALL
S RUBBER CL150
(NOTE-1) SHORE HARDNESS 60

THREAD 3000 / 2000 CL, NPT / IS 554 TAPER

< 40 ASTM A105 ANSI B 16.11
ED AS REQUIRED
FITTING
S

SIZE PRESSU TYPE

TYPE OF SPECIFICA
RANG MATERIAL RE OF REMARKS
VALVE TION OR
E RATING ENDS
inch / TAG
BODY TRIM ANSI/ IS
mm NUMBER
BRO
GATE BRONZ
NZE NPT/
E
GLOBE < 40 AST PN 1.6 IS 554
ASTM TAPER
CHECK M
B62
B62
GATE > 50
(NOTE-
4) BRO
CI IS NZE
GLOBE 210
FOR DETAILS REFER 125
INDIVIDUAL
AST FF DATA SHEETS.
(NOTE- Gr. FG
200 M
4)
B62
CHECK

SUITABLE FOR
BUTTER CI IS INSTALLATION
FLY NITR
>150 210 Gr. PN 1.6 WAFER BETWEEN
ILE
(NOTE-5) FG 200 FLANGES OF 150
CLASS
SS ANSI
50 TO IS I239 304 B16.5
RF
150 PART 1 SCRE 150
Y- TYPE EN CLASS
STRAINE
RS IS 3589 SS ANSI
GRADE 304 B16.5
200 RF
SCRE 150
FE 410 EN CLASS

235
 NOMINA
L PIPE MATERIAL DIMENSION
ITEM SIZE SPECIFICA AL REMARKS
RANGE TION STANDARD
inch / mm

NOTES
1. Use flat face flanges and full face gaskets with cast iron flanged valves.
2. Use flat end covers instead of caps for sizes > 200 mm.
3. Light weight flanges shall be ring type as per class d of table 1 or hub type as per class d of table 2
of awwa c207.
4. Hydrotest pressure of installed piping: 13.2 kg/cm2g.
5. Buried piping shall be coated and wrapped as per data sheets and requirements of TAC.

4.4.11 FIRE WATER PIPING GENERAL REQUIREMENTS

DATA SHEET A
1. Supply of pipes and fittings: 8. Piping: as per specification
Yes
2. Supply of valves and specialities: 9. Welding: as per specification
Design data

yes 10. Underground protection:

3. Supply of structural steel for as per specification and tac
pipe supports: yes 11. Valve chambers: brick masonry/
4. Erection, testing and Stone masonry/rcc as per drg
Scope

commissioning of piping system: *

yes 12. As per shop inspection and tests and/or
Tests and inspection

5. Excavation and back filling:

yes
6. Valve chambers with covers (whereever
(Note 1)
necessary):
No 13.
7. Painting and corrosion 14.
protection: yes 15.
Notes:
Additional tests indicated as 'B' in shops inpection requiremets shall also be carried out when it is applicable.
1.
Also be carried out when these are applicable.
* bidder shall submit the drawing and the same shall be revised to incorporate the comments of client / Project
Manager before being released for construction.

236
4.4.11.1. SCOPE
This specification covers the general design, materials, manufacture, shop inspection

and testing at manufacturer‟s works, delivery at site, handling at site, erection, testing,
commissioning, performance testing and handing over of fire water piping and accessories.
4.4.11.2. CODES AND STANDARDS
The design, materials, manufacture, erection, inspection, testing and performance of fire
water piping and accessories shall comply with all the currently applicable statutes,
regulations and safety codes in the locality where it is to be installed. The piping shall also
conform to the currently applicable Indian and international codes and standards. Nothing in
this specification shall be construed to relieve the CONTRACTOR of this responsibility
4.4.11.3. DESIGN AND GENERAL REQUIREMENTS
a) All pipes, fittings, flanges, valves and specialities etc. shall conform to the enclosed
piping material specifications.

b) Piping design and layout shall satisfy the requirements of applicable section of ASME
B31, Tariff Advisory Committee (TAC), other applicable codes and statutory regulations.

c) Piping shall be routed to avoid interference. If interference is noticed at site, piping shall
be suitably modified and rectified by the CONTRACTOR at no extra cost to the
EMPLOYER.

d) All high points in the piping system shall be provided with vents with valves and low
points with drains with valves.

e) Top of buried piping shall not be less than one (1) metre below the ground level. Buried
piping shall be provided with underground protection as per the enclosed specification
and requirements of TAC. Valves in buried piping shall be provided with valve chambers
with covers. At road crossings buried piping shall run through Hume pipes. Diameter of
Hume pipes shall be at least equal to two (2) times the diameter of fire water pipe. Hume
pipe shall extend at least 300 mm beyond the road.

f) Supports for above ground piping shall follow good engineering practice, requirements of
TAC and statutory regulations. Structural steel for pipe supports and other requirements
shall conform to IS 2062 grade A.

g) For underground piping wherever soil conditions are unsatisfactory, brick masonry or
concrete supports shall be provided at regular intervals not exceeding three (3) metres. In
case of poor soil conditions, it may be necessary to provide continuous brick masonry or
concrete support. The CONTRACTOR shall bring such conditions to the notice of the
EMPLOYER and follow his instructions.

237
h) Effective precautions such as capping or sealing shall be taken to protect ends of all
pipes, fittings, valves and specialities against ingress of dirt and damage during transit or
storage. Flange gasket contact surfaces shall be suitably protected against damage.

i) All piping shall be cleaned and purged with air blast to remove all rust, mill scale etc
from inner surface. Rotary wire brush may be used for cleaning pipes of sizes above 300
mm. The method of cleaning shall be such that no material is left on the inner surfaces,
which may affect the serviceability of the pipe.

j) The CONTRACTOR‟S scope for erection under this contract shall include supply of the
following:

(i) Welding materials like welding electrodes, filler rods and wires, oxygen,
acetylene, propane and other consumable materials and backing rings, etc. as
required

(ii) Joining material as required for all screwed joints and bolts, nuts, studs,
washers and gaskets as required for all flanged joints

(iii) Isotopes for gamma ray, equipment and films for radiography, liquid dye
penetrant and other required testing materials and equipment. All these shall
be taken back by the CONTRACTOR after completion of work.

(iv) Erection tools, tackles, scaffolding materials and materials including welding
machines, thermocouples, asbestos paper including blankets, cables,
temperature recorders and charts and testing equipment, air compressors etc.
All these shall be taken back by the CONTRACTOR after completion of
work.

(v) Services of erection superintendent, erection supervisors, fitters, riggers, and

other skilled and unskilled labour.

k) For general welding requirements refer enclosed specification. The CONTRACTOR shall
be responsible for the quality of welding carried out and shall conduct tests to determine
the suitability of the welding procedure used. Tests shall be conducted in accordance with
codes specified. The results and specimens from qualification tests and operator tests
shall be made available to the EMPLOYER. Only qualified welders shall be used and
the CONTRACTOR shall inform the EMPLOYER the names of the welders and their
experience for approval. A welding procedure qualification shall be submitted to the
EMPLOYER for approval before commencement of work.

l) All surplus materials from those supplied by the CONTRACTOR shall be taken back by
the CONTRACTOR.

m) All pipes and fittings shall be tested hydrostatically at the shops where manufactured, to
test pressures which are given in the respective codes and standards. All piping systems
shall be tested hydrostatically after erection to specified test pressure. The test duration
shall be two (2) hours or until all joints are examined, whichever is longer. In case of
leakage, re-test shall be carried out for the same duration after rectification of defects.

238
 n) At least 10% of all the butt-welded joints on hydrant mains shall be radiographically
tested and half of the joints radiographed shall be field joints. Acceptable levels of
defects shall be as per the applicable code.

o) For hydrostatic testing and water flushing, the CONTRACTOR shall furnish necessary
tanks, pumps, compressors, other equipment, instruments, piping and supports etc. The
EMPLOYER may provide water at one point of supply to which the CONTRACTOR‟S
temporary piping shall be connected. All temporary equipment, piping and supports shall
be dismantled and taken back by the CONTRACTOR after completion of testing and
flushing operation.
4.4.11.4. EXCAVATION AND BACK FILLING
a) The CONTRACTOR shall carry out necessary civil works associated with buried piping
such as excavation, de-watering, back-filling, levelling and compacting. During
excavation, large stones and rubbles shall be segregated and removed from the excavated
soil and stacked separately. The material from excavation shall be deposited on either
side of the trench leaving adequate clear distance from the edges of the trench. This is
necessary to prevent the excavated material or the sides of the trench to slip and to avoid
covering the laid pipes, hydrant valves, sluice valves and manhole covers etc.

b) All precautions shall be taken during excavation and laying operations to guard against
possible damage to any existing structures and pipelines. If rock is encountered, it shall
be removed up to 150 mm below the bottom of pipes, fittings, valves and specialities and
the space resulting shall be refilled with granular materials and properly consolidated.
The excess excavated material shall be carried away from site of works up to a distance
as directed by the EMPLOYER.

c) In case, during excavation, sub-soil water is encountered, the CONTRACTOR shall

provide necessary equipment and labour for de-watering the trenches. The
CONTRACTOR shall also make necessary arrangements for the disposal of drained
water to nearby storm water drain. In no case shall water be allowed to spread over the
adjoining areas. All precautions shall be taken to prevent dirt etc. from entering into
pipes, when the pipe laying is not in progress by closing the pipe ends with water tight
plugs or other approved methods. Trenches shall be back-filled with selected
excavated material only after the successful testing of the piping. Tamping around the
pipe shall be done by hand or other hand-operated mechanical means. Back filling shall
be done in layers not exceeding 300 mm. Each layer shall be consolidated by watering
and ramming.
4.4.11.5. PAINTING AND CORROSION PROTECTION
a) All exposed piping shall be painted with approved paints.

b) Before applying the paints, all surfaces shall be cleaned by sand blasting or rotary wire
brushing and by dry air blast. All surfaces shall be free of all dirt, mud, rust, grease,
scale, or other foreign material.

239
 c) After sand blasting or wire brushing is complete, the surfaces shall be protected so that
these do not come in contact with grease, oil, other organic matter or moisture prior to
application of primer coating.

d) Primer coating shall be carried out as quickly as possible after sand blasting or wire
brushing. No sand blasted or wire-brushed surface shall be allowed to remain un- coated
overnight. Any clean surface that subsequently rusts shall be re-blasted or re- wire
brushed before the application of primer.

e) Painting operation shall generally be in line with IS 1477 (Parts 1 and 2) and colour of
finish paint shall be fire red shade no. 536 of IS 5.
4.4.11.6. MEASUREMENTS
a) Above ground and underground pipe lengths shall be measured separately. Pipe length
shall be measured along the centre line of the pipe. End-to-end or flange face-to-flange
face length of fittings, flanges, valves and specialities shall not be deducted from the pipe
length. Unit price for supply of pipe shall include supply of fittings and flanges.
Similarly, unit price for erection of pipe shall include erection of fittings and flanges.
However, supply and erection of valves and specialities shall be considered separately as
per para 6.6 below.

b) Unit prices for supply and erection of above ground and underground pipes shall also
include supply and erection of all piping support items, auxiliary steel and accessories
like shoes, saddles, base plates, clamps, bolts and nuts etc.

c) Unit prices for supply and erection of above ground pipes shall also include supply of all
surface preparation and painting materials and application of painting.

d) Unit prices for supply and erection of underground pipes shall also include supply of all
surface preparation and wrapping and coating materials required and application of
underground protection.

e) For valves and specialities the BIDDER shall quote unit price for supply and unit price
for erection of each type and size of valve and speciality.

f) Non-destructive testing like radiography and die penetrant tests etc. shall be included in
the unit price for erection of pipe. No separate charges are payable on this account.

g) For concrete pedestals for support of above ground pipes, the BIDDER shall quote unit
price for erection of each type and size of pedestal. Supply of all materials required for
construction of such pedestals shall be included in the unit price.

h) For valve chambers for underground pipes, the BIDDER shall quote unit price for
erection. Supply of all materials required for construction of such valve chambers, shall
be included in the unit price.

i) For excavation and backfilling, the bidder shall quote unit price per M3 for each type of
soil indicated in the schedule of prices. Payment shall be made based on the volume
arrived at, as given below, irrespective of the width and depth of the trench actually

240
 excavated or larger trench excavated at locations of pipe fittings and flanges and
locations of weld joints:

V = L (D1+D2+...+0.5) (1.2+D1 or D2 ... whichever is higher) Where,

D1, D2 ...etc : Nominal diameters of pipes buried in the same trench in M L

: Length of trench in M

V : Volume of trench in M3

4.4.12 FIRE PROTECTION SYSTEM WELDING REQUIREMENTS FOR PIPING

Welding
P. No.

Filler material Gas

Notes
Sl. process
Material
No.
Root Filler Root Filler Purging Shielding
1.0 Carbon steel
1.1  50 mm
NPS and/or E
GTA GTA
up to and 1 R70 E 6013 -- -- 1
W W
including 3 S2
mm thick
1.2 > 50 mm SMA SMA E
1 E 6013 -- -- 1
NPS W W 6010
2.0 Stainless NITROG
ARGON
steel GTA GTA EN
ER ER 0.35 TO
type 304 8 W W 0.2 TO 2
308 308 0.6
0.3
M3/HR
M3/HR

241
 Notes

1. For fillet welds, E 6013 may be used.

2. Non-consumable electrode for gtaw process shall be 2% thoriated tungsten.

3. Electrodes and filler wires shall be from reputed manufacturers such as advani-oerlikon,
esab, d&h secheron.

Legend

GTAW - Gas tungsten arc welding

SMAW - Shielded metal arc welding

4.4.13 FIRE UNDERGROUND PROTECTION FOR PIPING

(DATA SHEET A)
1. Supply of all coating and By contractor/ Employer
Wrapping materials
2. Soil resistivity  1000 ohm-cm
General and materials

> 1000 ohm-cm

3. Type of underground protection 3.1 3 coats and 3 wraps of coal
tar coating / 3 layers of
wrapping tape
3.2 2 coats and 2 wraps of coal
tar coating / 2 layers of
wrapping tape / 1 layer of 4 mm
thick wrapping tape
4.
5. Application methodology As per specification
Application

6.

7. Coating thickness Required

8. Bond/ adhesion test for coating / Required
Testing

Wrapping tapes
9. Holiday test Required
Documents

10. Documents required after the 10.1 material test certificates

Award of contract 10.2 manufacturer's installation

instructions for storage,

242
 preparation and application
of coating materials
4.4.13.1. SCOPE
The purpose of this specification is to describe the technical requirements for the application
of hot coal-tar enamel and fibre glass wrapping or pipeline wrapping tapes for the protection
of external surface of underground carbon steel piping.
4.4.13.2. GENERAL
a) The coating shall consist of coal-tar enamel, inner wrap of fibre glass, final outer
wrap of enamel-impregnated fibre or enamel-impregnated kraft paper. The primer
and the enamel shall be from the same supplier.

b) Alternatively, if specified in Data Sheet-A, ready-made tapes available for

underground protection shall be used. Tape shall be of approved make. The
CONTRACTOR shall furnish all the technical information, experience details etc. of
the tapes proposed to be used for review.

c) The two ends of each length of pipe shall be left bare of primer coating and wrapping
for a distance of 150 mm from the end to facilitate field welding and subsequent field
coating or wrapping.

d) The supply, application, characteristics of materials and testing requirements shall be

strictly as per IS 10221.

e) Type of coating system based upon the soil resistivity may be selected on the
following basis :

Soil resistivity Corrosively Coal tar coatings Wrapping tap

 1000 ohm-cm Extremely 3 coats and 3 3 layers of taps

corrosive wraps
> 1000 ohm- Corrosive & non 3 coats and 3 3 layers of taps
cm Corrosive wraps
(a) If no specific choice is indicated in Data Sheet-A, system 2.5(b) using coal tar
coating shall be used.
4.4.13.3. SURFACE PREPARATION
Pipe surfaces to be provided with underground protection shall be cleaned by shot or sand
blasting. The cleaning shall be so carried out that the piping surface is free from mill scale,
rust, oil, welding scale and other foreign materials. Primer shall be applied immediately after
shot or sand blasting to prevent rust forming. Superficial rust formed shall be removed by
wire brushing or by the use of emery paper. If the rust formation is heavy, re-blasting may be
necessary. Around field joints, the pipe surfaces may be cleaned by wire brushing prior to the
application of anti-corrosive protection.
4.4.13.4. PRIMER COAT
243
 a) The primer shall be compatible with the grade of enamel used. It shall be thoroughly
mixed before using by stirring or by rocking the drum to provide uniformity of
material. The primer coat shall be applied over a thoroughly clean and dry surface
within three (3) hours of the cleaning operation, and shall be applied preferably
immediately with a uniform thickness on the entire surface of the piping using
appropriate quantity per unit area of surface as recommended by the manufacturer.
The primer coating shall be free of bubbles, globules, drips and runs. Pipes having a
longitudinal seam shall be carefully examined to determine that all excess primer has
been brushed out of each side of the welding seam. The primer shall be thoroughly
dry before the enamel is applied. If ready-made tapes are used, then primer, as
suggested by the manufacturer, shall be used.

b) Freshly-primed pipe shall be handled carefully to prevent damage. The damaged area
shall be re-primed before applying enamel/wrapping tapes.
4.4.13.5. ENAMEL AND WRAPPING MATERIALS FOR COAL TAR ENAMEL
APPLICATION
a) The material to be used for coating and wrapping shall be coal-tar enamel, fibre glass
inner wrap, fibre glass or kraft paper outer wrap, all as per IS 10221.

b) Well-experienced personnel shall be placed in charge of coating and wrapping

operations. They shall strictly follow the manufacturer's instructions regarding
recommended temperature in the heating kettles and the temperature at which the hot
coating is applied to the pipe. Clean dry enamel in lumps not exceeding 35 kg in
weight shall be heated slowly in clean kettles to the recommended temperature, and
after reaching the required temperature, the heating flame shall be controlled to
prevent over-heating. Any enamel heated in excess of manufacturer's specifications
shall be discarded. Only batch heating of enamel shall be permitted.

c) Kettles shall be completely emptied of one batch and cleaned, if necessary, before
preparing the next batch of enamel. The enamel shall be stirred continuously with
metal agitators. Enamel kettles shall be equipped with indicating or recording
thermometers having temperature range from 100 to 350°C. Enamel withdrawn from
the kettles shall be strained through a 1.5 mm strainer.

d) Enamel shall be moisture - and dirt-free at all times prior to and at the time of heating
and application. The primed surface shall be dry and clean at all times and the enamel
shall be applied not later than three (3) days after the application of primer. Along
with the first coat of enamel, a single spiral inner wrap of fibre glass shall be applied
overlapping at least 20 mm on pipes upto 250 mm diameter and 25 mm on larger
diameter pipes. It shall be ensured that fibre glass impregnates in the first coat. The
second coat of enamel and the second outer wrap of enamel-impregnated fibre glass
or enamel-impregnated kraft paper shall be applied in the same way and shall
conform to Table-10 or 12 of IS 10221. The total thickness of the coating shall not be
less than 2.5 mm.

e) A third coat of enamel and wrapping shall be applied wherever soil resistivity is
below 1000 ohm-cm (extremely corrosive).
244
 f) During cold weather, when the pipe surface temperature is below 7°C or during rainy
and foggy weather when moisture tends to collect on the cold pipe, enamelling shall
be preceded by warming of the primed pipe. Warming shall be done by any method
that will heat the pipe uniformly to the recommended temperature without damage to
the primer. Temperature of the pipe shall not exceed 70°C.

g) Each end of the pipe left bare for welding purpose shall be hand-coated and wrapped
after completion of field welding and satisfactory hydrotesting of pipe.
4.4.13.6. APPLICATIONN OF WRAPPING TAPES
a) After the surface preparation as per para 3.0, the primer shall be applied by brush or
spay so as to give a coating thickness is between 2 and 4 mils when wet. The primer
shall be allowed to dry to the touch prior to tape application. Primer and tape shall be
furnished by the same manufacturer. If application is done in cold weather, the
surface of the pipe shall be preheated until it is warm to the touch, and until all traces
of moisture are removed and then the primer shall be applied and allowed to dry.

b) The tape shall be wrapped strictly in accordance with the manufacturer's

recommendations in a manner that shall meet the adhesion and holiday detection
requirements of IS 10221. There shall be a minimum overlap of 12 mm per single
wrap. Each layer of tape shall be of 2 mm thickness.
4.4.13.7. TESTING
a) THICKNESS

i. The thickness of the pipe coating shall be measured either by elcometer or by

coating thickness gauge.

b) BOND

i. Bond test shall be carried out by cutting 25 mm square at three locations of

the coating on a sample test specimen to qualify the procedure. Coating shall
be pulled out by lifting one corner of the square. For a good coating, the
section shall not peel off easily.

ii. The coating on the pipe shall be carried out only after satisfactory completion
of the qualifying test.

iii. In case of doubt regarding the quality of coating, bond test shall be carried
out on any location of the pipe to the satisfaction of the EMPLOYER. The
tests indicated under clauses 7.1 and 7.2 are applicable for coal tar enamel
applications only.

c) FIELD ADHESION TEST FOR WRAPPING TAPES

i. Adhesion test shall be made to determine the proper bond between the tape
and primed pipe. The temperature of the tape and pipe to be tested shall be
between 10 and 27 C. If the temperature is outside this range, hot or cold
water shall be poured over the test area until this temperature range is
245
 attained. A test area shall be selected by the inspector where the tape is
smooth for 15 cm in the longitudinal direction of the tape. Two knife cuts
that are 15 cm long and 5 cm apart shall be made through the tape. A flat
blade shall be used to pry up 5 cm of the fabric. This 5 cm flap of fabric shall
be grasped firmly in one hand and shall be pulled with a quick motion in the
direction of the remaining 10 cm of the 15 cm knife cut.

ii. The adhesion is satisfactory if the tape tears at the point of stripping or the
fabric strips from the underlying coal tar component, leaving exposed not
more than 10% of the primer or metal.

d) HOLIDAY TEST

i. On completion of coating/wrapping, the quality of the coating shall be tested

using efficient high voltage holiday detectors, operating at a voltage high
enough to jump an air gap, the length of which is equal to the thickness of the
coating/wrapping. All holidays found shall be repaired and the repairs shall
be retested with the holiday detector to ensure that adequate repairs have
been made.

ii. The suggested test voltage shall be as follows :

V = 1250 (t)½ where

V = voltage, in volts

t = coating thickness in mils (1 mil = 0.001 in.)

e) CERTIFICATES

The CONTRACTOR shall furnish certificates of all the materials purchased by him
and also complete instructions from the manufacturer regarding the storage,
preparation and application of the coating materials.

4.4.14 FIRE PROTECTION EQUIPMENT WET PIPE TYPE SPRINKLER SYSTEM

DATA SHEET A
1. Standard:NFPA,IS ,/OISD/TAC/FM
Materials of construction (contd.)

11.3 clapper: bronze to IS 318

GLOBAL
2. Area to be covered: gr.ltb2/
11.4 clapper facing: bronze to IS 318
General

gr.ltb2/
3. Hazard class: light/ordinary/ 11.5 handhole cover: CI to IS 210
high/storage /class -iv GR.FG 225/
4. Quality of water: raw water 11.6 clapper/ handhole gasket:
5. neoprene rubber/

246
 6. 11.7
7. Installation control valve: 11.8
7.1 size: 150mm 12. Sprinkler: brass as per IS 319/
7.2 pressure at inlet: bronze as per is 318 gr.ltb2,
7.3 end connection: flanged to chrome plated
ANSI b 16.5,150# 13.
7.4 water motor gong to be 14.
provided:
15.
yes
Construction features

8. Sprinkler: 16. P&I diagram:

8.1 standard: is 9972/UL /FM
8.2 type: pendent/upright/universal/ 17. GA drawing:
sidewall
8.3 nominal temperature rating: Companion specifications 18. Pump:
As per individual risk requirement 19. Piping: as per specification
9.
10. 20. Instruments:as per specification
11. Installation control valve: 21. Control panel: as per
11.1 body: CI to is 210 GR.FG 200/ Specification
22.
11.2 seat ring: bronze to IS 318 23.
gr.ltb2/ 24.
25. As per shop inspection and tests and 33. Installation control valve:
33.1
186-30 and applicable nfpa, oisd, 33.2
tac and fm global regulations 33.3
Approved sub-vendors

(note 2)
Tests and inspection

26. Foc/ul/fm approval certificates 33.4

for installation controlvalve and 33.5
sprinkler
27. 34. Sprinkler:
28. 34.1
29. 34.2
30. 34.3
31. 34.4
32. 34.5
247
 Notes
1. Test connection at the remotest nozzle shall be provided.
2. Additional tests indicated as 'B' in shops inpection requiremets shall also be carried
out when it is applicable.

4.4.15 WELDING SPECIFICATION FOR SHOP AND SITE FABRICATED

EQUIPMENT
4.4.15.1. SCOPE

a) This specification shall apply to shop and site fabrication of all welded joints in
carbon steel, low alloy steel and stainless steel equipment like pressure vessels, tanks,
columns and heat exchangers etc.The specification shall apply to all the joints
indicated below:

i. Butt joints produced by double sided welding which produce the same
quality of deposited weld metal on both inside and outside weld surfaces

ii. Butt joints produced by single sided welding having backing strip which
remains in place and full penetration butt weld without backing strip

iii. Corner or those joints connecting two (2) members approximately at right
angles to each other in the form of L or T

iv. Partial penetration welds of the groove type which are used for
connections not subjected to external loading

v. Fillet welded joints of approximately triangular cross-section joining two

(2) surfaces at approximately right angles to each other and having a
throat dimension at least 70% of the thinner of the parts being joined but not
less than 6 mm

vi. Welds attaching nozzles and other connections

vii. Welds which are used to join non-pressure parts like supports, lugs,
brackets, stiffeners and other attachments to the vessel wall

viii. Any other similar joint which is not specified above but may be
encountered during fabrication
4.4.15.2. CODES AND STANDARDS

a) The welding equipment, welding consumables, preheating, Post weld Heat

Treatment (PWHT), other auxiliary functions and welding personnel shall comply
with all currently applicable statutes, regulations and safety codes in the locality
where the equipment are to be fabricated and installed. Nothing in this
specification shall be construed to relieve the VENDOR/CONTRACTOR of this

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 responsibility. Specifically, the latest editions of the codes and standards listed
below shall apply:

i. ASME Boiler and Pressure Vessel Code (BPV Code), Section II Part C -
Material Specifications for Welding Rods, Electrodes, and Filler Metals

ii. ASME BPV Code, Section V - Non-destructive Examination (NDE)

iii. ASME BPV Code, Section VIII Division 1- Rules for Construction of

iv. Pressure Vessels

v. ASME BPV Code, Section IX - Welding and Brazing Qualifications

vi. American Society of Non-destructive Testing (ASNT) SNT-TC-IA-

Recommended Practice

vii. Indian Boiler Regulations (IBR)

viii. Any other codes and standards specified in Specification or data sheet A of

Data sheetsof enquiry specification

b) The codes and standards listed in para 2.1 forms an integral part of this
specification. In the event of conflict between this specification and the codes and
standards, the more stringent shall govern.

c) If no specific requirements are given in this specification, the requirements of the

applicable code shall govern.
4.4.15.3. WELDING PROCESSES

a) GAS TUNGSTEN ARC WELDING (GTAW)

i. The root pass of single-sided groove welds without backing

ii. Full penetration nozzle connection where other side is inaccessible

iii. Any butt and fillet weld on equipment with thickness 5 mm or less

iv. For all passes of butt and fillet welding of nozzles on equipment and
integral piping of size 50 mm NB or smaller

b) Shielded Metal-Arc Welding (SMAW)

c) SUBMERGED ARC WELDING (SAW)

Maximum weld deposit per pass shall be 12.7 mm for carbon steel (P-1) and 9.5 mm
for other materials.

d) Gas Metal Arc Welding (GMAW) and Flux Cored Arc Welding (FCAW) processes

249
 e) Other processes such as plasma-arc and electro-slag welding may be used only
with the approval of the EMPLOYER and depending upon the process and
application proposed. These processes may require testing in addition to that
specified by the governing procedure qualification code.

f) Table 1 gives recommendations for welding processes to be used for carbon, low
alloy and austenitic stainless steels.
4.4.15.4. WELDING CONSUMABLES

a) The VENDOR/CONTRACTOR shall provide, at no additional cost, all the welding

consumables such as electrodes, filler wires, flux, oxygen, acetylene and argon etc.,
in order to complete the welding in all respects. The consumables shall be from
reputed and approved manufacturers. All the consumables shall be approved
by the EMPLOYER.

b) The electrodes and filler wires shall be of the class specified in Table 1 Welding
Specification Chart.

c) Electrode qualification test records shall be submitted for the EMPLOYER's

approval. The VENDOR/CONTRACTOR shall also submit batch test certificates
from the electrode manufacturer for physical and chemical tests.

d) Electrodes shall be in sealed containers and adequate care shall be taken for
storage, strictly in accordance with the manufacturer‟s recommendations.

e) Electrodes, which have been removed from the original containers, shall be kept in
baking ovens as per the manufacturer‟s recommendations and, once these are taken
out, shall be consumed within the time limits stipulated by the manufacturer. Care
shall be taken in handling the electrodes to prevent any damage to the flux
covering. Portable ovens shall be used for carrying the electrodes from the main
oven to the field. Electrodes of different specifications shall be stored in different
compartments of a baking oven to avoid mix up.

f) The electrodes, filler wires and flux used shall be free from contamination such as
rust, oil, grease and such foreign matter.

g) Low hydrogen electrodes shall be used for weld joints in carbon steel if the wall
thickness exceeds 19 mm and low alloy steel of all thicknesses except that non- low
hydrogen electrodes shall be permitted for the root pass of carbon steel only.

h) If ultimate tensile strength of base material permits, E 6010 electrodes may be used,
for root pass of butt welds and for fillet welds, in carbon steel.
4.4.15.5. WELDING QUALIFICATIONS

a) Qualification of the welding procedures to be used and the performance of

welders and welding operators shall conform to the requirements of the BPV
Codes and Section IX. For equipment under the purview of IBR, these shall also
meet the requirements of IBR.

250
b) No production welds shall be undertaken until the qualification requirements are
completed to the satisfaction of the EMPLOYER.

c) When impact testing is required by the code or by the specification, these

requirements shall be met in qualifying welding procedures.

d) The VENDOR/CONTRACTOR shall be responsible for qualifying any welding

procedure, welders and welding operators intended to be deployed. The
VENDOR/CONTRACTOR shall submit the Welding Procedure Specification
(WPS) for acceptance by the EMPLOYER. After approval by the
EMPLOYER, the procedure qualification test shall be carried out by the
VENDOR/CONTRACTOR, at his own expense, duly witnessed by the
EMPLOYER. A complete set of test results, in specified format, shall be
submitted to the EMPLOYER for approval immediately after successful
completion of procedure qualification test. All tests as required by the BPV code
Section IX or IBR shall be carried out. The WPS shall require re-qualification, if any
of the essential variables or supplementary variables is altered.

e) Welders and welding operators shall be qualified in accordance with BPV Code and
Section IX or IBR, as applicable. The qualification shall be carried out in the
presence of the EMPLOYER. Only those welders and welding operators who are
qualified by the EMPLOYER shall be deployed on the job. For equipment under the
purview of IBR, approval of the local IBR inspector shall be obtained by the
VENDOR/CONTRACTOR.

f) Welders and welding operators shall always keep their identification cards with
them and shall produce them on demand. The VENDOR/CONTRACTOR shall
issue the identity cards after the same are duly certified by the EMPLOYER. Welder
or welding operator, who is not in possession of the identity card, shall not be
allowed to work.

g) The VENDOR/CONTRACTOR shall use forms as per BPV code, section IX,
form QW-482, form QW-483 and form QW-484. Other forms are also
acceptable subject to approval by the EMPLOYER.

h) Unless agreed otherwise, the VENDOR/CONTRACTOR shall advise the

EMPLOYER, in writing, at least three (3) weeks before any welder or welding
operator is deployed on the work, the names and qualifications of the proposed
welders, welding operators and welding supervisors. It shall be the
VENDOR/CONTRACTOR‟s responsibility to ensure that all welders and welding
operators employed by him or his SUB-VENDORS/SUB-CONTRACTORS, on
any part of the work either in the VENDOR/CONTRACTOR‟s or his SUB-
VENDOR/SUB-CONTRACTOR‟s works or at site are fully qualified as required by
the code. Each welder and welding operator shall qualify for all types of welds,
positions and materials or material combinations he may be called upon to weld.

i) Should the EMPLOYER require to qualify or requalify any welder or welding

operator, the VENDOR/ CONTRACTOR shall make available, at no extra cost to

251
 the EMPLOYER the men, equipment and materials for the tests. The cost of testing
the welds shall be borne by the VENDOR/CONTRACTOR.

j) Welding supervisors shall have qualifications such as engineering degree or

engineering diploma in welding technology with adequate knowledge of welding
consumables, welding machines, NDE and a minimum of five (5) years of
experience in supervising welding of joints.

k) All welding, including the tacking up of all welds shall be carried out by qualified
welders and welding operators as per approved WPS. Any weld made by other than a
qualified welder or welding operator or not carried out as per approved WPS shall be
cut out and re-welded.

l) For purposes of identification and to enable tracing full history of each joint, each
welder and welding operator employed on the work shall be given a designation. The
welder and welding operator‟s designation and the date on which the joint was made,
shall be stamped near the relevant joint and on the relevant drawings also. Copies of
the drawings so marked shall be furnished to the EMPLOYER for record purposes.
For austenitic stainless steels, welder and welding operator‟s designation shall
be applied with water-proof paint or by etching or stencilling machine that is not
detrimental to the metal. Alternatively, record cards may be used.

m) For each welder and welding operator, a record card shall be maintained
showing the procedures for which he is qualified. These cards shall note the
production welds, the date of the welding done, the type of defects produced and
their frequency. The record shall be reviewed once in a week by the
EMPLOYER and those welders and welding operators whose work required a
disproportionate amount of repair shall be disqualified from welding. Re-
qualification of welders and welding operators disqualified more than three (3)
times shall be entirely at the discretion of the EMPLOYER. As far as possible, the
qualification shall be carried out at the location (site or shop) where the actual
fabrication and welding work is to be carried out.
4.4.15.6. PREPARATION FOR WELDING

a) Surfaces to be welded shall be smooth, uniform and free from fins, tears and other
defects, which would adversely affect the quality of the weld. All welding faces and
adjoining surfaces, for a distance of at least 50 mm from the edge of the welding
groove or 12 mm from the toe of the fillet in the case of socket welded or fillet
welded joints, shall be thoroughly cleaned of rust, scale, paint, oil or grease, both
inside and outside.

b) Joints for welding shall be as per the project specifications and approved
fabrication drawings.

c) Butt joints shall be prepared as per ASME BPV Code Section VIII Division 1,
unless specified otherwise. For equipment under the purview of IBR, these shall be
as per IBR. Any other end preparation which meets the WPS is acceptable.

252
d) Internal misalignment shall be reduced by trimming but such trimming shall not
reduce the finished wall thickness below the required minimum wall thickness.
Trimming shall not be abrupt. It shall be tapered with a minimum slope of 1:3. Root
opening of the joint shall be within the tolerance limits of the WPS.

e) Welds shall be as per ASME BPV Code Section VIII Division 1 or in accordance
with IBR for equipment under the purview of IBR.

f) Reinforcing pads and saddles shall have a good fit with the parts to which they are
attached. A tell-tale hole shall be provided on the side of any pad or saddle to reveal
leakage in the weld and to allow venting during welding and heat treatment.
Pad or saddle shall be added, after the branch weld has undergone satisfactory visual
and NDE.

g) The ends shall be prepared by machining, grinding, flame cutting or plasma

cutting. Where flame cutting is used, the effect on the mechanical and
metallurgical properties of the base metal shall be taken into consideration
Flame cutting of alloy steel is not advisable. If alloy steel is cut using flame, the heat
affected zone shall be removed completely by grinding and/or machining Magnetic
Particle (MT) or Liquid Penetrant (PT) testing shall be carried out to ensure
soundness of edges. However, flame cutting of carbon steel is permitted. Wherever
practicable, flame cutting shall be carried out by machine. Machine flame-cut edges
shall be substantially as smooth and regular as those produced by edge planning and
shall be cleaned free of slag. Manual flame cutting shall be permitted only where
machine flame cutting is not practicable and with the approval of the
EMPLOYER, and such surfaces shall be ground or dressed to a smooth finish as
required by the specification and to the satisfaction of the EMPLOYER. Slag,
scale or oxides shall be removed by grinding to bright metal at least two (2) mm
beyond the burnt area.

h) Thermal cutting of carbon steel shall be performed under the same conditions of
preheating and PWHT as for the welding of each class of material. However,
PWHT is not required when:

i. The heat affected zone produced by thermal cutting is removed by

mechanical means immediately after cutting. However, in any case, all
remaining slag, scale or oxides shall be removed by grinding to bright
metal at least two (2) mm beyond the burnt area, or

ii. Thermal cutting is part of fabrication, manufacturing or erection sequence

leading to a weld end preparation where welding immediately follows.

i) On austenitic stainless steels, plasma cutting, machining or grinding methods

shall be used for edge preparation. Flame cutting is not permissible. Cut
surfaces shall be machined or ground smooth after plasma cutting. Stainless steel
materials shall be ground with Al2O3 grinding wheels and cleaned with
stainless steel wire brushes.

253
 j) Before fitting up the weld joint, the profile and dimensions of the weld end
preparation shall be checked by the EMPLOYER. If the specified tolerances are
exceeded, this shall be corrected (with prior approval) by grinding, machining or any
other method acceptable to the EMPLOYER.

k) Fit-ups shall be examined by the EMPLOYER prior to welding the root pass.
4.4.15.7. TECHNIQUE AND WORKMANSHIP

a) Stainless steel welding shall be carried out at a location away from carbon steel
welding.

b) Components to be welded shall be aligned and spaced as per the requirements of the
code and WPS.

c) Alignment and spacing shall be achieved using suitable wires to maintain the gap.
These shall be removed after tack welding. The ends to be welded shall be held using
suitable clamps, yokes or other devices which will not damage the surfaces in any
manner. It shall be ensured that welding operations do not result in distortions.

d) Earthing shall be provided on the job using earthing clamps of similar material as the
job. Earthing shall not be given through welding rotators.

e) Tack welds at the root joint, for maintaining joint alignment, shall be made only by
qualified welders or welding operators and with filler metal equivalent to that used in
the root pass. Tack welds shall be fused with the root pass weld, except that those
which have cracked shall be removed. Peening is prohibited on the root and final
passes of a weld. The required preheat shall be maintained prior to tack welding.
Means shall be made available to measure preheat temperature.

f) No welding shall be carried out if there is any impingement in the weld area of rain,
snow, excessive wind or if the weld area is wet.

g) Irrespective of the class of steel, root runs shall be made without interruption other
than for changing the electrodes or to allow the welder or welding operator to
reposition him. Root runs made in the shop may afterwards be allowed to cool by
taking suitable precautions to ensure slow cooling e.g. by wrapping in a dry asbestos
blanket. Welds made at site shall not be allowed to cool until the thickness of
weld metal deposited exceeds one third of the final weld thickness or 10 mm,
whichever is greater.

h) When welding alloy steels, it is strongly recommended that interruption of

welding be avoided. Where such interruption is unavoidable, either the preheat shall
be maintained during the interruption or the joint shall be post heated or wrapped in
dry asbestos blankets to ensure slow cooling. Before recommencing welding, preheat
shall be applied again.

i) Welded-on bridge pieces and temporary attachments shall preferably be

avoided. Where approved by the EMPLOYER, these may be used. Material of these
shall be compatible with material with which they are temporarily welded. All such
254
 pieces shall be removed after welding of joints and the weld area ground flush.
These areas shall be subjected to MT and PT examination. These pieces shall be
welded by qualified welders and welding operators and with electrodes compatible
with the parent material. The preheating requirements of material shall be
applied and maintained during the welding of attachments. These temporary
attachments shall be removed by grinding, chipping, sawing or by arc or flame
gouging. When arc or flame gouging is used, at least three (3) mm of metal shall be
left around the surface which shall be removed by grinding. This metal shall not be
removed by hammering or by use of force.

j) The arc shall be struck only on those parts of parent metal where weld metal is to be
deposited. When inadvertent arc-strikes are made on the base metal surfaces
outside the joint groove, the arc-strikes shall be removed by grinding and shall be
examined by MT and PT procedures.

k) Oxides shall not be permitted to form during welding or heat treatment or both, on
the internal surfaces which will not be subsequently cleaned. Inert gas purging
is an acceptable method to prevent such oxidation. All joints in materials which
contain more than 1¼ % chromium shall be purged to assure that less than 1% of
oxygen is present on the joint underside before initiation of the welding. The
purging operation shall be maintained for a minimum of two (2) passes.

l) Argon gas used in GTAW process for shielding and purging shall be at least
99.95% pure. Purging shall be carried out at a flow rate depending on diameter until
at least five (5) times the volume between dams is displaced. In no case shall the
initial purging period be less than 10 minutes. After initial purging, the flow of the
backing gas shall be reduced to a point where only a slight positive pressure prevails.
Any dams used in purging shall be fully identified and removed after welding
and accounted for in order to avoid leaving them in the system. The rate of flow
for shielding purposes shall be established in the procedure qualification.

m) Thorough check shall be exercised to maintain the required inter-pass

temperature.

n) All equipment necessary to carry out the welding, for supporting of the work, for
preheating and PWHT including thermal insulation for retaining the heat and for the
protection of the welder and welding operator shall be provided by the
VENDOR/CONTRACTOR at no extra cost. All necessary precautions shall be
taken during cutting and welding operations. It shall be ensured that proper
ventilation is available in the welding area and adequate protective gear such as
goggles, masks, gloves, protection for the ears and body are used at all times. For
guidelines refer ASME standard Z49.1, “Safety in Welding and Cutting”.

o) After deposition, each layer of weld metal shall be cleaned with a wire brush to
remove all slag, scale and defects, to prepare for the proper deposition of the next
layer. The material of wire brush shall be compatible with parent material. Stainless
steel materials shall be cleaned with grinding wheels or stainless steel brushes which
have not been used on other materials. Either aluminium oxide or silicon carbide
255
 grinding wheels shall be used. Special care shall be taken to secure complete and
thorough penetration of the fusion zone into the bottom of the weld. It is
recommended that the root run be checked by MT or PT procedures for
critical equipment.

p) If specified, upon completion of welding, the joints shall be wrapped in dry

asbestos blankets to ensure slow cooling, unless PWHT is applied immediately.

q) No welding or welded parts shall be painted, plated, galvanised or heat treated until
inspected and approved by the EMPLOYER. Welds shall be prepared and ground
in such a way that the weld surfaces merge smoothly into the base metal surface,
particularly for welds which are to undergo NDE.

r) Except where necessary to grind flush for NDE, reinforcement for butt welds may be
provided. The height of such reinforcement shall meet the requirements of the
code. The reinforcement shall be crowned at the centre and tapered on each side
of the joined members. The exposed surface of the weld shall be ground where
required to present a workmanlike appearance and shall be free from depressions
below the surface of the joined members. The exposed surface of the butt
welds shall be free from undercuts, overlaps or abrupt ridges or valleys and shall
merge smoothly into the surface at the weld toe.

s) Repair of weld metal defects shall meet the requirements of the code.

t) Any weld repair shall be subject to the approval of the EMPLOYER.

u) In the event of several unsuccessful repair attempts or if the EMPLOYER feels that a
satisfactory repair is not feasible, the joint shall be completely remade.

v) It is preferable to use welding rectifier or DC generator for welding of austenitic

steels and while using low hydrogen electrodes.

w) IDENTIFICATION OF WELDS

Wherever code symbol stamps are required on carbon steel and ferritic alloy
steel they shall be applied directly on to the member with low stress dotted
design metal die stamps or to a small stainless steel plate especially provided for such
marks. These plates shall be lightly tack welded using electrodes, of diameter
three (3) mm or less, of the type specified for the material. Before making the
required tack weld, the material in the immediate surrounding area shall be
preheated, as required, by electric means or propane or natural gas burners.
Cooling shall take place under asbestos insulation in a draft-free area. Stress relieving
of these welds is not required. Steel stamping directly on the surface of alloy steel
with other than low stress die stamps shall not be used.

x) SEAL WELDS

i. Seal welding shall be carried out by qualified welders and welding

operators and in accordance with approved drawings.

256
 ii. Threaded joints that are to be seal welded shall be made without the use
of thread lubricating compound. Seal weld shall cover all exposed
threads.

y) WELD ENCROACHMENT AND MINIMUM DISTANCE BETWEEN WELDS

i. Welded joints, more specifically longitudinal welds, shall be placed

not closer than 50 mm to opening or branch welds, reinforcements,
attachment devices or from supports etc. In case of deviation, the
EMPLOYER may specify additional NDE.
4.4.15.8. The longitudinal welds of two adjacent components shall be staggered by at least
30o. The minimum distance between welds shall be 50 mm or three (3) times the
wall thickness, whichever is greater. Intersection of welds shall be avoided as far
as possible. If such welds are present, they shall be subject to suitable NDE at the
discretion of the EMPLOYER.
4.4.15.9. PREHEATING

a) Preheating prior to tack welding, welding and thermal cutting shall be used as a
means of crack prevention and improving weld reliability. The general
requirements of PWHT also apply to preheating.

b) Preheating shall be used as per the recommendations of ASME BPV Code

Section VIII Division 1. For equipment under the purview of IBR, the
requirements of IBR shall govern. Preheating of austenitic stainless steels is not
required, except at low ambient temperatures, in which case a minimum preheat
temperature of 10oC is recommended. Table 2 gives the requirements of
preheating for commonly used materials

c) The preheating zone shall extend 75 mm or a distance equal to four (4) times the
material thickness, whichever is greater, beyond the edge of the weld.

d) The preheat temperature shall be measured at least 75 mm away from the weld
preparation.

e) Where preheating is specified, welding shall continue without interruption. In

case interruption cannot be avoided, preheating shall be carried out before re-
commencement of welding.

f) Oxy-acetylene preheating shall not be applied.

g) For preheating, fuel gas/air torches, burner systems (high velocity gas or oil
burners) or electrical heating may be used either locally or in a furnace. For
preheating above 250oC, electric heating (resistance or inductive heating) is
recommended.

h) Approved temperature - indicating crayons, thermocouples or digital contact or

laser pyrometers shall be used to measure preheat and inter-pass temperatures. A
calibration report of the pyrometers and thermocouples shall be available.

257
 i) When the preheat temperature is 150oC or higher, the metal shall be maintained at or
above the preheat temperature until the weld is completed.

j) The welding of groove welds in low alloy steels of P-3 to P-5 groups with wall
thickness of 19 mm or greater may only be interrupted, provided at least 10 mm of
weld metal is deposited, or 25% of the welding groove is filled, whichever is greater.
If the welding is interrupted prior to the above, the weld area shall be adequately
covered with insulating material to ensure slow cooling. After cooling and before
welding is resumed, visual examination of the weld shall be performed to
assure that no cracks are formed. Required preheat shall be applied before
welding is resumed.
4.4.15.10. POSTWELD HEAT TREATMENT

PWHT shall meet the requirements of ASME BPV Code Section VIII Division 1. Table 3
summarises the PWHT requirements for commonly used materials. For equipment under the
purview of IBR, PWHT shall be as per IBR.

a) GENERAL REQUIREMENTS

i. A complete automatic temperature recording shall be made of

preheating and stress relieving operations. Where propane gas burners or
electrical resistance coils are employed, a complete temperature record of
the preheating and stress relieving operation shall be made by means of a
box type potentiometer. Other means of recording temperatures are
permissible subject to the EMPLOYER's approval.

ii. Stress relief may be local or full furnace. Local stress relief shall be
performed with electric induction or electric resistance coils. Suitable gas
burning equipment using natural gas or propane may be employed.

iii. At no time during a stress relieving/preheating cycle shall any water or

liquid cooling medium be employed.

iv. Where members being joined are unequal in thickness, the dimension
of the heavier section shall govern the selection of width of the heated
band and the duration of the holding period shall be based on maximum
weld thickness.

v. For local stress relief, using electrical methods, a minimum of

two (2) thermocouples tack-welded to the surface and potentiometers
shall be used on the part under at least four (4) layers of asbestos paper.
The hot junctions of the thermocouples shall be located on either side of
the joint at least 12 mm from the edge of the joint but no further away than
100 mm. When employing induction heating, at least six (6) turns of
induction cable shall be used on each side of the weld. Induction coils
shall be wrapped on top of the asbestos paper protecting the
thermocouples with the first turn approximately 150 mm from the centre
of the weld.

258
 vi. Local stress relief using gas torches or ring burners may be
employed.

However, the procedure shall be limited to small items and shall be

approved by the EMPLOYER.

vii. The stress relieving temperature shall be maintained for a period of

time proportioned on the basis of one (1) hour per 25 mm of weld
thickness at the joint, but in no case less than one (1) hour.

viii. For piping joints and socket welded joints, pads, bosses, branch
welds and couplings, one (1) thermocouple shall be positioned at a
minimum distance of two (2) pipe wall thicknesses from the weld.

ix. Equipment on both sides of any joint shall be adequately supported

throughout the preheating, welding and stress relieving operations to
prevent distortion.

x. All heating and cooling rates shall be maintained as per ASME BPV Code
and time-temperature charts from the recorder shall be made available
for review and acceptance.

xi. The VENDOR/CONTRACTOR shall submit a detailed written procedure

for the

PWHT for the approval of the EMPLOYER.

b) CARBON STEEL

i. Welded joints in carbon steel shall be stress relieved, upon completion

of the welding operation, in accordance with Table 3.

ii. When local stress relief is employed, the welded joint shall be
heated to a temperature of not less than 600°C. The temperature level
shall be maintained between 600 and 650°C, one (1) hour per 25 mm of
weld thickness but in no case less than one (1) hour. The weld area
shall then be allowed to cool undisturbed in still air to a temperature
not exceeding 315°C.

iii. Heating and Cooling

Carbon steels, after having reached their specific stress relief temperatures,
may be cooled in the furnace or under wraps, i.e., leaving the
induction coils or resistance heaters and insulation in place. This means
that, at the stress relief temperatures, the power to the furnace or heating
coils may be shut off and cooling takes place in the furnace or with all
insulation and coils remaining on the part. For furnace stress relief, the
doors of the furnace may be opened after the power is shut off, at or
below 315°C. Thermocouples controlling the temperatures shall
remain during the cooling cycle so that excessive cooling, if it occurs, can
259
 be observed and immediately corrected. The stress relieving coils and
insulation shall only be removed after the part has cooled to below 315°C
or if stress relieved in a furnace the part may be removed from the
furnace and permitted to cool in still air at a temperature not below 10°C.

c) ALLOY STEEL

i. Welds in alloy steel shall be stress relieved after the welding

operation in accordance with Table 3. After welding, the material
shall be wrapped in asbestos and allowed to cool slowly if PWHT is not
carried out immediately.

ii. For full furnace stress relief of a welded assembly, the entire fabricated
section shall be heated uniformly to the temperature specified. The
temperature shall be maintained for a period of time proportioned on the
basis of one (1) hour per 25 mm of weld thickness of the piece having
the greatest weld thickness in the furnace charge, but in no case, less than
one (1) hour.

d) AUSTENITIC STAINLESS STEEL

i. Welded joints in austenitic stainless steel need not be stress relieved

after welding. Solution annealing shall be carried out, if specified.
4.4.15.11. ELECTRODES

(a) The specification and size of the electrodes, voltages and amperages, thickness of
beads and number of passes shall be as specified in the approved welding procedure
or otherwise agreed in writing. Only basic coated electrodes shall be used, which
will deposit weld metal having the same or higher physical properties and
similar chemical composition to the members being joined. For each batch of
approved brand, certificate showing compliance with the specification shall
be submitted to the EMPLOYER for review before being released for use. All
electrodes shall be purchased in sealed containers and stored properly to prevent
deterioration. As welding electrodes deteriorate under adverse conditions of storage
leading to dampness in the electrode coating, they shall normally be stored in
dehumidified air-conditioned rooms or in hot boxes or ovens in their original sealed
containers whose temperatures shall be maintained within specified limits. The
condition of electrodes shall be frequently inspected Electrodes with damage to
coating shall not be used. Electrodes shall remain identified until consumed. It is
preferable to procure low hydrogen electrodes in hermetically sealed containers
and preserve them without damage to the containers

(b) All low hydrogen electrodes, after baking as per the manufacturer‟s
recommendations, shall be stored in ovens kept at 80 to 100°C before being used.
Recommendations of the electrode manufacturer shall be strictly followed. Until the
electrodes are taken out for welding, they shall be stored in portable ovens. The
electrodes shall not be exposed to open atmosphere.

260
 (c) For welding of all grades of steel and alloys by the GTAW process, a
2%thoriated tungsten electrode conforming to SFA-5.12-86 EWTh-2 (AWS-
A5.12-80, EWTh-2) classification shall be used.

(d) All electrodes to be used on alloy and carbon steel shall conform to ASME BPV
Code Section II Part C or any other equivalent code.

(e) The type of electrodes used shall be only those recommended by the
manufacturer for the use in the position in which the welds are to be made.

(f) Current and polarity shall be maintained as recommended by the electrode

manufacturer.
4.4.15.12. INSPECTION AND TESTING

(a) The EMPLOYER shall have free access to inspect welding or any other related
operations at any time and at any stage of fabrication.

(b) The EMPLOYER may require NDE of any weld for reasons other than those given
in the specification. The responsibility for the cost of such testing shall be mutually
decided between the EMPLOYER and the VENDOR/CONTRACTOR.

(c) The VENDOR/CONTRACTOR shall inform the EMPLOYER when the weld
preparation and set-up for welding of various members selected by the EMPLOYER
are in progress so that the EMPLOYER can inspect the assembly before
welding starts.

(d) The responsibilities of the EMPLOYER's representative shall in no way reduce the
VENDOR/CONTRACTOR‟s responsibilities to ensure that the work is carried out in
accordance with the specificatio

(e) Any examination by NDE methods shall be performed before or after PWHT
based on the applicable code requirements

(f) For a welded branch connection and for any weld, necessary repairs and NDE shall
be completed before any reinforcing pad is added.
4.4.15.13. EXAMINATION OF WELDS

(a) Examination refers to the quality control functions performed by the VENDOR /
CONTRACTOR during fabrication, erection and testing.

(b) As a minimum, the following shall be examined by visual examination:

i. Materials and components to ensure that these are as per the

specification and are free from defects. If defects are noticed on “free-
issue” items, these shall be brought to the notice of the EMPLOYER
without delay.

ii. Joint preparation and cleanliness

iii. Fit-up, joint clearance, and internal alignment prior to joining

261
 iv. Preheating as applicable

v. Variables specified by the welding procedure, including filler

material, position and electrode

vi. Condition of the root pass after cleaning - external and where accessible,
internal

vii. Slag removal and weld condition between passes

viii. Appearance of the finished joint and weld dimensions

(c) Acceptance for the visual examination shall be as per ASME BPV Code Section VIII
Division 1 or IBR as applicable.
4.4.15.14. QUALIFICATION AND CERTIFICATION OF NDE PERSONNEL

(d) Approved and documented NDE procedure prepared by level III personnel shall be
made available.

(e) The VENDOR‟s/CONTRACTOR‟s examining personnel shall have training and

experience commensurate with the needs of the specified examinations. NDE
supervisors/ examiners shall be qualified at level II or above of ASME BPV Code
Section V.

(f) The VENDOR/CONTRACTOR shall make available to the EMPLOYER copies of

certificates of qualification of the examiners he proposes to use for the
EMPLOYER‟s approval.
4.4.15.15. METHODS OF EXAMINATION

(a) The methods of examination used, Ultrasonic (UT), Radiographic (RT), MT and PT
shall be in accordance with ASME BPV Code, Section V.
4.4.15.16. ACCEPTANCE STANDARDS

(a) Levels of acceptance of defects in welds shall be in accordance with ASME BPV
Code Section VIII Division 1.

(b) For equipment under the purview of IBR, the levels of acceptable defects shall be as
per IBR.

4.4.15.17. REPAIR WELDING

(a) All defects in welds requiring repair shall be removed by flame or arc gouging,
grinding, chipping or machining. The major repairs may involve:
(i) Cutting through the weld
(ii) Cutting out a portion of material containing the weld, or
(iii) Removing the weld metal down to the root depending
upon the magnitude of the defects.

262
 (b) After removing the defect, the repaired portion and adjacent area shall be
examined by the same NDE methods as specified for the original weld and the same
acceptance criteria shall hold good.

(c) All the repair welds shall be made using the same or other specified welding
procedures as those used in making the original welds including preheating and stress
relieving if originally required.

TABLE 1

WELDING SPECIFICATION CHART FOR COMMONLY USED MATERIALS

Welding
L. Filler material
Base material P. No. process Notes
No.
Root Filler Root Filler
1.0 Carbon steels
ER 70S2
ER 70S2 OR
1 GTAW GTAW OR
1.1 5 mm thick ER 70S3
ER 70S3

E 6013
GTAW SMAW ER 70S2 OR
5 mm and 19 mm F6--EL8
1.2 1 OR OR ER 70S3 OR
thick OR E 7018
SMAW SAW E 6010
F7--EL12
GTAW SMAW ER 70S2 OR
E 7018
1.3 19 mm thk 1 OR OR ER 70S3 OR 1
F7--EL12
SMAW SAW E 6010
2.0 Low alloy steels
1¼% cr ½% mo 5 mm 4 GTAW GTAW ER 80S B2 ER 80S B2
2.1
thick
1¼% cr ½% mo 5 mm E 8016 OR
2.2 4 GTAW SMAW ER 80S B2
thick E8018-B2
2¼% cr 1% mo 5 mm
2.3 5 GTAW GTAW ER 90S B3 ER 90S B3 2 to 7
thick
E 9015 OR
2¼% cr 1% mo 5 mm
2.4 5 GTAW SMAW ER90S B3 E 9016 OR 2 to 7
thick
E 9018-B3
Austenitic stainless GTAW
3.0
steels FOR 5 ER 308
MM (ER 308L)
THICK
ER 308
8 GTAW SMA 2 to 7
Type 304 (ER 308L)
3.1 W FOR
(304l) E 308
>5
(E 308L)
MM
THICK

263
 GTAW
FOR 5 ER 316
MM (ER 316L)
THICK
Type 316 ER 316
3.2 8 GTAW SMA 2 to 7
(316l) (ER316L)
W FOR
E 316
>5
(E 316L)
MM
THICK
GTAW
ER 321
FOR
OR ER
5 MM
ER 321 347
THICK
3.3 Type 321 8 GTAW OR 2 to 7
SMAW ER 347
FOR E 321 OR
> 5 MM E 347
THICK
Stainless steel to
4.0
carbon steel GTAW ER 309
8 to 1 OR SMAW OR E 309
4.1 SS 304/321 SMAW E 309

ER 309
GTAW MO
4.2 SS 316 8 to 1 OR SMAW OR E 309 MO
SMAW E 309
MO
GTAW ER 309L
4.3 SS 304L 8 to 1 OR SMAW OR E 309L
SMAW E 309L
ER 309
GTAW MOL
E 309
4.4 SS 316L 8 to 1 OR SMAW OR
MOL
SMAW E 309
MOL
N

NOTES

1.Low hydrogen electrodes shall be used for critical systems such as chlorine,
hydrogen, caustic and similar toxic inflammable fluids and also whenever the wall
thickness exceeds 19 mm

2. The argon shielding gas flow rate shall not be less than 0.34 M3/Hr.

3. For purging and shielding argon gas shall be used. However, nitrogen may be
used as an alternative to argon for purging purpose only. In case of stainless steel,
nitrogen may be used where corrosion resistance is not critical.
264
4. For fillet welds, SMAW may be used instead of GTAW for thicknesses above 5
mm.

5. For GTAW, electrode shall be 2% thoriated tungsten.

6. Initial purging prior to welding process shall be a minimum of five (5) times the
volume between dams or ten minutes minimum whichever is higher. When welding
commences, The purge gas flow shall ensure that the gas pressure is only marginally
higher than atmospheric pressure to ensure no root concavity.

7. Back purging using argon/nitrogen shall be maintained for the root run and a
minimum of one (1) additional pass.

8. Electrodes and filler wires manufactured by reputed firms duly approved by the
EMPLOYER shall only be used.

9. Electrodes shall have at least the same or higher physical properties and similar
chemical composition to the members being joined.

10. Read the table in conjunction with para 3.0

265
 TABLE 2

PREHEAT REQUIREMENTS
Specified Recommended
Nominal
minimum minimum
Sl. P. wall
Base material tensile preheat
No. No. thickness
strength temperature,
, mm
, mpa °c
1. Carbon steel 1 25 490 10
2. Carbon steel 1 25 490 100
Low alloy steel
3. - 1¼% cr ½% 4 All All 149
mo
Low alloy steel
4. 5 All All 210
- 2¼%cr 1% mo

TABLE 3

POSTWELD HEAT TREATMENT REQUIREMENTS (FOR COMMONLY USED STEEL

MATERIALS)
Nominal Metal
Sl. wall temperature
Base material P. No.
No. thickness range
mm °c
1. Carbon steel 1 32 None
2. Carbon steel 1 > 32 600 to 650
4 GR
Low alloy steel 1
3. All 600 to 650
1¼% cr ½% mo AND
2
Low alloy steel 5A
4. All 680 to 700
2¼% cr 1% mo GR 1
Austenitic
5. 8, 9 All Note 3
stainless steels

NOTES

1. In IBR systems, in carbon steels, PWHT is also required, when the carbon percentage
exceeds 0.25%, at the temperature range of 600 +/- 20°C.

2. For all low alloy steel welds under the purview of IBR, the PWHT shall be carried out at
the temperature range of 620 to 660° C for 1 1/4% Cr 1/2% Mo steels and at a range of 660 to
750°C for 2 1/4% Cr 1% Mo steels.

266
 3. Solution annealing shall be carried out after welding of austenitic stainless steel as per the
applicable services.

4. For equipment in carbon steels or alloy steels and meant for lethal service, PWHT of all
welds shall be carried out.

4.4.16 LOW VOLTAGE INDUCTION MOTORS

4.4.16.1. SCOPE
The specification covers the design, material, constructional features, manufacture,
inspection and testing at the VENDOR's / his SUB-VENDOR'S works, delivery to site and
performance testing of Low Voltage induction motors rated up to 1000V.
4.4.16.2. CODES AND STANDARDS
The design, material, construction, manufacture, inspection, testing and performance of
induction motors shall comply with all currently applicable statutes, regulations and safety
codes in the locality where the equipment will be installed. The equipment shall also
conform to the applicable standards specified in data sheet A1 latest revision as on the date
of offer. Nothing in this specification shall be construed to relieve the VENDOR of this
responsibility. In case of conflict between the standards and this specification, this
specification shall govern.
4.4.16.3. DRIVEN EQUIPMENT

(a) When this specification forms part of the driven equipment specification, information
not given in the Data Sheet-A will be governed by the driven equipment
specification.

(b) Motors shall be capable of satisfactory operation for the application and duty as
specified in the motor Data Sheet-A and as specified for the driven equipment.
4.4.16.4. PERFORMANCE AND CHARACTERISTICS

(c) Motors shall be capable of giving rated output without reduction in the expected life
span when operated continuously under either of the following supply conditions
as specified in Data Sheet-A.
Supply Condition
I II
(i) Variation in supply voltage
from rated voltage +6% +10%

(ii) Variation in supply frequency

from rated frequency +3% +5%

(ii) Combined voltage and

Frequency variation 9% 10%

(a) Motors shall be suitable for the method of starting specified in the Data Sheet-A.

(b) The minimum permissible voltage shall be 85% of the rated voltage during motor
starting.

267
 (c) Motors shall be capable of starting and accelerating the load with the applicable
method of starting, without winding temperatures reaching injurious levels, when the
supply voltage is in the range of 85% of the rated motor voltage to maximum
permissible voltage specified in Data Sheet-A.

(d) The locked rotor current of the motor shall not exceed 600% of full load current
(subject to tolerances as per the applicable standard) unless otherwise specified. The
locked rotor current of VFD controlled motor shall be within the limit of IS12615 /
IEC.

(e) Motors shall be capable of developing the rated full load torque even if the supply
voltage drops to 70% of the rated voltage. The pull out torque of the motor shall be at
least 205% of full load torque.

(f) Motors when started with the driven equipment coupled shall be capable of
withstanding at least two successive starts from cold conditions & one start from hot
condition without injurious heating of windings. The motors shall also be suitable for
three equally spread starts per hour under the above referred supply conditions.

(g) Motors shall be of Energy Efficient type if specified in Data sheet-A1. Category of
Energy efficiency shall be as mentioned in data sheet-A1.
4.4.16.5. SPECIFIC REQUIREMENTS OF VFD DRIVEN MOTORS

(a) The motor shall be suitable for operation with a solid-state power supply consisting
of an adjustable frequency inverter for speed control.

(b) The motor shall be suitable for the current waveforms produced by the power supply
including the harmonics generated by the drive.

(c) The Motor shall be designed to operate continuously at any speed over the range 10-
100 % of rated speed.

(d) The permitted voltage variation should take into account the steady state voltage drop
across the AC drive and all other system components upstream of the motor.

(e) The motor shall be constructed to withstand torque pulsations resulting from
harmonics generated by the solid-state power supply.

(f) The driven equipment manufacturer shall be solely responsible for proper selection of
the motor for the given load application and the output characteristics of the driven
equipment.
4.4.16.6. INSULATION

(a) The insulation shall be given tropical and fungicidal treatment for successful
operation of the motor in hot, humid and tropical climate.

(b) Motors which are VFD controlled shall be inverter grade and shall be suitably
derated to take care of reduced cooling at lower speeds.

268
 (c) Insulation of VFD controlled Motors shall be designed to withstand a dv/dt of 0.1
micro sec rise from 10 % to 90 % of steady voltage and a maximum peak of 1600
volts as per NEMA standard MG1 Part 31.40.4.2 .

(d) The insulation shall be of double coat winding wires which having superior electric
strength and thermal capability for VFD controlled motors.

(e) Winding shall be insulated as VPI (Vacuum Pressure Impregnation) of winding with
suitable resin forces which eliminating voids for VFD controlled motors.
4.4.16.7. TEMPERATURE RISE

(a) The temperature rises shall not exceed the values given in IS 12802. Under extremes
of supply condition, the temperature rise shall not exceed the value indicated in IS by
10ºC.

(b) For motors specified for outdoor installation heating due to direct exposure to solar
radiation shall be considered.
4.4.16.8. CONSTRUCTIONAL FEATURES

(a) All windings shall be of Copper. The winding insulation shall be Non-hygroscopic,
oil resistant and, flame resistant.

(b) Motors weighing more than 25 kg. shall be provided with eyebolts, lugs or other
means to facilitate safe lifting.

(c) Noise level and vibration limit should not exceed as specified in relevant IS / IEC.
4.4.16.9. BEARINGS

(a) Unless otherwise specified in data sheet-A, motor bearings shall not be subjected to
any external thrust load.

(b) Unless otherwise specified, motor bearings shall have an estimated life of at least
40,000 hrs.

(c) The bearings shall permit running of the motor in either direction of rotation.

(d) When forced oil lubrication or water cooling is required, prior approval from the
Employer shall be obtained.

(e) It shall be possible to lubricate the bearings without dismantling any part of the
motor.

(f) VFD controlled Motors shall have their bearings insulated to prevent motor shaft
currents from entering the bearing race.
4.4.16.10. TERMINAL BOX

(a) Terminal boxes shall have a degree of protection of atleast IP 55 for out door
applicable.

269
 (b) Unless otherwise approved, the terminal box shall be capable of being turned through
360o in steps of 90o.

(c) Terminals shall be of stud type & the terminal box shall be complete with necessary
lugs, nuts, washers.

(d) When single core cables are to be used the gland plates shall be of non magnetic
material.

(e) Sizes of terminal boxes and lugs shall be as given in Table-I, unless specified
otherwise in data sheet A or Specification.

TABLE-I
415 V MOTORS - SIZES OF CABLES, STUDS, TERMINAL LUGS & TERMINAL BOXES
(TO BE PROVIDED ON MOTORS BY VENDOR)

Motor Rating 1100V Al Conductor, armoured PVC/XLPE

Sl No.
(kW) Cable Cores x mm2
1. Upto 3 3x4
2. 3.1 - 7.5 3x6
3. 7.6 - 15 3x16
4. 16 - 25 3x35
5. 26 - 40 3x70
6. 41 - 55 3x120
7. 56 - 70 3x185
8. 71 - 85 3x240
9. 86 - 110 3x400
10. 111 - 200 3Rx1Cx500

4.4.16.11. PAINT AND FINISH

(a) All motor parts exposed directly to atmosphere shall be finished and painted to
produce a neat and durable surface which would prevent rusting and corrosion. The
equipment shall be thoroughly degreased, all rust, sharp edges and scale removed and
treated with one coat of primer and finished with two coats of grey enamel paint.
4.4.16.12. HEATING DURING IDLE PERIODS

(a) Motors rated above 30 kW shall have space heaters suitable for 240V, single phase,
50 Hz, AC supply. Space heaters shall have adequate capacity to maintain motor
internal temperature above dew point to prevent moisture condensation during idle
period. The space heaters shall be placed in easily accessible positions in the lowest
part of the motor frame.
4.4.16.13. ACCESSORIES

270
 (a) Two independent earthing points shall be provided on opposite sides of the motor, for
bolted connection of the EMPLOYER'S earthing conductors as specified in data
sheet-A. These earthing points shall be in addition to earthing stud provided in the
terminal box.

(b) Except when otherwise specified, the motors shall be provided with a bare shaft
extension having a key slot and a key at the driving end.
4.4.16.14. TESTS

(a) Motor shall be subjected to all the routine tests as per applicable standard in the
presence of the EMPLOYER'S representative. Copies of test certificates of type and
routine tests shall be furnished as specified in the distribution schedule, for the
EMPLOYER'S approval. The VENDOR shall ensure to use calibrated test
equipment/instruments having valid calibration test certificates from standard
laboratories traceable to national/international standards.

(b) If type tests have not been carried out on similar Motors, or if the type test reports
submitted are not found in order, then VENDOR shall carry out these tests without
any extra cost to the Employer.
4.4.16.15. LOW VOLTAGE INDUCTION MOTORS DATA SHEET-A1

Sl.no
Description Unit Technical particulars
.
1.0 General
1.1 Application (*)
1.2 Numbers required (*)
1.3 Type of motor Squirrel cage (energy efficient- IE-3 as
per 12615) type
1.4 Supply system fault level Mva 16KA
1.5 Type of earthing of supply system Effectively earthed system
neutral
2.0 Rating
2.1 Rated output : Kw Kw (*)
2.2 Rated voltage : V 415v
2.3 Number of phases & frequency 3 phase, 50 hz
2.4 Supply condition as per Ii
specification
2.5 Synchronous speed Rpm Rpm(*)
3.0 Duty
3.1 Type of duty (clause 9.2 of is:325 (*)
or equivalent)
3.2 Power required by load Kw (*)

271
Sl.no
Description Unit Technical particulars
.
3.3 Energy efficiency class as per is- IE3
12615-2011

4.0 Method of starting D.O.L /STAR DELTA

5.0 Insulation
5.1 Class of insulation F with temp. Rise class-b
5.2 Ref. Ambient temperature °c 50°c
5.3 Temperature rise by Corresponding to class b insulation
5.3.1 Thermometer method °c 55°c
5.3.2 By winding resistance method 65°c (class b)
6.0 Installation
6.1 Location Indoor
6.2 Hazardous area division (is:5572 or
Not applicable
equivalent)
6.3 Atmosphere Chemical
7.0 Enclosure
7.1 Type of cooling (is 6362) Tefc
7.2 Designation for degree of
Ip 55
protection (is 4691)
8.0 Main terminal box
8.1 Location as seen from non- drive
Top/right/left (*)
end:
Ratings (*)
8.2 (a) Short time
I. Current : Ka(rms
)
Ii. Duration : Secs. 0.1
Ka
(b) Dynamic :
(peak)
8.3 External cable details (#)
8.3.1 Type
8.3.2 Size & no of cores
8.4 Earthing conductors
8.4.1 Material Gi
8.4.2 Size (#)

272
 Sl.no
Description Unit Technical particulars
.
9.0 To be filled if motors are bought
Miscellaneous requirements
seperately
9.1 Shaft orientation Horizontal/vertical/hollow vertical (*)
9.2 Mounting symbol (is:2253 or
(*)
equivalent)
9.3 Rotation as seen from non-drive Clockwise/anti-clockwise/ bi-
end directional (*)
9.4 Type of bearing
9.4.1 Drive end (*)
9.4.2 Non drive end (*)
9.5 Whether bed plate required (#)
9.6 Motor shall match the following
torque requirements of the driven (*)
equipment:
A) Starting torue
B) Full load (rated) torque
C) Pull out torque
D) Pull up torque
9.7 Coupling by motor supplier Yes/no (will be informed later)
9.8 If yes, type of coupling
10.0 Colour shades of paint Light grey ( shade -631 of is-5)
11 Whether vibration pads required (#)
12 Temperature detectors/indicators
12.1 Embedded temperature detectors
No
for winding required
12.2 Embedded temperature detectors
No
for bearings required
12.3 Bearing thermometers for driving
No
end & non driving ends required
13 Space heaters for motors required
Yes for motors of 30kw & above
(for motors greater than 30kw )

4.4.16.16. LOW VOLTAGE INDUCTION MOTORS DATA SHEET-A2

Sl.no. Brief title Reference number of standards

1. Three phase induction motors  IS-325  BS-4999  IEC-34

2. Rotating electrical machines  IS-4722  BSEN60034-1  IEC-34-1

273
Sl.no. Brief title Reference number of standards

3. Single phase induction motors  IS-996  BS  IEC

4. Code of practice for climate  IS  BS-6751  IEC

proofing

5. Designations for types of  IS-2253  BSEN60034-7  IEC-34-7

construction and mounting
arrangement of rotating electrical
machines

6. Terminal marking & direction of  IS-4728  BS-4999-108  IEC-34-8

rotation for rotating electrical
machinery

7. Designation of methods of cooling  IS-6362  BSEN 60034-6-  IEC-34-6

for rotating electrical machines 1994

8. Degrees of protection provided by  IS-4691  BS-EN60529  IEC-529

enclosure for rotating electrical
machinery

9. Guide for testing three phase  IS-4029  BSEN60034-2  IEC-34-2

induction motors

10. Measurement and evaluation of  IS-12075  BS-4999142  IEC-34-14

vibration of rotating electrical
machines

11. Classification of hazardous areas  IS-5572  BS  IEC-79

for electrical installation

12. Dimensions of slide rails for  IS-2968  BS-4999-141  IEC

electric motors

13. Permissible limits of noise level for  IS-12065  BSEN 60034-9-  IEC
rotating electrical machines 1994

14. Guide for testing insulation  IS-7816  BS  IEC

resistance of rotating machines

15. Induction motors- energy efficient  IS-  IEC-60034-

three phase squirrel cage- 12615-2011 3
specification

16. Flame proof a c motors for use in  IS- 3682

mines.

17. Flame proof enclosures of electrical  IS-2148

apparatus

274
Sl.no. Brief title Reference number of standards

18. Starting performance of single  IS-8789  BSEN-60034-12  IEC-34-12

speed three phase cage induction
motors for voltage up to 600 v

19. Cage induction motors when fed  IEC-34-17

from converters – application guide

20. Adjustable speed electrical power  BS-EN-61800  IEC-61800

drive system- emc requirements and
specific test methods.

21. Dimensions and output series for  IS-1231  BS-4999-141  IEC- 72-1
rotating electrical machines.

22. Electrical apparatus for explosive  IS-5571  BSEN-60079  IEC-79-10

gas atmosphere – classification of
hazardous area.

23. Temperature rise measurement of  IS-12802  BS  IEC

rotating electrical machines

24. Type of duty and classes of rating  IS 12824  BS  IEC

assigned to rotating electrical
machines

25. Cbip recommendation for motors

NOTES:

1. Details marked thus (*) will be decided and intimated by the bidder based on driven
equipment characteristics

2. Data marked thus (#) will be intimated to vendor after placement of order.

3. Data marked thus (^) will be decided and intimated by the bidder.

4. Associated accessories, components/parts, raw material and tests shall in general conform to
 is  bs  iec .

5. Offers conforming to other authoritative standards may also be considered/may not be

considered.
6. Use  mark for applicable for relavent is and iec.

275
276

4.4.16.17. SHOP INSPECTION REQUIREMENTS VALVES-METALLIC

Serial no.

Visual examination
Dimensions
Material test cert.
and correlation
Identification
Pouring
Pt / mt
Radiography
Ultrasonic test
Heat treatment
Hardness test
-hydrostatic
Shell,
leaktest-hydrostatic
Seat, back seat
Seat leak test - air
Set point
Disc strength test
operation tests
Performance /
Type tests
Routine tests
thickness
hardness, spark,
Adhesion,
Endurance (type) test
gland leak test
Description

1 Pressure parts - materials D C D D B B B C D D

2 Trims (seats, stem, plug, disc etc.) C D B B
3 Springs C C C
x
4 Diaphragm C D
5 Non - metalli c items, if any C D
6 Actuators, positioners, if any A A Az A C C
7 Finished items A A A A B A
8 Safety relief valves - additional tests D A A
9 Butter fly valves - additional tests B
10 Control valves - additional tests Ay
11 Linings, if any A A
Leged Nots
A - witnessed by tce. 1 - all stages shall be checked 100 % by vendor and records thereof show n to tce.
B - witnessed by tce if requirement is specified. 2 - witnessing by tce may be 100 % or on random samples.
C - records verified by tce w herever applicable.
3 - this document shall be read in conjunction with inspection requirements mentioned in and relevant technical
D - a or c, at tce's discretion w herever appli cable. X - scrag test and specifications.
load / deflection test.
4 - the pressure gauges and instruments for measuring critical parameters shall have valid calibration certificate
Y - including cv.
traceable to national laboratory.
Z - for actuator chamber.

276
4.4.16.18. SHOP INSPECTION REQUIREMENTS PIPES AND PIPE FITTINGS-METALLIC
Serial no.

Visual examination
Dimensions
Material test cert.
and correlation
Identification
Ultrasonic test
qualification
Welding
Fit up

Backchip-pt
Pt / mt

Radiography

Ovality, thinning

Heat treatment
Surface finish

Hydrostatic leak test

Hardness test

Spark, adhesion test

Thickness check

Material check test

Description

A Ordered on manufacturer

1 Plates / pipes for fabricated items D D C D D

2 Rolling, forming for fab. Items D D D

3 Butt, groove w elds for fabricated items D D B C/a D D B B

4 Finished items A A C A B C B B D

5 Linings, if any A A A A

6 Coatings, if any A A

B Ordered on dealers / stockists etc. A A C A A C Ax Ax Ax D

277
 Leged Notes
A - witnessed by tce. 1 - all stages shall be checked 100% by vendor and records thereof show n to tce.
B - witnessed by tce if requirement is specified. 2 - witnessing by tce may be 100 % or on random samples.
C - records verified by tce w herever appli cable. 3 - this document shall be read in conjunction with inspection requirements mentioned in and relevant technical
specifications.
D - a or c, at tce's discretion w herever appli cable.
4 - the pressure gauges and instruments for measuring critical parameters shall have valid calibration certificate
X - for lined items.
traceable to national laboratory.

4.4.16.19. SHOP INSPECTION REQUIREMENTS FOR STRAINERS

Serial no.

Performance /
operation test
Hydrostatic leak test

Spark, adhesion test

Visual examination

and correlation
Identification
Material test cert.

Thickness check
Hardness test
qualification
Dimensions

Welding
Description

1 Pressure parts - materials C D

2 Finished item A A C/a A D

3 Linings, if any A A A A

Legend Notes
A - witnessed by tce. 1 - all stages shall be checked 100 % by vendor and records thereof show n to tce.
B - witnessed by tce if requirement is specified. 2 - witnessing by tce may be 100 % or on random samples.
C - records verified by tce w herever applicable. 3 - this document shall be read in conjunction with inspection requirements mentioned in and relevant technical specifications.
D - a or c, at tce's discretion w herever applicable. 4 - the pressure gauges and instruments for measuring critical parameters shall have valid calibration certificate traceable to
national laboratory.

4.4.16.20. SHOP INSPECTION REQUIREMENTS FIRE PROTECTION EQUIPMENT

278
 C A/

279

Routine test
C

Type test
Fire test
Flame/smok
e detection
H.v., i,r.,
continuity test
Interlock test
Wiring, function
check
Makes and ratings of
parts
A

Fitment
D

Balancing
Weight per unit
A

length
B B

Accelerated ageing
Kink test
Change in dia.
A

And length
B

Percolation test
A

A A

A A
D

Performance test
A A D A

Operation test
Flow test
A A

D D
Seat leak test
A

C
Body leak test
C

C
Material test cert.

C
A A

A A

A A

A A

A A

A A

A A

A A

A A

A A

D D
Dimensions
Visual
EXAMINATION
Branch pipes, nozzles, hose couplings
DESCRIPTI
ON

17 Motors > 30 kw / <30 kw

Portable fire extinguisher
Landing / hydrant valve

Main and jockey pump

Pipes, fittings, valves

10 Fire hose boxes

Diesel engine
Alarm valve
Fire hoses

Sprinkler
1

7
Serial Numbers

9
 Legend Notes
A - witnessed by tce. 1 - all stages shall be checked 100 % by vendor and records thereof shown to tce.
B - witnessed by tce if requirement is specified. 2 - witnessing by tce may be 100 % or on random samples.
C - records verified by tce wherever applicable. 3 - this document shall be read in conjunction with inspection requirements mentioned in tce.
And relevant technical specifications.
D - a or c, at tce's discretion wherever applicable.
4 - the pressure gauges and instruments for measuring critical parameters shall have valid calibration certificate traceable to national
laboratory.

280
281

4.4.17 SHOP INSPECTION AND TESTS

4.4.17.1. SCOPE

(a) This specification covers the requirements for Shop Inspection and Tests to be carried out by
the EMPLOYER/PROJECT MANAGER/INSPECTION AGENCY.
4.4.17.2. GENERAL

(a) The plant and equipment covered by the PURCHASE ORDER/CONTRACT shall be
subjected to inspection and testing. The VENDOR/CONTRACTOR shall provide all
services to establish and maintain quality of workmanship in his works and that of his SUB-
VENDOR‟s/SUB-CONTRACTOR‟s works to ensure the mechanical accuracy of
components, compliance with approved drawings, identification and acceptability of all
materials, parts and equipment.

(b) For supply of systems, the VENDOR/CONTRACTOR shall, at the start of the PURCHASE
ORDER/CONTRACT, furnish a total list of items in his scope of work. This list, giving a
brief description of the item, quantity, names of probable SUB-VENDORS/SUB-
CONTRACTORS, and a blank column for agency for final approval of drawings and
documents, shall be submitted for approval by EMPLOYER/PROJECT MANAGER. The
blank column shall be filled by EMPLOYER/PROJECT MANAGER. The list shall be
submitted within two weeks from the date of Letter of Intent.

(c) For systems and major items such as pressure and load bearing items, machineries etc.,
the VENDOR/CONTRACTOR shall furnish quality plan giving details of checks and tests to
be conducted by them on material, process, sub- assembly and assembly. These shall include
requirements as prescribed in the applicable specifications, codes and statutory requirements.
The quality plan shall be reviewed by the EMPLOYER/PROJECT MANAGER and the
stages to be witnessed and verified shall be indicated by the EMPLOYER/PROJECT
MANAGER in the approved quality plan.

(d) The VENDOR/CONTRACTOR shall give the EMPLOYER/PROJECT MANAGER written

notice of any material being ready for testing as per format enclosed. The clear notice period
shall be seven (7) days for local inspection and fifteen (15) days for outstation inspection.
Such tests shall be to the VENDOR‟s/CONTRACTOR's account except for the expenses of
the EMPLOYER/PROJECT MANAGER. The EMPLOYER/PROJECT MANAGER, unless
the inspection of the tests is virtually waived, shall fix a date for inspection with the
VENDOR/CONTRACTOR and attend such tests within fifteen (15) days of the date on
which the equipment is notified as being ready for test and inspection failing which, the
VENDOR/CONTRACTOR may proceed with the tests and shall forthwith forward to the
EMPLOYER/PROJECT MANAGER duly certified copies of tests in triplicate. If the
VENDOR/CONTRACTOR fails to offer the equipment for inspection as per the agreed date,
he is liable to pay for the time and expenses for the infructuous visit of the
EMPLOYER/PROJECT MANAGER.

(e) In all cases where inspection and tests are required whether at the premises or works of the
VENDOR/CONTRACTOR or of any SUB-VENDOR/SUB- CONTRACTOR or at

281
 laboratory, the VENDOR/CONTRACTOR, except where otherwise specified, shall provide
free of charge all facilities such as labour, materials, electricity, fuel, water, stores, test bed,
apparatus and instruments, laboratory tests etc. as may be required by the
EMPLOYER/PROJECT MANAGER to carry out effectively such tests of the equipment in
accordance with the PURCHASE ORDER/CONTRACT and shall give facilities to the
EMPLOYER/ PROJECT MANAGER to accomplish testing.

(f) The EMPLOYER/PROJECT MANAGER shall at all working hours have access to all parts
of the VENDOR‟s/CONTRACTOR's and his SUB-VENDOR‟s/SUB- CONTRACTOR's
factory where the items of the plant are being prepared, for carrying out inspection activities
as deemed necessary. A set of the relevant latest approved drawings with approval marking of
the EMPLOYER/ PROJECT MANAGER and drawings for proprietary items shall be made
available by the VENDOR/CONTRACTOR to the EMPLOYER/PROJECT MANAGER,
for reference during inspection.

(g) In the case of stage inspection hold points, the VENDOR/CONTRACTOR shall proceed
from one stage to another only after the component is inspected by the
EMPLOYER/PROJECT MANAGER and written permission given to proceed further. The
same procedure shall be adopted for any rectifications and repairs suggested by the
EMPLOYER/PROJECT MANAGER.

(h) The EMPLOYER/PROJECT MANAGER shall have the right to inspect any
machinery, material, structures, equipment or workmanship furnished or used by the
VENDOR/CONTRACTOR and may reject any which is defective or unsuitable for the
use and purpose intended, or which is not in accordance with the intent of the PURCHASE
ORDER/CONTRACT. The VENDOR/ CONTRACTOR, upon demand by the
EMPLOYER/PROJECT MANAGER, shall remedy or replace at the
VENDOR‟s/CONTRACTOR's expense such defective or unsuitable items of the plant, or the
EMPLOYER/PROJECT MANAGER may, at the expense of the VENDOR/CONTRACTOR,
remedy or replace such defective or unsuitable items of the Plant.

(i) All principal mill test reports, the VENDOR/CONTRACTOR inspection and tests reports,
test certificates and test curves shall be supplied for all inspection and tests carried out
including other records such as stress relieving charts, radiographic charts and other non-
destructive testing records in accordance with the provisions of the PURCHASE
ORDER/CONTRACT, duly certified by the main VENDOR/CONTRACTOR. The
EMPLOYER/PROJECT MANAGER shall reserve the right to call for certificates of origin
and test certificates for all raw material and equipment at any stage of manufacture.

(j) The EMPLOYER/PROJECT MANAGER shall within fifteen (15) days from the date of
inspection as defined herein give notice in writing to the VENDOR/ CONTRACTOR of any
non-conformance pertaining to all or any equipment and workmanship which in his opinion is
not in accordance with the PURCHASE ORDER/CONTRACT. The
VENDOR/CONTRACTOR shall give due consideration to such objections and shall either
make the modifications that may be necessary to meet the said objections or shall confirm in
writing to the EMPLOYER/PROJECT MANAGER giving reasons therein that no
modifications are necessary to comply with the PURCHASE ORDER/CONTRACT.
282
 (k) When the factory tests and documentation have been satisfactorily completed at the
VENDOR‟s/CONTRACTOR's or SUB-VENDOR's/CONTRACTOR's works, the
EMPLOYER/PROJECT MANAGER shall issue acceptance note or shipping release note or
a certificate to this effect within fifteen (15) days after completion, but if the tests are
not witnessed by the EMPLOYER/ PROJECT MANAGER, the certificate or comments
thereof shall be issued within fifteen (15) days of the receipt of the
VENDOR‟s/CONTRACTOR's test certificate by the EMPLOYER/PROJECT MANAGER.
Failure of the EMPLOYER/ PROJECT MANAGER to take such an action shall not prevent
the VENDOR/ CONTRACTOR from proceeding with the work. The completion of these
tests or the issue of the certificates shall not bind the EMPLOYER/ PROJECT MANAGER
to accept the equipment, should it, on further tests after erection, be found not to comply with
the PURCHASE ORDER/CONTRACT.

(l) None of the plant and the equipment to be furnished or used in connection with the
PURCHASE ORDER/CONTRACT shall be despatched until shop inspection,
satisfactory to the EMPLOYER/PROJECT MANAGER has been made. However, such shop
inspection and/or certification shall not relieve the VENDOR/CONTRACTOR of his
responsibility for furnishing the plant and the equipment conforming to the requirements of
the PURCHASE ORDER/ CONTRACT nor prejudice any claim, right or privilege which the
EMPLOYER/ PROJECT MANAGER may have because of the use of defective or
unsatisfactory items. Should the EMPLOYER/PROJECT MANAGER waive the right to
inspect any item, such waiver shall not relieve the VENDOR/CONTRACTOR in any way
from his obligation under the PURCHASE ORDER/CONTRACT. In the event of the
EMPLOYER‟s/PROJECT MANAGER's inspection revealing poor quality of goods, the
EMPLOYER/PROJECT MANAGER shall be at liberty to specify additional inspection
procedures, if required, to ascertain the VENDOR/CONTRACTOR's compliance with the
equipment specifications.
4.4.17.3. SUB-ORDERS AND SUB-CONTRACTS

(a) In order to facilitate the inspection of bought-out materials and plant, the
VENDOR/CONTRACTOR shall submit for approval, three (3) copies of all sub- orders and
sub-contracts placed by him as soon as these are issued. Copies of any drawings referred to
in the sub-order or sub-contracts shall also be submitted, unless agreed otherwise by the
EMPLOYER/PROJECT MANAGER.

(b) The sub-orders, sub-contracts and drawings referred to above shall include all components
which are subjected to electrical and mechanical pressure or stress when the plant is in
operation, and also auxiliaries and spares which are to be directly despatched to site from the
SUB-VENDOR‟s/SUB-CONTRACTOR's works.

(c) All sub-orders and sub-contracts of the main VENDOR/CONTRACTOR shall clearly be
marked with the main VENDOR‟s/CONTRACTOR's name and the
EMPLOYER‟s/PROJECT MANAGER‟s name and the PURCHASE ORDER/ CONTRACT
reference. These shall include the following statement:

283
 The plant or the equipment which is the subject of this PURCHASE ORDER/ CONTRACT
shall comply in every respect with the requirements of the

EMPLOYER‟s/PROJECT MANAGER's technical specifications and shall be subject to

inspection and tests to the satisfaction of the EMPLOYER/PROJECT MANAGER.

(d) For the purpose of this para, it is obligatory on the VENDOR/CONTRACTOR that he
advises his SUB-VENDOR/SUB-CONTRACTOR of the pertinent clauses in this
specification when ordering bought-out plant, equipment or materials. In particular, the
VENDOR/CONTRACTOR shall advise every SUB- VENDOR/SUB-CONTRACTOR that
he is required to supply design calculations, drawings, inspection reports and test
certificates strictly in accordance with this specification and technical information for
inclusion in the Instruction Manual as specified in specification. The SUB-VENDORS/SUB-
CONTRACTORS should also be reminded that they shall include with their offer all
tools and appliances necessary for proper maintenance and all spare parts as per
specified in specification. Itemised prices of the recommended spare parts shall be submitted
together with the appropriate part numbers and drawings.

(e) Sub-ordering and sub-contracting for major items such as pressure and load bearing items,
machinery etc. can be done only with the approval of the EMPLOYER/PROJECT
MANAGER.
4.4.17.4. MATERIAL TESTS

(a) In the event of the EMPLOYER/PROJECT MANAGER being supplied with the
certified particulars of tests which have been carried out for the VENDOR/ CONTRACTOR
by the supplier of material, the EMPLOYER/PROJECT MANAGER may, at his own
discretion, accept the same as proper evidence of compliance with the requirements of
appropriate specifications for the materials.

(b) The VENDOR/CONTRACTOR is to provide test pieces as required by the

EMPLOYER/PROJECT MANAGER to enable him to determine the quality of material
supplied under the PURCHASE ORDER/CONTRACT. If any test piece fails to comply with
the requirements, the EMPLOYER/PROJECT MANAGER may reject the entire lot of
material represented by the test piece.

(c) Critical materials used in manufacture of the equipment and construction of the plant covered
by the PURCHASE ORDER/CONTRACT may also be subjected to one or more of the Non-
Destructive Tests (NDT) as called for in the enquiry document or as mutually agreed.
Salvaging of material due to unacceptable defect is to be attempted by the
VENDOR/CONTRACTOR only after getting specific concurrence from the
EMPLOYER/PROJECT MANAGER and according to the approved procedures.
4.4.17.5. WELDING

(a) All welding involved in construction and fabrication of the plant and items covered
under the PURCHASE ORDER/CONTRACT shall be carried out in accordance with
specifications and applicable codes.

284
 (b) Welding procedures and welders' qualifications shall be approved by the

EMPLOYER/PROJECT MANAGER. Where applicable, welders shall be tested as

detailed in codes specified for pipe welding, vessel welding and structural welding and
appropriate to the corresponding weld position using test pieces of appropriate parent metal to
be used on the job. The EMPLOYER/ PROJECT MANAGER shall have the right to have
any welder re-tested at any time during the PURCHASE ORDER/CONTRACT.

(c) Recommendations of applicable codes shall be followed for non-destructive tests, wherever
applicable.

(d) Copies of all welding procedures, procedure qualification records, welders' performance
qualification certificates, post-heating and stress relieving records, NDT records and other
test results shall be made available upon request of the EMPLOYER/PROJECT MANAGER.
4.4.17.6. FABRICATION AND INSPECTION

(a) Fabrication and inspection procedures for vessels, heat exchangers, pipes, tubes and valves
etc. shall be in accordance with procurement specifications, quality plan, applicable codes or
any other approved equal.
4.4.17.7. TESTS AT MANUFACTURER'S WORKS

(a) GENERAL

The tests at works shall include electrical, mechanical and hydraulic tests in accordance with
the appropriate clauses of Statutory Regulation, relevant codes and standards and approved
drawings and specifications and in addition any test called for by the EMPLOYER/PROJECT
MANAGER to ensure that the plant being supplied fulfils the requirements of the
specifications. The VENDOR/ CONTRACTOR shall carry out all the shop tests and
inspections specified under individual items of the equipment in Data Sheets of the enquiry
document, in addition to those normally required as per codes and standards. For items not
covered by any code or specifically mentioned in the specifications, the tests are to be agreed
with by the EMPLOYER/PROJECT MANAGER. If considered necessary by the
EMPLOYER/PROJECT MANAGER, multi-part assemblies shall be fully erected and
tested in the works prior to packing and despatch to the site.

(b) TEST CERTIFICATES

Test certificates including test records, performance curves and balancing certificates shall be
supplied according to the Distribution Schedule. All the tests shall be carried out in
accordance with the provisions of the PURCHASE ORDER/CONTRACT.

All test certificates must be endorsed with sufficient information to identify the material or
the equipment to which the certificates refer, and must carry at the top right hand corner the
identification of the EMPLOYER/PROJECT MANAGER and the PURCHASE
ORDER/CONTRACT.

(c) CALIBRATION
285
All instruments used for critical measurement such as pressure gauges for leak tests,
instruments for measuring performance parameters; instruments for precision dimension
measurements shall have valid calibration certificates traceable to national standards. This
means that the calibrating agency engaged by the VENDOR/CONTRACTOR shall use
instruments which are in turn calibrated by Government approved agencies and such
information shall be recorded in the calibration certificate issued by the calibrating agency by
giving the certificate number, date and date of validity of the certificate given by the
Government approved agency.

286
4.5 LIST OF APPROVED MAKES

4.5.1 FIRE PROTECTION SYSTEM

This section provides details of the Approved Vendors / Approved makes for bought-out items,
which form a part of this enquiry package.
BIDDER shall clearly indicate the makes of all bought-out items and shall at no point in time during
execution shall deviate from those indicated in the offer document.
NOTE:
- All materials and products shall conform to the relevant standards and shall be of approved
make and design. A list of manufacturers/ vendors is given separately herein below for
guidance. The Engineer shall give the approval of a manufacturer/ vendor/ only after review
of the sample/ specimen. In case the same is not available in the market or in case of change
in trade name, equivalent makes/ re-designated manufacturer then an equivalent approved
make shall be used with the approval of Employer/ Engineer. The complete system and
installation shall also be in conformity with applicable Codes & Standards and Tender
specifications.
- Only “First” class quality materials shall be used.
- Employer reserves the right to choose any of the approved make / vendors as per this list.
- In case of products not indicated in this list, bis marked products shall be preferred.
- Specification of manufacturer‟s item shall be checked against tender item / specifications
before selecting any product or brand name. In case of any discrepancy, tender item/
specifications shall prevail, and any such brand of item shall not be used which is not
conforming to tender specifications even if it is listed in this list.
- For use of material from a bis listed/ certified manufacturer, the contractor shall furnish a
copy of the BIS certificate to Employer before procuring the material.
- In case non-availability of any item/ material among approved manufacturers/ brands at a
particular site/ region, alternate manufacturers/ brands conforming to BIS/ BS etc. shall be
used subject to approval by Employer.
- In case of non-availability of any manufacturer among approved manufacturers at a particular
site/ region, alternate manufacturer‟s name shall be proposed along-with required credentials
for Employer‟s approval.
- In case of any item/ product neither covered in this list nor having A BIS specifications, the
contractor shall submit the proposed item/ product along-with technical details/ specifications
(as per bid), test certificates etc. And other credentials of the manufacturer for Employers
approval.

LIST OF APPROVED MAKES FOR PRODUCTS AND MATERIALS FOR FIRE

PROTECTION WORKS ARE INDICATED IN THE TABLE BELOW. HOWEVER, ANY
OTHER MAKE WHICH IS EQUIVALENT AND MEETING THE TENDER
SPECIFICATIONS ARE ALSO ACCEPTABLEWITH PRIOR APPROVAL OF THE
ENGINEER
287
SR.
ITEMS MANUFACTURER
NO.
1. Pump Grundfos/ KBL/ Mather & Platt / Armstrong/
Greaves Ltd.

2. Motors Refer Appendix-2 of specification for

approved/preferred makes of electrical items.

3. Diesel Engines Cummins/ Kirloskar Oil Engines / Greaves /

Clarke

4. C.I. Gate Valves KBL / Nibco /Zoloto

5. Butterfly valves Audco / KSB / KBL / Tyco

6. C.I.Non Return Valves (Wafer Pattern) Kirloskar / Upadhaya/ BDK/ Intervalve.

7. valves (For hose reels, sprinkler test/ ZOLOTO/ Leader/ Hawa Valves (India) Pvt.
drain connection, air release valve) Ltd./ Avishkar Engineers Pvt. Ltd./ Upadhaya

8. Wrapping coating (for underground IWL (PYPEKOTE)/Rustech

pipes)

9. Pipe Fittings (below 50 mm dia) 'T', JK Forging / Gautam Industries / M. S.

elbow, sockets, reducers Fitting Manufacturing Pvt. Ltd.

10. Pipe Fittings (bends, reducers) (above MS Fittings (Calcutta) / Echjay / Tubebend
50mm dia)

11. M.S Pipes Tata steel / Jindal(Hissar) / SAIL

12. Sprinkler Heads(pendent, upright, Viking /Newage /Tyco /Globe /Star

concelaed sprinkler with rosette, side wall
) / Nozzle/ (UL/FM)

13. Hydrant valves, Branch Pipe with nozzles Newage / Sukan / SBJ/Shah Bhogilal
and Hose coupling.

14. Hoses Newage / CRC.

15. Paint Berger Paints/ Asian Paints/ Nerolac /

Shalimar Paints

16. Strainers Filtration Engineers Pvt. Limited, Mumbai/

Kwikflow Filters & Equipment, Mumbai/
Pennant Engg Pvt Ltd., Pune/ Spirax Marshall
Ltd., Pune / Superflow Filters Ltd., Mumbai,
Jaypee./zoloto

17. Anti vibration pads Dunlop, EasyFlex

288
 SR.
ITEMS MANUFACTURER
NO.
18. Fire Extinguishers Minimax/Safex/Firex /Ceasefire/Nitin Fire

19. Installation Control Valve LPC / UL / Viking/HD/Newage/Tyco

FM / TAC

4.5.2 ELECTRICAL SYSTEM

APPENDIX-2
Sr. No. Items Manufacturer

1. L V Switchgear L&T/ Schneider/ ABB

2. Distribution Boards L&T/ Legrand/ ABB

3. Moulded Case Circuit Breaker L&T/ Schneider/ ABB

4. Motor Protection Circuit L&T/ Schneider/ ABB

Breaker

5. Contactors L&T/ Legrand/ Schneider

6. Current Transformer Kappa/ Silkans / Pragati / Indcoil / Precise

7. Ammeter and Voltmeter AE/Rishabh / Conzerve

8. Push buttons Siemens/Teknic/Vaishno/BCH

9. LED Indicating lamps Teknic / Mathura / Siemens / Binay

10. MCB L&T/ Schneider/ ABB

11. Control fuses SIEMENS / GE

12. Terminal Block SIEMENS / GE

13. Switch-socket Anchor / Reputed

14. Space Heater Girish / reputed

15. L T Motor Siemens/ABB/Kirloskar/CGL

16. L T Cable KEI/ CCI/ Finolex

17. HFFR wires (including panel Finolex/ LAPP/ RR KABEL

wiring)

18. Local Push button station L&T/ Teknic/ Schneider/ Mathura

(LPBS)

289
 Sr. No. Items Manufacturer

19. Cable Trays Indiana/ Patny/ Profab/ OBO

Any other make subjected to prior approval of Employer / Project Manager.

4.5.3 INSTRUMENTATION & CONTROL SYSTEM

This section provides details of the Approved Vendors / Approved makes for Electrical and
I&C items, which form a part of this tender. For any other type of item/instrument; makes
shall be subject to Employer's/Project Manager's Approval.
Sr.
Description Manufacturer
No
1. Pressure Indicators Forbes Marshal/Waree/H. Guru/FIEBIG

2. Pressure switch Switzer /Dunfoss/System sensor

3. Water flow switch System sensor/Potter

4. level gauge Pune Techtrol/Levcon/Chemtrol/R.K.Dutt

5. Level switch Yokogawa/SBEM/Chemtrol/R.K.Dutt

Industrial controls & Appliances/Industrial

6. Panel Integrators
switchgear control/Sun Industrial Automation

7. Panel Enclosure Rittal/President

8. Local Indicator Emerson/Yokogawa/Masibus

9. Instrument erection Hardware Parker/Swagelok/Excel Hydropneumatics/Wintec

Polycab/CCI/Nicco/Aisan(RPG)/Lapp
10. Cables cable/Sterlite/RP cables/Thermocable Ltd,
AP/Universal

11. Relays Siemens/OEN/Omron

12. Terminals Elmex/Connectwell/Wago/Phoenix

13. 24V DC power supply units Apla/Pheonix/Cosel

14. GI Cable trays Indiana/Profab /Patny /Sterlite/Reliance

290
TECHNICAL SPECIFICATION

HVAC WORKS

291
 HVAC WORKS

5.1 SPLIT AIR-CONDITIONERS

5.1.1 SCOPE

This specification covers the general design, materials, construction features, manufacture, shop
inspection and testing at manufacturer‟s works, delivery at site, handling at site, installation, testing,
commissioning, performance testing and handing over of split air-conditioners (SAC).

5.1.2 CODES AND STANDARDS

The design, materials, construction, manufacture, inspection, testing and performance of split air-
conditioners shall comply with all currently applicable statutes, regulations and safety codes in the
locality where the equipment is to be installed. Nothing in this specification shall be construed to
relieve the CONTRACTOR of this responsibility. In particular, the split air-conditioners shall
conform to the latest editions of following standards:

a) ASHRAE 15 Safety Standard for Refrigeration Systems & Addenda.

b) ASHRAE 37 Methods of Testing for Rating Electrically Driven
Unitary Air-Conditioning and Heat Pump Equipment
c) ANSI B 31.5 Code for Refrigeration Piping

5.1.3 CONSTRUCTION FEATURES

5.1.3.1 CABINETS

The split air-conditioners comprise of two cabinets viz. indoor unit (IDU) and condensing/outdoor
unit (ODU).
Indoor unit shall house air handling fan, cooling coil, insulated drain tray and filter. The unit shall be
of heavy gauge steel, corrosion resistant, finished with synthetic enamel paint and acoustically
insulated with resin bonded fiberglass or equivalent material. Suitable drain connection shall be
provided for removal of condensate collected inside the drain tray under cooling coil. The front
panel shall be decorative type with supply air grille of adjustable type and having adequate return air
passage. The front panel shall be made of plastic or aluminum and shall be easily removable for
cleaning of filter. The unit shall be suitable for wall mounting and can also be ceiling suspended.
Condensing/outdoor unit shall house compressor and condenser and shall be of heavy gauge
corrosion resistant carbon steel and shall be suitable for mounting in open space (e.g. on terrace or
on outside wall).

292
5.1.3.2 COMPRESSOR

The compressor shall be hermetic Scroll or Rotary and shall be mounted on vibration absorbers.
Necessary crank case heaters shall be provided.

5.1.3.3 CONDENSER

The air cooled condenser shall be with copper tubes and aluminium fins with low noise fan(s). Speed
of axial fan(s) shall not exceed 960 RPM for fan with impeller diameter above 450 mm and 1440
RPM for fan with impeller diameter 450 mm and less. The impeller shall be statically and
dynamically balanced. Condenser coil shall have anti-corrosion treatment.

5.1.3.4 AIR HANDLING FAN

The fan shall be centrifugal type with forward curved impeller. The impeller shall be statically and
dynamically balanced.

5.1.3.5 COOLING COIL AND FILTER

The cooling coil shall be of direct expansion type with copper tubes and aluminium fins. This shall
be minimum three (3) rows deep and with minimum three (3) fins per centimetre. The air before it
enters the cooling coil shall be filtered by dry and cleanable type filter.

5.1.4 REFRIGERATION PIPING AND CONTROLS

5.1.4.1 The refrigeration piping shall be complete with externally equalised thermostatic expansion
valve, liquid line strainer, dehydrator with replaceable drying agent and liquid line shut-off
valve.

5.1.4.2 Refrigerant piping, fittings, piping joints shall conform to the requirements of ANSI B 31.5.

5.1.4.3 The piping shall be designed for an internal pressure representing the most severe condition
of coincident pressure and temperature expected in normal operation.

5.1.4.4 Vacuum testing shall be done for medium vacuum of around 40 mm Hg absolute and held
with vacuum pump in operation for at least 4 hours. Thereafter unit shall be sealed and
vacuum held for at least 12 hours. Vacuum break shall be done using refrigerant and pressure
raised to standing pressure in refrigerant cylinder.

5.1.4.5 ON-OFF thermostat with adjustable setting shall be provided for temperature control. A
selector switch enabling the running of the air handling fan alone or fan with cooling shall be
provided. Interlock shall be provided such that compressor can start only after starting the air
handling fan. Provision shall also be made to interlock the compressor with the air cooled
condenser fan motor. Safety devices such as high/low refrigerant pressurestat (HP/LP) and
compressor oil pressurestat (OP), hermetic motor winding thermostat etc. shall be provided.
HP and OP cut out shall be manual reset type while LP cut out shall be auto reset type.

293
5.1.4.6 Refrigerant and oil shall be supplied along with the unit. The refrigerant and oil charging
shall be carried out at site. Exposed refrigerant piping shall have anti-corrosive coating.

5.1.5 ELECTRICAL

5.1.5.1 A sequential controller shall be provided if asked for in Datasheet A. This controller shall
facilitate the automatic periodic switching of the units from working to standby mode in a
predefined sequence so that all the units shall be in operation for a defined period of time.
This system shall be required in (N+1) OR (N+2) type combination of working & standby
units.

5.1.5.2 The unit shall be provided with single phase preventers for all motors.

5.1.5.3 Each SAC shall be provided with three pin Plug and cable.

5.1.5.4 The indoor and outdoor units shall be pre-wired at the factory and shall be complete with
starters for all motors.

5.1.5.5 Wiring between indoor and outdoor units shall be carried out at site.

5.1.5.6 Cordless remote controller shall be provided. Remote controller shall have ON/OFF &
temperature control option.

5.1.6 PERFORMANCE GUARANTEE

5.1.6.1 Performance guarantees for the Split Air conditioners (SAC) shall be as specified in data
sheet- A.

5.1.7 DATA SHEET – A

SL.
ITEM UNIT
NO.
1.0 GENERAL
1.1 DESIGNATION SPLIT ACS FOR SERVE ROOM
NUMBERS REQUIRED: TABLE HAS
1.2 Nos. TABLE HAS GIVEN BELOW
GIVEN BELOW
TAG NUMBERS: TABLE HAS GIVEN
1.3 811-SAC-01 & 02
BELOW
1.4 REFRIGERANT USED R-410a/ R407C
1.5 STAR RATING (BEE) 3/4/5
CONTINUOUS / INTERMITTENT
1.6 OPERATION
hrs/DAY
2.0 DESIGN DATA
2.1 REQUIRED MINIMUM ACTUAL TR 2.0

294
SL.
ITEM UNIT
NO.
CAPACITY REQUIRED
2.2 DESIGN OUTDOOR CONDITIONS
0
2.2.1 DRY BULB TEMPERATURE C 42.0
0
2.2.2 WET BULB TEMPERATURE C 26.8
2.3 DESIGN INDOOR CONDITIONS
0
2.3.1 DRY BULB TEMPERATURE C 20.0
0
2.3.2 WET BULB TEMPERATURE C 14.5
3.0 INDOOR UNIT
3.1 TYPE HI-WALL / CASSETTE / FLOOR
3.2 REQUIRED DEHUMIDIFIED AIR
FLOW CAPACITY OF EACH INDOOR MINIMUM 330 CFM / TR
UNIT
3.3 FILTRATION
3.3.1 ANTIDUST FILTERS (PRE-FILTERS) YES / NO
3.3.2 DEODORIZATION FILTERS YES / NO
3.3.3 ANTI-BACTERIA FILTERS YES / NO
3.4 ULTRAVIOLET SCREEN YES / NO
3.5 FAN TYPE FORWARD CURVED, COUPLED
3.6 FAN SPEED SINGLE / MULTISPEED
3.7 FAN MOTOR TYPE STD / FLAMEPROOF
3.8 NOISE LEVEL @ 1.0 M FROM UNIT dB(A) 45 (MAXIMUM)
3.9 NO. OF UNITS / OUTDOOR ONE / TWO
3.10 RETURN GRILLE FRONT / TOP
3.11 COOLING COIL INNER GROOVED COPPER
3.12 FINS ALUMINUM
3.13 ANTI-CORROSIVE COATING ON COIL YES / NO
4.0 OUTDOOR UNIT
HERMETIC SCROLL / ROTARY /
4.1 COMPRESSOR
RECIPROCATING
4.2 VIBRATION ISOLATORS NEOPRENE RUBBER PADS
4.3 NOISE LEVEL @ 1.0 M FROM UNIT dB(A) 65
ANTI-CORROSIVE COATING ON
4.4 YES / NO
BODY
4.5 ANTI-CORROSIVE COATING ON COIL YES / NO
295
SL.
ITEM UNIT
NO.
4.6 FAN TYPE AXIAL, PROPELLER
4.7 FAN SPEED SINGLE / MULTISPEED
5.0 ELECTRICAL
5.1 OUTDOOR MOTOR AS PER MFR‟s STD
5.2 POWER SUPPLY 230V, 1 PHASE, 50 Hz
NEAR INDOOR UNIT / AT BOTH
5.3 POWER SUPPLY LOCATION
LOCATIONS
MINIMUM CABLE LENGTH WITH
5.4 PLUG & m 3
SOCKET
6.0 INTERCONNECTED PIPING
MAXIMUM PERMISSIBLE DISTANCE
6.1
BETWEEN IDU AND ODU
6.1.1 VERTICAL m 15
6.1.2 TOTAL m 25
INSULATED REFRIGERANT PIPING
6.2 m UP TO 7
BETWEEN IDU AND ODU
ACCESSORIES IN REFRIGERANT
6.3
PIPING
6.3.1 ECONOMIZER YES / NO
6.3.2 SIGHT GLASS YES / NO
INSULATED CONDENSATE DRAIN UPTO 10 M / NEAREST DRAIN
6.4
PIPING POINT
ACCESSORIES, AUXILIARIES AND
7.0
SERVICES
7.1 CORDLESS REMOTE CONTROLLER YES / NO
7.2 OCCUPANCY SENSOR IN IDU YES / NO
7.3 ON-OFF TIMER YES / NO
MOUNTING FRAME FOR IDU & ODU BY EMPLOYER / BY
7.4
WITH ALL ACCESSORIES CONTRACTOR
MOUNTING FRAME WITH EPOXY
7.5 YES / NO
COATING
7.6 SEQUENTIAL CONTROLLER YES / NO
SPARES AND MAINTENANCE
8.0
TOOLS AND TACKLES
8.2 ESSENTIAL SPARES
8.3 SPECIAL TOOLS
9.0 PERFORMANCE GUARANTEES
296
 SL.
ITEM UNIT
NO.
CAPACITY OF EACH SAC AT DESIGN
9.1 TR 2.0 Min.
CONDITION
TOTAL POWER INPUT AT DESIGN
9.2 kW 2.4 Max.
CONDITION
DEHUMIDIFIED AIR FLOW OF
9.3 m3/hr 660 Min.
INDOOR UNIT
9.4 NOISE LEVEL
9.4.1 AT INDOOR UNIT @ 1.0 M dB(A) 45
9.4.2 AT OUTDOOR UNIT @ 1.0 M dB(A) 75
10.0 COST LOADING AND PENALTY
FOR DIFFERENTIAL TOTAL POWER
10.1 Rs/kW
INPUT AT DESIGN CONDITIONS
11.0 TESTS AND INSPECTION
11.1 AS PER STANDARD

5.1.8 SPLIT AC DETAILS:

Sr.
Building Name Area Selected Configuration of IDU
No.
Qty Total Model/
(sqft.) (TR) TR
Nos TR Type

A ADMIN BUILDING
A.1 SECOND FLOOR
1.1 SERVER ROOM 273 2.50 1.5 1 1.50
1 1 1.00
TOTAL 2.50 2.00 2.50

B EXECUTIVE HOSTEL
B.1 GROUND FLOOR
1.1 GUEST ROOM-2 153 1.00 1 1 1.00
Split AC
1.2 GUEST ROOM-1 153 1.00 1 1 1.00
1.3 LOUNGE 221 1.50 1.5 1 1.50 Window AC

SUB TOTAL 3.50 3.00 3.50

B.2 FIRST FLOOR

297
2.1 GUEST ROOM-3 153 1.00 1 1 1.00
2.2 GUEST ROOM-4 153 1.00 1 1 1.00
2.3 GUEST ROOM-5 153 1.00 1 1 1.00
2.4 GUEST ROOM-6 153 1.00 1 1 1.00 Split AC

SUB TOTAL 4.00 4.00 4.00

TOTAL 7.50 7.00 7.50

C DINING BLOCK
C.1 GROUND FLOOR
1.1 DISPENSARY LOBBY 119 1.00 1 1 1.00
1.2 EXMINATION RM 105 1.50 1.5 1 1.50
1.3 WARD 102 1.50 1.5 1 1.50 Window AC
1.4 INJECTION RM 102 1.00 1 1 1.00
1.5 BANK COUNTER 320 3.00 1.5 2 3.00 Split AC
1.6 KITCHEN 307 5.50 5.5 1 5.50 TFA

SUB TOTAL 13.50 7.00 13.50

C.2 FIRST FLOOR

2.1 KIOSK 142 1.50 1.5 1 1.50
2.2 EXECUTIVE DINING 1369 6.50 1.5 3 4.50 Split AC
2 1 2.00
306.6
2.3 5.50 5.5 1 5.50 TFA
KITCHEN 6

SUB TOTAL 13.50 6.00 13.50

13.0
TOTAL 27.00 27.00
0

D TRAINING
1.1 SERVER ROOM 286 3.00 1.5 2 3.00

TOTAL 3.00 2.00 3.00

E UTILITY BLOCK
E.1 GROUND FLOOR
1.1 UPS ROOM 271 3 1.5 2 3.00 Split AC

GRAND TOTAL 37.50 37.50

298
5.2 AIR-COOLED VARIABLE REFRIGERANT FLOW SYSTEM

5.2.1 SCOPE

The scope of this section comprises the supply, erection testing and commissioning of inverter based
Variable Refrigerant Volume System with Scroll Compressor conforming to these specifications and
in accordance with the requirements of drawing and Schedule of Quantities.

5.2.2 TYPE

Units shall be air cooled, variable refrigerant volume air conditioner of R410A gas based consisting
of outdoor unit and multiple indoor units. Each indoor units having capability to cool or heat
independently for the requirement of the rooms. It shall be possible to connect several indoor units
on one refrigerant circuit. The indoor units on any circuit can be of different type and also controlled
individually. Following type of indoor units shall be connected to the system:

a. Floor Mounted Packaged units

b. Ductable type
c. Wall hung
Both indoor units and outdoor unit shall be factory assembled, tested and filled with first charge of
refrigerant before delivering at site.

5.2.3 OUTDOOR UNIT

The outdoor unit shall be factory assembled, weather proof casing, constructed from heavy gauge
mild steel panels and coated with baked enamel finish. The unit should be completely factory wired
tested with all necessary controls and switch gears: The outdoor unit shall be modular in design and
should be allowed for side by side installation. The outdoor unit shall be provided with welded steel
support with two coats of paint for erection purpose.

a. All outdoor units above 8 HP shall have minimum two scroll compressors and be able to
operate even in case one of compressor is out of order.

b. In case of outdoor units above 14HP, the outdoor unit shall have at least 2 inverter
compressors and inverter motor of brushless DC Type so that the operation is not disrupted
with failure of any compressor.

c. It should also be provided with duty cycling for switching starting sequence of multiple
outdoor units.

d. The noise level shall not be more than 68 dB (A) at anechoic chamber conversion value,
measured horizontally 1m away and 1.5m above ground level.

e. The outdoor unit shall be modular in design and should be allowed for side by side
Installation.

f. The unit shall be provided with its own microprocessor control panel. The outdoor unit
should be fitted with low noise, aero spiral design fan with large airflow and should be
299
 designed to operate compressor-linking technology. The unit should also be capable to
deliver 78 Pa external static pressure to meet long exhaust duct connection requirement.

The condensing unit shall be designed to operate safely when connected to multiple fan coil units,
which have a combined operating nominal capacity up to 160 % of indoor unitsfor outdoor units up
to 40 HP.

5.2.4 COMPRESSOR

The compressor shall be highly efficient scroll type and capable of inverter control. It shall change
the speed in accordance to the variation in cooling or heating load requirement:

The inverter shall be IGBT type for efficient and quiet operation. All outdoor units shall have at least
10 to 30 steps of capacity control to meet load fluctuation and indoor unit individual control. All
parts of compressor shall be sufficiently lubricated stock. Forced lubrication may also be employed.
Oil heater shall be provided in the compressor casing. C.O.P for the units shall not be less than 4.5.

5.2.5 HEAT EXCHANGER

The heat exchanger shall be constructed with copper tubes mechanically bonded to aluminum fins to
form a cross fin coal.

The aluminum fins shall be covered by anti-corrosion resin film.

The unit shall be provided with necessary number of direct driven low noise level propeller type fans
arranged for vertical discharge. Each fan shall have a safety guard.

5.2.6 REFRIGERANT CIRCUIT

The refrigerant circuit shall include liquid & gas shut-off valves and a solenoid valves at condenser
end.

All necessary safety devices shall be provided to ensure the safely operation of the system.

5.2.7 SAFETY DEVICES

All necessary safety devices shall be provided to ensure safe operation of the system. Following
safety devices shall be part of outdoor unit; high pressure switch, fuse, crankcase heater, fusible
plug, over load relay, protection for inverter, and short recycling guard timer.

5.2.8 OIL RECOVERY SYSTEM

Unit shall be equipped with an oil recovery system to ensure stable operation with long refrigeration
piping lengths.

5.2.9 INDOOR UNIT

300
This section deals with supply, installation, testing, commissioning of various type of indoor units
confirming to general specification and suitable for the duty selected. The type, capacity and size of
indoor units shall be as specified in detailed Bill of Quantities.

5.2.10 GENERAL

Indoor units shall be wall mounted type or ceiling mounted ductable type as specified in BOQ.
These units shall have electronic control valve to control refrigerant flow rate respond to lead
variations of the room.

a. The address of the indoor unit shall be set automatically in case of individual and group
control

b. There shall be localized control only.

The fan shall be dual suction, aerodynamically designed turbo, multi blade type, statically &
dynamically balanced to ensure low noise and vibration free operation of the system. The fan shall
be direct driven type, mounted directly on motor shaft having supported from housing.

The cooling coil shall be made out of seamless copper tubes and have continuous aluminum fins.
The fins shall be spaced by collars forming an integral part. The tubes shall be staggered in the
direction of airflow. The tubes shall be hydraulically/ mechanically expanded for minimum thermal
contact resistance with fins. Each coil shall be factory tested at 21kg/sqm air pressure under water.

Unit shall have cleanable type filter fixed to an integrally molded plastic frame. The filter shall be
slide away type and neatly inserted.

Each indoor unit shall have computerized PID control for maintaining design room temperature.
Each unit shall be provided with microprocessor thermostat for cooling and heating.

The outdoor unit shall be pre-charged with first charge of R 410A refrigerant. Additional charge
shall be added as per refrigerant piping at site. All the units shall be suitable for operation with 380 -
415 V 50 Hz + 3%, 3 Phase supply for outdoor units & 220 – 240 V, 50 Hz + 3%, 1 Phase supply for
in-door units.

5.2.10.1 The units shall be integrated with Fire Alarm system and in case of fire all units shall
be switched off.

5.2.10.2 The Al fins of Condenser Coils shall be provided with suitable factory installed
protective for corrosion prevention.

5.2.10.3 The outdoor units must be suitable for up to 150m (straight length) refrigerant piping
between outdoor unit & the farthest indoor units, total piping of 500m for all the
indoor units. Allowable level difference between outdoor unit & indoor units shall be
50m in case of outdoor unit on top & 40 m in case of outdoor unit at bottom.
Allowable level difference between various indoor units connected to one out door
unit shall be up to15m.

301
5.2.10.4 The outdoor unit shall employ system of equal run time for all the compressors,
inverter or on/ off type, within each outdoor unit – Single Module or Multi Module.

5.2.10.5 The outdoor units shall be suitable to operate within an ambient temperature range of
– 5 Deg C to 43 Deg C, in cooling mode & -20 Deg C to 15 Deg C in heating mode.

5.2.10.6 Air cooled condenser shall have Axial Flow, upward throw fan, directly coupled to
fan motors with minimum IP 55 protection. The outdoor unit condenser fan shall be
able to develop external static pressure up to 6 mm of H2O.

5.2.10.7 The entire operation of outdoor units shall be through independent remotes of indoor
units. No separate Start/ Stop function shall be required.

5.2.10.8 Starter for the Outdoor Unit compressor shall “Direct on Line” type. Inverter
compressor of the unit shall start first & at the minimum frequency, to reduce the
inrush current during starting.

5.2.10.9 Refrigerant control in the outdoor unit shall be through Electronic Expansion Valve.
Complete refrigerant circuit, oil balancing/ equalizing circuit shall be factory
assembled & tested.

5.2.10.10 Outdoor units shall be complete with following safety devices:

a. High pressure switch

b. Fan driver overload protector
c. Over current relay
d. Inverter Overload Protector
e. Fusible Plug

5.2.11 CEILING MOUNTED DUCTABLE TYPE UNIT

5.2.11.1 Unit shall be suitable for ceiling mounted type. The unit shall include pre filter, fan
section & DX coil section .The housing of unit shall be light weight powder coated
galvanized steel. The unit shall have high static fan for Ductable arrangement.

5.2.11.2 These units shall be ceiling suspended with suitable supports to take care of operating
weight of the unit, without causing any excessive vibration & noise. The cold air
supplied by these units will be supplied to the area to be air conditioned, through duct
system specified in the tender.

5.2.11.3 Each indoor unit must have electronic expansion valve operated by microprocessor
thermostat based temperature control to deliver cooling/ heating as per the heat load
of the room.

302
5.2.11.4 Unit must be insulated with sound absorbing thermal insulation material, Glass Fiber.
The noise level of unit at the highest operating level shall not exceed 49 dB(A), at a
vertical distance of 1.5 m below the units with duct connected to the unit.

5.2.11.5 Unit must have Thermal Fuse for fan motor protection, in case of motor heating. The
unit will be connected in series to a suitable outdoor unit & it must be possible to
operate the unit independently, through corded/ cordless remote specified in the bill
of quantities. The unit will be further connected to Intelligent Building Management
System (To be supplied by other vendors) & it shall be possible to operate the unit
through this IBMS system.

303
5.2.12 DATA SHEET – A

1.0 Make Dakin/ Bluestar/ Voltas

2.0 Casing CS/ (CS/ CAST AL)/ EN8
3.0 Type: Ductable/ Cassete/ High Ductable/Package Floor Mounted/ High
wall wall
4.0 Dimension WxDxH (M) Ducatble - 1500x750x650
Package Floor Mounted - 1250x750x1800
High wall - 1100x300x350
50 Cooling Capacity VRF Table is given below
6.0 Air quantity at max. Speed
And 1 m long duct collar CMH
7.0 Air quantity at min. Speed
And 1.0 m. Long duct collar CMH
8.0 Whether auxiliary drain pan
Provided: Yes/No. Yes/No.
9.0 Make & model of room
thermostat.
10.0 Whether acoustic lined Yes/No.
duct collar included in Unit price Yes/No.
11.0 Does Indoor Unit have return air
plenum. Yes/No. Yes/No.
12.0 Noise Level at 1 m distance: 55db

OUTDOOR
1. Manufacturer Dakin/ Bluestar/ Voltas
2. Type Copeland
3. Model
4. Overall dimensions (mm) WxDxH 1100x1100x1750
5. Operating Weight (kg.) 300
6. No. of fans 1
7. CMH per fan
8. Outlet velocity (Mts. Per min)
9. Tip speed (Mts per min)
10. Compressor Type Digital Scroll + Fixed Scroll
11. Vibration isolator Rubber pads
12. Noise Level at 1 m distance: 62db

304
5.2.13 VRF Equipment Details:

Sr.
Building Name Area Selected Configuration of IDU
No.
Qty Total Model/
(sqft.) (TR) TR
Nos TR Type

A ADMIN BUILDING
A.1 GROUND FLOOR
1.1 FIRE CONTROL ROOM 152 1.00 1 1 1.00
ENTRANCE LOBBY AND
1.2 3.00 1.5 2 3.00
GUEST WAITING AREA 1010
1.3 CONFERENCE ROOM-1 719 4.50 1.5 3 4.50
1.4 WAITING &PS 372 1.50 1.5 1 1.50
1.5 GM OFFICE 303 1.50 1.5 1 1.50
1.6 ELECTRICAL & UPS ROOM 191 1.50 1.5 1 1.50
1.7 CONFERENCE 271 1.50 1.5 1 1.50
1.8 SR. ENGG 107 1.00 1 1 1.00
1.9 SR. MANAGER-NE 100 1.00 1 1 1.00
1.1 DGM CABIN 113 1.00 1 1 1.00
1.11 SR. MANAGER-N 107 1.00 1 1 1.00
1.12 MARKETING OFFICE 434 1.50 1.5 1 1.50
1.50 HI-Wall
1.13 MANAGER ADMIN 379 1.5 1 1.50
1.14 MANAGER ADMIN CABIN 87 1.00 1 1 1.00
1.15 MEETING RM 81 1.00 1 1 1.00
1.16 OFFICE 460 3.00 1.5 2 3.00
1.17 PURCHASE OFFICER 408 3.00 1.5 2 3.00
1.18 CABIN 87 1.50 1.5 1 1.50
1.19 CABIN-1 94 1.50 1.5 1 1.50

SUB TOTAL 32.50 24.00 32.50

A.2 FIRST FLOOR

2.1 GREEN ROOM 166 1.00 1 1 1.00
2.2 GREEN ROOM-1 163 1.00 1 1 1.00
2.3 CONFERENCE HALL 3128 20.00 8 2 16.00
CSU
4 1 4.00
SUB TOTAL 22.00 5.00 22.00

A.3 SECOND FLOOR

3.1 IT DEPT 284 1.50 1.5 1 1.50
3.2 SERVER ROOM 273 2.50 1.5 1 1.50 HI-Wall
1 1 1.00
305
 SUB TOTAL 4.00 3.00 4.00
TOTAL 58.50 32.00 58.50

D TRAINING
D.1 GROUND FLOOR
1.1 Sr. MANAGER 110 1.00 1 1 1.00
1.2 HOD ROOM 102 1.00 1 1 1.00
1.3 TRAINING OFFICE 581 3.00 1.5 2 3.00
1.4 MANAGER ROOM 258 1.50 1.5 1 1.50 HI-Wall
1.5 PLACEMENT CELL WITH VC 581 3.00 1.5 2 3.00
1.6 COUNCELLING ROOM 258 1.50 1.5 1 1.50
1.7 VC 221 2.00 2 1 2.00
1.11 CNC AREA 7076 10.00 5 2 10.00
CSU
1.12 INCUBATION CENTRE 4700 10.00 5 2 10.00

SUB TOTAL 33.00 13.00 33.00

D.2 FIRST FLOOR

2.1 FACULTY ROOM 2107 16.00 2 8 16.00
2.5 LABORATORY (S&E) 710 5.00 2 2 4.00
1 1 1.00
2.8 LABORATORY (S) 710 4.50 1.5 3 4.50
2.5 LABORATORY (S) 710 4.50 1.5 3 4.50
2.6 LABORATORY (S) 710 4.50 1.5 3 4.50
2.7 LABORATORY (S) 710 4.50 1.5 3 4.50
2.9 LABORATORY (S) 710 4.50 1.5 3 4.50
2.10 LABORATORY (S) 710 4.50 1.5 3 4.50
2.11 LABORATORY (E) 710 4.50 1.5 3 4.50
2.12 LABORATORY (E) 807 4.50 1.5 3 4.50
2.13 LABORATORY (N) 710 4.00 2 2 4.00
HI-Wall.
2.14 LABORATORY (N) 710 4.00 2 2 4.00
2.15 LABORATORY (N) 710 4.00 2 2 4.00
2.16 LABORATORY (N) 710 4.00 2 2 4.00
2.17 LABORATORY (N) 710 4.00 2 2 4.00
2.18 LABORATORY (N) 807 4.00 2 2 4.00
2.19 LABORATORY (N&E) 710 5.00 2 2 4.00
1 1 1.00
2.20 CLASS ROOM (N) 807 7.00 2 3 6.00
1 1 1.00
2.21 CLASS ROOM (N) 807 7.00 2 3 6.00
1 1 1.00
2.22 CLASS ROOM (N) 807 7.00 2 3 6.00

306
 1 1 1.00
2.23 CLASS ROOM (N) 807 7.00 2 3 6.00
1 1 1.00
2.24 CLASS ROOM (S) 807 7.00 2 3 6.00
1 1 1.00
2.25 CLASS ROOM (S) 807 7 2 3 6.00
1 1 1.00
2.26 CLASS ROOM (S) 807 7 2 3 6.00
1 1 1.00
2.27 CLASS ROOM (S) 807 7 2 3 6.00
1 1 1.00
2.29 LANGUAGE LABORATORY 538 3.50 2 1 2.00
1.5 1 1.50
2.28 BOARD ROOM 215 2.50 1.5 1 1.50
1 1 1.00
2.27 EXAMINATION CELL 323 3.50 2 1 2.00
1.5 1 1.50
2.28 SERVER ROOM 286 3.00 1.5 2 3.00

SUB TOTAL 154.50 90.00 154.50

D.2 SECOND FLOOR

EXAMINATION/DRAWING
15.00 1.5 10 15.00
HALL 2107
LIBRARY 3925 14.00 7 2 14.00 CSU

SUB TOTAL 29.00 12.00 29.00

TOTAL 216.50 115.00 216.50

PRODUCTION
GROUND FLOOR
1.8 DESIGN OFFICE-1 1033 6.00 2 3 6.00
1.9 DESIGN OFFICE-2 1033 6.00 2 3 6.00
1.10 DESIGN OFFICE-3 352 2.00 2 1 2.00
1.13 MEETING ROOM / OFFICE 506 1.50 1.5 1 1.50
Hi-wall
1.14 PROG. RM 506 1.50 1.5 1 1.50
1.15 3D MFG. AREA 1549 3.00 1.5 2 3.00
1.16 Q.C. ROOM 1549 2.50 1.5 1 1.50
1 1 1.00
1.17 C.N.C MILLING AREA 4222 5.00 5 1 5.00 Package
1.18 C.N.C LATHE GRINDER 1549 2.50 1.5 1 1.50
1 1 1.00 HI-Wall
1.19 E.D.M SECTION 2715 4.00 4 1 4.00 Package

307
 SUB TOTAL 34 17 34

FIRST FLOOR
2.2 PRODUCTION OFFICE 1 1033 7.00 2 3 6.00
1 1 1.00
2.3 PRODUCTION OFFICE 2 654 4.50 1.5 3 4.50 HI-Wall
2.4 PRODUCTION OFFICE 3 1033 7.00 2 3 6.00
1 1 1.00
SUB TOTAL 19 11 19
TOTAL 53 28 53

GRAND TOTAL 327.50 175.00 327.50

308
5.3 MTHERMAL INSULATION FOR COLD SURFACES:

5.3.1 SCOPE

This specification covers the technical requirements and essential particulars for the supply,
application and finishing of the complete thermal insulation for cold equipment, piping systems, air-
conditioning ducts etc. for temperatures between ambient and (-) 80oC and also for dual
temperatures (both hot and cold) service with hot temperature above ambient and up to 230 oC.
Unless specified otherwise in data sheet A, the scope of supply of the CONTRACTOR shall include,
but not be limited to, the following items:
a. Insulation materials of all types as specified and required
b. Insulation adhesives, vapour barriers and finishing materials of all types as specified and
required
c. Auxiliary materials such as binding and lacing wires, wire netting, bands, screws, pop rivets
etc., as specified and required
d. Angles, clamps, lugs etc. for supporting insulation
e. Weather hoods
f. Any other material as may be required for making the insulation complete

5.3.2 CODES AND STANDARDS

The supply and application of thermal insulation and finishing covered under this specification shall
comply with all currently applicable statutes, regulations and safety codes in the locality where it is
to be applied. The materials and application shall also conform to the latest editions of the codes and
standards listed. Nothing in this specification shall be construed to relieve the CONTRACTOR of
this responsibility.

5.3.2.1 The following are some of the codes and standards relevant to this specification :

IS 277 Galvanised Steel Sheets (Plain and Corrugated)

IS 737 Wrought Aluminium and Aluminium Alloy Sheet and Strip for
General Engineering Purposes

IS 3144 Mineral Wool Thermal Insulation Materials - Method of Test

IS 3677 Unbonded Rock and Slag Wool for Thermal Insulation

IS 4671 Expanded Polystyrene for Thermal Insulation Purposes

IS 8183 Bonded Mineral Wool

IS 9842 Preformed Fibrous Pipe Insulation

IS 14164 Industrial Application and Finishing of Thermal Insulation

Materials at Temperatures above (-) 800C and up to (+) 7500C

309
 BS 3927 Rigid Phenolic Foam (PF) for Thermal Insulation in the Form of
Slabs and Profiled Sections

BS 5608 Preformed Rigid Polyurethane (PUR) and Polyisocyanurate

(PIR) Foams for Thermal Insulation of Pipework and Equipment

BS 5970 Thermal Insulation of Pipework and Equipment (in the

Temperature Range (-) 1000C to (+) 8700C )

5.3.3 MATERIALS

5.3.3.1 GENERAL

All materials shall be new and fresh, incombustible, fire retardant, rot-proof, non-
hygroscopic, vermin proof, fungus proof, non-injurious to health, chemically inert,
non-corrosive to steel and aluminium (even if soaked in water for extended periods) and
shall be guaranteed to withstand continuously and without deterioration the minimum and
maximum temperatures to which these shall be subjected to under the specified applications.

5.3.3.2 The insulation materials and any component of the finished insulation job shall not react
chemically, singly or in combination, with water or moisture to form substances that are
more actively corrosive to applied surface than water or moisture alone.

5.3.3.3 In order to protect the workers from the hazards of insulation materials, suitable protective
gadgets shall be provided. Required safety precautions shall be taken during handling and
application of insulation.

5.3.3.4 The insulation material shall be kept dry at all times during transport, storage and installation.
Decking and covering tarpaulins alone are not adequate for any length of time and shall not
be allowed except in extreme emergencies and only for short period. Stacking of insulation
materials directly on ground shall not be done. No wet insulation shall be installed. If wet
insulation is present, it shall be removed and replaced with new dry insulation. The insulation
may be protected with plastic film but shall be vented to prevent sweating.

5.3.4 INSULATION MATERIALS

The insulation material shall be one or more of the following types as specified in data sheet A.

SL. INSULATION MATERIAL STANDAR DENSIT TEMP. MATERIA

NO. D Y, Kg/M3 RANGE, 0C L CODE

1. Fire-retardant quality expanded IS 4671 20 (-)80 to 80 EP

polystyrene

2. Rigid polyurethane / BS 5608 32 (-)80 to 110 PUR/ PIR

Polyisocyanurate foam
310
3. Phenolic foam BS 3927 32 (-)80 to 130 PF

4. Lightly resin-bonded glass wool IS 8183 32 (-)40 to 230 LRG

mattresses

5. Resin-bonded glass wool pipe IS 9842 85 (-)40 to 230 PSG

sections

6. Unbonded rock and slag wool IS 3677 150 (-) 80 to 230 U150

5.3.5 INSULATION ADHESIVES

The insulation adhesive shall be one or more of the following types as specified in data sheet A.

Material Description Material Code

1. Hot bitumen of grade 85/25 or 85/40 conforming to IS 702 shall BIT

be uniformly applied at 1.5 Kg/M2 on the surface to be insulated.
A similar layer shall also be applied on the inside surface of the
insulation. This material shall not be used for stainless steel
surfaces.

2. CPRX compound shall be uniformly applied at 1.5 Kg/M2 on the CPRX

surface to be insulated. A similar layer shall also be applied on
the inside surface of the insulation. This material shall not be
used for stainless steel surfaces.

3. MAS 83 with 0.5 mm wet film thickness shall be uniformly MAS 83

applied at 0.5 lit/M2 by trowelling. MAS 83 shall not be used
with polystyrene as insulation material. MAS 83 can be used
only between (-) 46 and (+) 149oC.

5.3.6 VAPOUR BARRIERS

The vapour barrier shall be one or more of the following types as specified in data sheet A.

Material Description Material Code

1. Hot bitumen of grade 85/25 or 85/40 conforming to IS 702 shall VB1

311
 be uniformly applied at 2.5 Kg/M2 on the outer surface of
insulation and allowed to dry. Reinforced Plastic (RP) tissue
paper shall be applied on the dried bitumen. This material shall
not be used for stainless steel surfaces.

2. 0.1 mm thick factory-laminated aluminium foil with craft paper ALF

shall be provided. All joints shall be provided with 50 mm
overlap and all joints shall be sealed with aluminium tape. For
temperature between (-) 43 and (+) 149oC MAS 35 may also be
used as sealant.

3. MAS 130 with 1.02 mm wet film thickness primer coat at 1.0 MAS 130
lit/M2 and 2.25 mm wet film thickness finish coat at 2.5 lit/M2
shall be uniformly applied over the insulation by spatula or
trowelling. MAS 130 shall not be used with polystyrene as
insulation material. MAS 130 can be used only between (-) 40
and (+) 60oC.

5.3.7 FINISHING MATERIALS

The finishing material shall be one or more of the following types as specified in data sheet A.

Material Description Material Code

Portland cement and inorganic fibre with water proofing compound at an FC

application density of 1050 to 1100 Kg/M3.

Aluminium sheet as per IS 737, designation 31000, condition H3. AL1

(a) Insulation outside diameter above 450 mm - sheet thickness 18

SWG

(b) Insulation outside diameter 150 to 450 mm - sheet thickness 20

SWG

(c) Insulation outside diameter below 150 mm - sheet thickness

(d) Air-conditioning ducts - sheet thickness AL1

(e) Equipment - sheet thickness

312
 Galvanized Steel (GS) sheet as per IS 277, designation GP

Insulation outside diameter above 450 mm - sheet thickness 20

(a)
SWG

Insulation outside diameter 150 to 450 mm - sheet thickness 22

(b)
SWG

Insulation outside diameter below 150 mm - sheet thickness 24 GS1

(c)
SWG

(d) Air-conditioning ducts - sheet thickness 26 SWG

(e) Equipment- sheet thickness 20 SWG

MAS 134 with 1.0 mm wet film thickness at 1.0 lit/M2 shall be uniformly
applied when using over porous insulation materials. Wet film thickness
MAS 134
shall be 0.5 mm at 0.5 lit/M2 for impervious insulation surfaces including
polystyrene. MAS 134 can be used only between (-)18 and (+) 82oC.

5.3.8 AUXILIARY MATERIALS

5.3.8.1 Binding and Lacing Wires

Binding and lacing wire shall be annealed GS 24 SWG.

5.3.8.2 Wire Netting

Wire netting shall be with GS 24 SWG wire and 20 mm hexagonal opening.

5.3.8.3 Bands
(a) For securing insulation material : 24 SWG GS, 20 mm wide
(b) For securing aluminium and GS : 24 SWG anodised
sheets aluminium or
SS 304, 20 mm wide

5.3.8.4 Screws
Screws shall be of self-tapping type and shall be of aluminium or stainless steel for
aluminium sheets and GS for GS sheets.

313
5.3.8.5 Pop Rivets
Pop rivets shall be of aluminium or stainless steel for aluminium sheets and GS for GS
sheets.

5.3.9 APPLICATION

5.3.9.1 GENERAL

The application of insulation shall be made in a professional manner. The insulation shall be
applied to all surfaces when these are at ambient temperature. Ample provision shall be made
for the maximum possible thermal movement and the insulation shall be applied in a manner
which shall avoid breaking or telescoping due to alternate periods of contraction and
expansion. A single layer of insulation shall not be more than 75 mm thick.

5.3.9.2 Insulation shall be applied after all leak tests on equipment and piping are over and the
section of the plant has been specifically released by the EMPLOYER for such work. If
insulation has to be applied before the leak test, all welded and flanged joints shall be left
exposed and insulated after satisfactory completion of the leak test.

5.3.9.3 All surfaces to be insulated shall be clean and dry before the insulation is applied. The
surfaces shall be cleaned of all foreign material such as scale, dirt, rust and paint, by the use
of steel wire brushes and steel scrapers, where necessary. Where a surface is not free of paint
the CONTRACTOR shall notify the EMPLOYER of the condition for remedial action. The
insulation shall be applied after remedial action, suggested by the EMPLOYER, has been
taken by the CONTRACTOR. One coat of primer paint shall be applied and allowed to dry
before application of insulation.

5.3.9.4 After cleaning and application of one coat of primer paint on the surface to be insulated, the
insulation adhesive shall be applied for fluid operating temperatures between 200C and (-)
200C. Insulation material of required thickness shall be stuck to the surface with joints
staggered. The adjoining sections shall be tightly pressed together. All the joints shall be
sealed with adhesive material. Voids, if any, shall be packed with suitably cut pieces of
insulation material. Vapor barrier and insulation finish shall be applied as per Para‟s 3.4 and
3.5 or 4.5 respectively.

5.3.9.5 For fluid operating temperatures below (-) 200C, the insulation shall be applied directly over
the surface to be insulated without applying the insulation adhesive. Vapor barrier shall be
applied over the insulation material. Vapor barrier and insulation finish shall be applied as
per Para‟s 3.4 and 3.5 or 4.5 respectively.

5.3.9.6 Where multilayer insulation is provided, insulation adhesive shall be used between two
layers, based on temperature criterion given in Para 4.1.4.

314
5.3.9.7 If aluminium or GS sheet is specified as finishing material, all joints shall be sealed with
bitumastic paint and made effectively weather and water-proof. For temperatures between (-)
40 and (+) 120oC, MAS 94 may also be used as sealant. MAS 94 shall, however, not be used
with polystyrene as insulation material. All flat surfaces shall be adequately sloped to prevent
pools of water collecting. The sheet shall be protected internally with 2 coats of bitumastic
paint.

5.3.9.8 All actions shall be taken to complete the application of finishing on exposed surfaces
covered with insulation before closing the day's work. If this is not practicable, adequate
precautions shall be taken to protect the insulation from weather, for example by wrapping it
with polythene sheet, roofing felt or other approved material.

5.3.10 PIPES, PIPE FITTINGS, VALVES AND SPECIALITIES

5.3.10.1 All vertical pipes shall be provided with suitable insulation supports to prevent the
insulation from collapsing due to its own weight. Any welding required, shall be carried out
by the CONTRCATOR with the prior permission of the EMPLOYER and only under his
direct supervision. Where welding is not permitted, suitable clamped supports shall be used.
The insulation shall be applied starting from bottom up. Mattress type insulation materials
shall be clamped from top.

5.3.10.2 All pipe fittings, valves and specialties shall be covered with the same type and
thickness of insulation as specified for the adjoining pipe. On pipe fittings, insulation outside
diameter shall be same as the outside diameter of adjacent pipe insulation. Unless specified
otherwise, valves and specialties of sizes 100 mm NB and larger shall be provided with
removable box type insulation. Box shall be fabricated from sheet material specified for
adjoining pipes. Pipe insulation on adjoining flanges shall be stopped at one bolt length plus
25 mm before flange to permit removal of the bolts and nuts. The insulation shall be applied
after the finish has been applied over insulation on the adjacent piping. Flanged joints shall
also be insulated with removable type of boxes. Arrangement shall be similar to that for
valves.

5.3.10.3 The sheets shall be installed with the longitudinal lap joints at 450 below the
horizontal for horizontal pipes and the joints sealed with bitumastic paint.

5.3.10.4 On vertical pipes the sheets shall be applied working from bottom up. Each section
of sheets shall have a minimum overlap of 50 mm longitudinally and circumferentially. Each
circumferential joint shall be made weather-proof by securing with a band of sheet material
and sealing with bitumastic paint. Longitudinal lap joints shall be fixed with screws or pop
rivets at approximately 150 mm centers.

5.3.10.5 Valves shall be insulated up to and including their bonnet flange.

5.3.10.6 Insulation of pipe hanger clamps shall be as per Standard.

315
5.3.10.7 Weather hoods shall be provided for insulated piping passing through roof and
external walls as per standard.

5.3.11 EQUIPMENT

5.3.11.1 Where the insulation material is in the mattress form, cleats in the form of wire nails
or nuts or angles and flats for supporting the insulation material, shall be welded to the
equipment by others. If wire nails are to be used as insulation cleats, these shall be bent and
secured with the metal fabric of the mattress, after the insulation has been applied. Where
insulation cleats are in the form of M6 and M10 nuts, the CONTRACTOR shall supply and
install bolts of suitable length for fixing the insulation. The insulation applied to equipment
shall be reinforced with wire netting. One course of wire netting shall be applied to the
surface of the equipment and each layer of insulation shall be backed up with wire netting.
All irregularities of the surface shall be filled and leveled over with insulating cement. All
mattress joints shall be butted tightly and the mattresses shall be secured with 20 mm wide 24
SWG GS bands at 450 mm centers. After banding, all mattress edges shall be laced tightly.

5.3.11.2 All equipment, unless specified otherwise, shall have a smooth aluminum or GS sheet
finish as specified in data sheet A, applied in a manner similar to that specified for piping.
For fixing of aluminum or GS sheets, wooden spacer rings at 1000 mm centers shall be fixed
to the equipment by the CONTRACTOR. All vertical and horizontal sheets shall be
overlapped a minimum of 75 mm. The lapped joints of adjoining sections of sheets shall be
secured with screws or pop rivets. On all equipment above 2500 mm diameter and flat
surfaces, the sheet shall be further secured by circumferential bands at approximately 1000
mm centers. Each sheet joint shall be sealed with bitumastic paint. The roof sections shall
overlap the side walls to prevent water seepage between insulation and the equipment wall.
Side wall sheets shall be securely banded at intersections of the side wall and roof sections.

5.3.11.3 All equipment manholes, hatches, bolted or screwed cover plates, flanged ends etc.
shall have removable box type insulation, with same thickness of insulation as for adjacent
surfaces. Insulation adjoining such equipment openings shall be tapered towards these
openings to permit removal of bolts, screws, heads, covers or plates with no damage to
adjacent surface insulation or cover

5.3.11.4 Nozzles and other connections on tanks and other equipment shall be insulated in the
same manner as the pipes.

5.3.11.5 Pump casing shall be completely insulated with removable type of boxes fabricated
from the specified sheet material. Proper care shall be taken to maintain continuity of vapour
barrier between static and removable portion of insulation.

5.3.11.6 Name plates on equipment shall not be insulated. Proper care shall be taken to
eliminate seepage of moisture from such un-insulated portions into the insulating material.

5.3.12 CONTRACTION JOINTS IN INSULATION

316
 Depending on the type of insulation material used and the operating temperature, contraction
joints shall be provided for equipment or pipes to prevent rupturing or buckling when the
cold surface contracts CEMENT SAND PLASTER FINISH
Where cement sand plaster finish is specified following procedure shall be followed.
5.3.13 Indoor Application
After the application of hot bitumen or CPRX compound vapor barrier, the surface shall be
wrapped with GS wire netting, butting all the joints and lacing down with lacing wire. The
ends of all wire loops shall be firmly twisted together with pliers, bent over and carefully
pressed into the surface of insulation.
A total of 15 mm thick finishing cement sand(1:4) plaster shall be applied in two layers after
a GS wire netting is stretched over the entire surface of insulation material and securely
fastened down. The plaster shall be hand trowelled over the wire netting to a smooth finish.
The application of finishing plaster shall be terminated, at the end of day‟s work, at a
contraction joint.
5.3.14 Outdoor Application
After the application of the plaster as per procedure for indoor application, an additional 6
mm thick water-proofing compound Shalikote 30 or equivalent shall be applied in two layers.
Outdoors, the finishing plaster shall be applied immediately after application of insulation. If
this is not practicable, the CONTRACTOR shall take adequate precautions to protect the
insulation from weather, e.g. by wrapping it with polythene sheet, roofing felt or other
approved material.
The cement sand plaster finish shall have the following properties:
a. A light shower of rain, falling immediately after application shall not wash off the
plaster.
b. At any time, one week or more after application, it shall not shatter if struck a sharp
blow with a 0.7 Kg hammer. Such a blow may damage the finishing locally but shall
not cause large pieces to break away.
c. When set, it shall withstand prolonged exposure to the weather without additional
protection.

5.3.15 DUAL TEMPERATURE INSULATION

For dual temperature application, resin-bonded glass wool or unbounded rock or slag wool
thermal insulation shall be provided, depending on the lower temperature limit given in Para
3.2. Insulation thicknesses shall be as indicated in Insulation Schedule (Equipment) and
Insulation Schedule (Piping). The insulation application procedure shall be same as that for
cold surfaces.

5.3.16 MEASUREMENT

Measurement of insulation over equipment and piping shall be as per IS 14164.

317
 Measurement for air-conditioning ducts shall be taken over finished insulation surface and 5%
additional area shall be considered to account for reinforcement and flanged angle joints.

5.3.17 MISCELLANEOUS

Approval of the EMPLOYER shall be obtained of samples of all materials and necessary test
certificates of approved national laboratories, before dispatching these to site. Insulation shall
not be applied until specific release is given by the EMPLOYER.

5.3.18 DATA SHEET - A

1. AMBIENT TEMPERATURE : 40 O C 13.

2. 14.
3. 15.
4. 16.
5. 17.
6. INSULATION MATERIALS 18.
6.1 EQUIPMENT: 19.
EP/PUR/PIR/PF/LRG/U150
6.2 PIPING SYSTEMS : 20.
EP/PUR/PIR/PF/LRG/
PSG/U150 21.
6.3 AIR-CONDITIONING DUCT : 22.
EP/PUR/
PIR/PF/LRG/U150 23.
6.4 24.
6.5 25.
7. INSULATION ADHESIVES : 26.
BIT/CPRX/
MAS 83 27.
8. VAPOUR BARRIERS : VB1/ALF/MAS 28.
130
9. FINISHING MATERIALS
9.1 EQUIPMENT : FC/AL1/GS1/MAS
134
9.2 PIPING SYSTEMS:FC/AL1/GS1/MAS 30. TEST CERTIFICATES FOR ALL
134
9.3 AIR-CONDITIONING DUCT : MATERIALS REQUIRED :
FC/AL1/ YES/NO
GS1/MAS 134 31.
9.4 32.
9.5 33.
318
10. INSULATING CEMENT MATERIAL: 34.
SAME AS THE BASIC INSULATION 35.
MATERIAL 36.

319
5.4 PANEL TYPE AIR FILTERS

5.4.1 SCOPE

This specification covers the design, materials, construction features, manufacture, shop inspection
and testing at manufacturer's works, delivery at site, installation, testing, commissioning and
carrying out performance test at site of Panel Type Air Filters.

5.4.2 CODES AND STANDARDS

The design, materials, manufacture, inspection, testing and performance of filters shall comply with
all currently applicable statutes, regulations, codes and standards in the locality where the filters are
to be installed. Nothing in this specification shall be construed to relieve the CONTRACTOR of this
responsibility. In particular, the filters shall conform to the latest edition of following standards:

ASHRAE 52.1 Gravimetric and Dust - Spot Procedures for Testing Air-
Cleaning Devices Used in General Ventilation for Removing
Particulate Matter

IS 7613 Methods of Testing Panel Type Air Filters for

Air-Conditioning and Ventilation Purposes

ISO 14644-1 AND 2 Cleanrooms and Associated Controlled

Environments

5.4.3 GENERAL REQUIREMENTS

5.4.3.1 PRE-FILTER

Pre-filter shall contain washable synthetic fibre or High Density Polyethylene (HDPE) media having
18G Galvanised Steel Sheet (GSS) frame. The filter media shall be supported with HDPE mesh on
one side and aluminium on the other side. Filter frame shall be provided with suitable handles. The
gravimetric efficiency of the pre-filter as per IS 7613 with test dust G3 (fused aluminium oxide dust)
shall be 90% down to particle size of 20 microns or as specified in data sheet A.

5.4.3.2 FINE FILTER

Fine filter shall contain HDPE filter media having 18G GSS frame. The filter media shall be
supported with HDPE mesh on either side. Filter frame shall be provided with suitable handles. The
gravimetric efficiency of the fine filter as per IS 7613 with test dust G2 (fused aluminium oxide
dust) shall be 99% down to particle size of 5 microns or as specified in data sheet A.

5.4.3.3 HIGH EFFICIENCY PARTICULATE AIR (HEPA) FILTER

320
HEPA filter shall contain sub-micron glass fibre paper with or without aluminium separators having
18G aluminium frame. Filter media shall be designed for velocities not exceeding 1.25 metres per
second. Filter frame shall be provided with suitable handles. HEPA filter shall have cold Di-Octyl-
Phthalate (DOP) test efficiency of 99.97% down to particle size of 0.3 microns or as specified in
data sheet A.

321
5.4.3.4 DATA SHEET A

SL. ITEM
UNIT
NO.

GENERAL

1
DESIGNATION
AMBIENT AIR / EXHAUST AIR /
2
SERVICE RECIRCULATED AIR
PRE-FILTER / FINE FILTER / HEPA
3 APPLICATION
FILTER

4 TYPE: CASSETTE / FLANGE

CLEANABLE / NOT CLEANABLE

5 CLEANING METOD
(THROW AWAY)

DESIGN DATA

6 TOTAL AIR FLOW RATE : M3/Hr TABLE IS GIVEN BELOW

7 TEMPERATURE OF AIR : OC AMBIENT

8 RELATIVE HUMIDITY : % 98 % Max.

9 DUST LOADING : gms/M3

EFFICIENCY 90 % DOWN TO 10 MICRONS

10 TYPE OF CONTAMINATION RADIO ACTIVE / CORROSIVE

MAXIMUM FILTER FACE

11 M/sec 2.5 FOR PRE & FINE & 0.5 FOR HEPA
VELOCITY
TOTAL FACE AREA OF FILTERS
12 M2 N.A.
REQUIRED
PREFERRED SIZE OF EACH FILTER
13 mm x mm x mmTHK
PANEL

14 NUMBER OF FILTER PANELS REFER SCHEDULE - F

MAXIMUM ALLOWABLE
15 PRESSURE DROP FOR DESIGN
FLOW RATE IN
mmWC
16 CLEAN CONDITION 2 MM/ 5 MM/ 25 MM WG.

mmWC
17 CLOGGED CONDITION 10 MM/ 15 MM/ 75 MM WG.

322
 GSS / ALUMINIUM / SS / HOT DIP
MOUNTING FRAME / SUPPORTING GALVANISED OR EPOXY OR
18 FRAME WORK FOR SYNTHETIC ENAMEL PAINTED
FILTERASSEMBLY AUXILIARY STEEL CHANNELS OR
ANGLES
19 GASKETS FOR FILTER ASSEMBLY NEOPRENE RUBBER

20 FASTENERS GS / SS

TESTS AND INSPECTION

EFFICIENCY AND PRESSURE DROP
21 TESTING AT WORKS FOR ALL FILTERS AND LEAKAGE
TEST FOR HEPA FILTERS
EFFICIENCY AND PRESSURE DROP,
22 TESTING AT SITE LEAKAGE AND FILTER BANK
LEAKAGE

FILTER DETAILS:

SL.
EQUIPMENT LIST CFM TR QUANTITY MODEL PRE FILTER
NO.
CONFERENCE
1 3100 8 2 CSU REQUIRED
HALL
CONFERENCE
2 1600 4 1 CSU REQUIRED
HALL
3 CNC AREA 1800 5 2 CSU REQUIRED
INCUBATION
4 2300 6 1 CSU REQUIRED
CENTERE
INCUBATION
5 1800 5 1 CSU REQUIRED
CENTERE
6 LIBRARY 3100 8 2 CSU REQUIRED
7 LIBRARY 1200 1 1 CSU REQUIRED

323
5.5 AXIAL FANS FOR VENTILATION SYSTEM

5.5.1 SCOPE

This specification covers the general design, materials, construction features, manufacture, shop
inspection and testing at manufacturer‟s works, delivery at site, handling at site, erection, testing,
commissioning, performance testing and handing over of Axial Fans for Ventilation System.

5.5.2 CODES AND STANDARDS

The design, materials, construction, manufacture, inspection, testing and performance of axial fans
shall comply with all currently applicable statutes, regulations and safety codes in the locality where
the equipment is to be installed. The equipment shall also conform to the latest applicable Indian or
equivalent standards. Other international standards are also acceptable, if these are established to be
equal or superior to the listed standards. Nothing in this specification shall be construed to relieve
the VENDOR / CONTRACTOR of this responsibility.

5.5.3 CONSTRUCTION FEATURES

5.5.3.1 CASING

Casing shall be provided with suitable supports. Access door shall be provided in the casing for easy
access to motor and impeller. Suitable arrangement for mounting of motors shall be provided.

5.5.3.2 IMPELLER

The impeller shall have blades of an airfoil design. Blades shall be mounted on streamlined hub.
Impeller with fabricated blades are acceptable up to 450 mm impeller diameter. The impeller shall
be statically and dynamically balanced. Adjustable pitch blades shall be provided if specified in data
sheet A.

5.5.3.3 GENERAL

Guide vanes shall be provided on the discharge side for vane axial fans. Belt driven fans shall be
provided with V- belts, V-belt pulleys and belt guards. Pulleys shall have minimum two(2) grooves
to prevent start-up failure and premature belt failure. Pulleys shall be statically and dynamically
balanced. Belts shall have a minimum service factor of 1.5.

Common base frame for belt driven fans shall be with adjustable rails for motors. Bolts, nuts and
washers used shall be of non-corrosive material and of superior quality. Bearings shall have
minimum life of 50,000 hours.

5.5.3.4 DRIVE MOTOR

324
 Drive motor shall be rated at least 15 % higher than the power requirement at duty point or 10 %
higher than the maximum power requirement at selected speed, whichever is higher. Starting torque
requirements of fan shall also be considered while selecting the motor.

5.5.3.5 NOISE AND VIBRATION

Noise level produced by any rotating equipment individually or collectively shall not exceed 85
dB(A) measured at a distance of 1.5 metres from the source in any direction. The overall vibration
level shall be as per zones A and B of ISO 10816-1. Balance quality requirement shall be G 6.3
conforming to ISO 1940/1.

5.5.3.6 PERFORMANCE GUARANTEES

Performance parameters to be guaranteed by the VENDOR/ CONTRACTOR and tolerances

permitted shall be as indicated in data sheet A. BIDDER shall confirm acceptance of these by
indicating values in data sheet B. Fan or any portion thereof is liable for rejection, if it fails to give
any of the guaranteed performance parameters.

5.5.3.7 DATA SHEET – A

GENERAL
1 DESIGNATION : AXIAL FANS FOR 5 DUTY : CONTINUOUS / INTERMITTENT
VENTILATION SYSTEM 24 Hrs/Day
1.1 FOR NORMAL VENTILATION: YES/ NO 6 LOCATION IN HAZARDOUS AREA :
YES / NO
1.2 FOR VENTILATION UNDER FIRE: 7 HAZARDOUS AREA CLASSIFICATION
YES/ NO AS PER IS 5572 ZONE 0 / 1 / 2
2 NUMBER REQUIRED : TABLE GIVEN 8
BELOW 1 & 2
3 TAG NUMBERS: TABLE GIVEN BELOW 1&2 9
4 LOCATION : INDOOR / OUTDOOR 10
DESIGN DATA
11 CAPACITY AT SUCTION CONDITIONS 15 MAXIMUM FAN SPEED
11.1 NORMAL : M3/Hr 15.1 FOR IMPELLER DIAMETER 450 mm AND LESS :
1500 RPM
11.2 MINIMUM : 11050 M3/Hr 15.2 FOR IMPELLER DIAMETER ABOVE
450 mm : 1000 RPM
11.3 MAXIMUM : F M3/Hr 16 DESIGN AMBIENT TEMPERATURE: 40 C
12 FLUID HANDLED :GAS/AIR 17 ELEVATION ABOVE MEAN SEA LEVEL :
233 M

13 FLUID CONDITION AT SUCTION 18 FAN POSITION: VERTICAL/ HORIZONTAL

13.1 TEMPERATURE : 28 C 19 FIRE RATING: ( ONLY FOR FIRE APPLICATION
325
 )
13.2 RELATIVE HUMIDITY : 60 % 19.1 TEMPERATURE (MAX): 250C FOR 2 H
13.3 DENSITY : 1.2 Kg/M3 20
14 STATIC PRESSURE : 21
35 mmWC
22 TYPE : VANE AXIAL / TUBE AXIAL / 28 FIRE RESISTANT PAINT: YES / NO
PROPELLER
23 SPARK RESISTANT CONSTRUCTION 29 FAN MOTOR ASSEMBLY- STATICALLY /
TYPE AS PER AMCA : A / B / C DYNAMICALLY BALANGED AS PER AMCA-
204: YES/NO
24 DRIVE : DIRECT / BELT 30
25 ADJUSTABLE PITCH BLADES REQUIRED 31
: YES

/ NO
26 TYPE OF MOUNTING : 32
FLOOR / WALL / IN DUCT
27 PAINTING : MANUFACTURER'S 33
STANDARD / EPOXY PAINTED
MATERIALS OF CONSTRUCTION

34 CASING : CS / 38 OUTLET CONE :

35 IMPELLER : CS / CAST AL / 39 GUIDE VANE :
36 SHAFT : EN 8 / 40
37 INLET CONE OR BELL : 41
ACCESSORIES
42 FLEXIBLE CONNECTION AT FAN INLET 49 WOODEN BLOCK FOR MOUNTING :
/ OUTLET : YES / NO YES / NO
43 TYPE OF FLEXIBLE CONNECTION: 50 COMMON BASE FRAME OR SUPPORTING
NORMAL / FIRE PROOF FRAME FOR MOUNTING: YES / NO
44 VOLUME CONTROL DAMPERS AT FAN 51 NEOPRENE RUBBER PADS : YES / NO
INLET / OUTLET : YES / NO
45 INLET GUARD : YES / NO 52 FOUNDATION BOLTS: YES/NO
46 INLET CONE OR BELL AND OUTLET 53 VIBRATION ISOLATORS : YES / NO
CONE : YES / NO
47 LOUVERED SHUTTERS : YES / NO 54 RIBBED NEOPRENE RUBBER PADS BETWEEN
FOUNDATION BLOCK AND FLOOR FOR
FLOOR MOUNTED FANS:
YES / NO
48 WALL COWL WITH BIRD SCREEN: 55
YES / NO
SERVICES
56 ERECTION : YES / NO 58 TESTING AND COMMISSIONING :
YES / NO
57 ERECTION SUPERVISION : YES / NO 59
326
ELECTRICAL
60 MOTORS: BYCONTRACTOR/ 61 STARTERS : BY CONTRACTOR / EMPLOYER
EMPLOYER
SPARES AND MAINTENANCE TOOLS AND TACKLES
62 63.3
63 ESSENTIAL SPARES 63.4
63.1 63.5
63.2 63.6
TESTS AND INSPECTION
64 65

CODES AND STANDARDS

66 FOR DESIGN, TESTING AND 68
INSPECTION : IS 2312, IS 3588,
AMCA 203, AMCA 210, AMCA 300
67 69
PERFORMANCE GUARANTEES
70 CAPACITY AT SUCTION CONDITIONS 72 POWER CONSUMPTION :
(+) 10 % (-) ZERO M3/Hr (+) ZERO (-) 10 % KW
71 STATIC PRESSURE : 73
(+) 5 % (-) ZERO mmWC
COST LOADING AND PENALTY
74 POWER CONSUMPTION : 76
Rs. / KW

5.5.3.8 Axial Fans Details:

Selected
Building Name Area Fan Qty.
Air Qty.
(sqm.) CMH Type Nos.

ADMIN BUILDING
GROUND FLOOR
TOILET 3.2 80 Propeller 1
PANTRY 4.1 250 Inline 1
PANTRY-1 6.2 380 Inline 1
ELECTRICAL RM 18.8 1130 Propeller 1
HOUSE KEEIPING 3.8 160 Propeller 1
TOILET - SHE 19.5 470 Inline 1
TOILET - HE 19.5 470 Inline 1

327
Sub Total 74.9825 7

FIRST FLOOR
PANTRY 10.5 630 Propeller 1
LUNCH RM 99.8 1340 Propeller 3
HOUSE KEEIPING 3.8 160 Propeller 1
TOILET - SHE 19.5 470 Inline 1
TOILET - HE 19.5 470 Inline 1

Sub Total 7

SECOND FLOOR
STAFF TOI 4.8 120 Propeller 1
RECORDS RM 39.6 480 Propeller 2

Sub Total 3
Total 17

EXECUTIVE HOSTEL
GROUND FLOOR
KITCHEN 10.1 1210 Propeller 1
TOILET 3.4 90 Propeller 1
ELECTRICAL RM 2.5 160 Propeller 1
TOILET 3.4 90 Propeller 1

Sub Total 4

FIRST FLOOR
TOILET 3.4 90 Propeller 1
TOILET 3.4 90 Propeller 1
TOILET 3.4 90 Propeller 1
TOILET 3.4 90 Propeller 1

Sub Total 4
Total 8

DINING BLOCK
GROUND FLOOR
MALE TOILET 19.35 470 Inline 1
ELECTRICAL ROOM 11.25 680 Propeller 1
STORE RM 2.64 70 Propeller 1
TOILET 2.52 70 Propeller 1

328
STATIONARY SHOP 11.25 270 Propeller 1
FEMALE TOILET 19.35 470 Inline 1
WET STORE 2.1 60 Propeller 1
DRY STORE 2.1 60 Propeller 1
KITCHEN 67 5590 Inline 1
Dining area 424.02 11067 Propeller 11

Sub Total 20

FIRST FLOOR
MALE TOILET 19.35 470 Inline 1
FEMALE TOILET 19.35 470 Inline 1
KIETCHEN 67 5410 Inline 1
Boys Common Room 105.86 2500 Propeller 5
Girls Common Room 105.86 2500 Propeller 5

Sub Total 13
Total 33

STAFF ACCOMODATION
GROUND FLOOR
KITCHEN 4.9 590 Propeller 1
WC 1.6 40 Propeller 1
KITCHEN 4.9 590 Propeller 1
WC 1.6 40 Propeller 1
KITCHEN 4.9 590 Propeller 1
WC 1.6 40 Propeller 1
KITCHEN 4.9 590 Propeller 1
WC 1.6 40 Propeller 1

Sub Total 8

FIRST FLOOR
KITCHEN 4.9 590 Propeller 1
WC 1.6 40 Propeller 1
KITCHEN 4.9 590 Propeller 1
WC 1.6 40 Propeller 1
KITCHEN 4.9 590 Propeller 1
WC 1.6 40 Propeller 1
KITCHEN 4.9 590 Propeller 1
WC 1.6 40 Propeller 1

329
Sub Total 8
Total 16

TRAINING
GROUND FLOOR
S MALE TOI. 34.7 840 Inline 5
PHY, SHE & STAFF TOILET 22.3 540 Inline 1
PANTRY 3.3 200 Inline 1
SHE& HE TOILETS 16.2 390 Inline 1
S FEMALE TOI. 34.7 840 Inline 1
ELECTRICAL RM 26.6 800 Propeller 2
HOUSE KEEPING 20.9 510 Propeller 1

Tool Making & Metal Cutting 657.6 21000 Propeller 21

Advance Welding Workshop 436.8 35000 21

Propeller

Sub Total 54

FIRST FLOOR
S MALE TOI. 34.7 840 Inline 1
PHY, SHE & STAFF TOILET 22.3 540 Inline 1
PANTRY 7.0 430 Inline 1
STORE 10.4 260 Propeller 1
S FEMALE TOI. 34.7 840 Inline 1
SERVICE ROOM 14.3 350 Inline 1

Sub Total 6

SECOND FLOOR
S MALE TOI. 34.7 840 Inline 1
PHY, SHE & STAFF TOILET 22.3 540 Inline 1
PANTRY 7.0 430 Inline 1
STORE 10.4 260 Propeller 1
S FEMALE TOI. 34.7 840 Inline 1

Sub Total 5
Total 65

PRODUCTION
GROUND FLOOR
330
MALE TOILET 19.2 470 Inline 1
PHY. TOI. 3.1 80 Inline 1
PANTRY 7.7 470 Inline 1
FEMALE TOILET 19.2 470 Inline 1
MAINTENANCE 108.0 1300 Propeller 2
HEAT TREATMENT 108.0 1300 Propeller 2
STORES 144.0 1730 Propeller 2
Conventional Machines &
Large Machines 395.694 13000 Propeller 13
Tool Asembly 392.04 13000 Propeller 13
Future Expansion 400.14 13000 Propeller 13
Future Expansion-1 394.2 13000 Propeller 13
Trial Section 396.1386 13000 Propeller 13

Sub Total 75

FIRST FLOOR
MALE TOILET 19.2 470 Inline 1
PHY. TOI. 3.1 80 Inline 1
PANTRY 7.7 470 Inline 1
RECORD ROOM 34.2 830 Propeller
FEMALE TOILET 19.2 470 Inline 1

Sub Total 4
Total 79

UTILITY BUILDING-1
GROUND FLOOR
COMPRESSOR ROOM 61.11 800 Propeller 2
MAIN ELEC. RM 163.8 2150 Propeller 5

Total 7

UTILITY BUILDING-2
GROUND FLOOR
PUMP ROOM 164 11050 TAF 1

Total 1

UTILITY BUILDING-3
GROUND FLOOR
HT ROOM 29.16 955 Propeller 2

331
Total 2

BOYS HOSTEL
Ground floor 1.35 100 Propeller 8

First Floor 1.35 100 Propeller 8

Second Floor 1.35 100 Propeller 8

Total 24

GIRLS HOSTEL
Ground floor 1.6 100 Propeller 4

First Floor 1.35 100 Propeller 4

Second Floor 1.35 100 Propeller 4

Total 12

Exhaust Fan with Scrubber

Canteen - Ground Floor 7100 Scrubber 1
Canteen - First Floor 6900 Scrubber 1

Sub Total 2

5.5.3.9 PROPELLER EXHAUST FAN DETAILS:

Area Selected Each Static

Sl. No. Exhaust Propeller Fans NoS (mm)
(Sqm.) CMH Unit
Production - Ground Floor
Conventional Machines & 8
1 Large Machines 13000 1000 13
2 Tool Asembly 13000 1000 13 8
3 Future Expansion 13000 1000 13 8
4 Future Expansion-1 13000 1000 13 8

332
5 Trial Section 13000 1000 13 8

Total 65

Training - Ground Floor

Tool Making & Metal 657 21000 1000 21 8
6 Cutting
Advance Welding 436 35000 1700 21 8
7 Workshop

Total 42

Dining Building
Ground Floor
8 Dining area 424.02 11067 1000 11 8

First floor
9 Boys Common Room 105.86 2500 500 5 8
10 Girls Common Room 105.86 2500 500 5 8

333
5.6 AIR HANDLING UNITS

5.6.1 SCOPE
This specification covers the general design, materials, construction features, manufacture,
shop inspection and testing at manufacturer's works, delivery at site, handling at site,
installation, testing, commissioning and carrying out performance test at site of Air
Handling Units (AHUs).
5.6.2 CODES AND STANDARDS
The design, materials, manufacture, inspection, testing and performance of AHUs shall
comply with all currently applicable statutes, regulations, codes and standards in the
locality where the equipment is to be installed. Nothing in this specification shall be
construed to relieve the CONTRACTOR of this responsibility. In particular, the AHUs
shall conform to the latest edition of following standards:
IS 7613 Method of Testing Panel Type Air Filters for Air-Conditioning
and Ventilation Purposes

ASHRAE 33 Method of Testing - Forced Circulation Air Cooling and Air

Heating Coils

ASHRAE 52.1 Gravimetric and Dust-Spot Procedures for Testing Air-

Cleaning Devices Used in General Ventilation for Removing
Particulate Matter

ARI 410 Forced-Circulation Air-Cooling and Air-Heating Coils

ARI 430 Central Station Air-Handling Units

AMCA 210 Laboratory Methods of Testing Fans for Aerodynamic

Performance Rating

ISO 14644-1 Cleanrooms and Associated Controlled Environments

AND 2

NFPA 90A Installation of Air-conditioning and Ventilating Systems

5.6.3 CONSTRUCTION FEATURES

5.6.3.1 TYPE
The AHUs shall be draw or blow through type as specified in data sheet A. The unit shall
comprise of various sections such as mixing box, pre-filters, fine-filters, cooling coil,
heating coil, humidifier, fan, High Efficiency Particulate Air (HEPA) filters, etc.
5.6.3.2 CASING

334
 Casing shall be of single skin or double skin construction as specified in data
sheet A.
5.6.3.3 Single Skin Construction
AHU shall be of sectionalised construction fabricated out of 16G Galvanised Steel Sheet
(GSS) or Cold Rolled Cold Annealed (CRCA) sheet.
5.6.3.4 Double Skin Construction
Double skin wall panels shall be 25 mm thick made of GSS, pressure injected with
polyurethane foam insulation of density 48 Kg/M3 and K factor not exceeding 0.02W/MoC.
Double skin wall panels shall be fixed to 2.5 mm thick aluminium alloy twin box section
structural framework with stainless steel screws. Outer sheet of the panels shall be made of
0.8 mm thick GSS pre-plasticised or powder coated. Inner sheet shall be 0.8 mm thick plain
GSS.
The entire frame work shall be mounted on a 100 mm (minimum) aluminium alloy channel
base. The panels shall be sealed to the frame work by heavy duty "O" ring neoprene gaskets
held captive in the framed extrusion. All panels shall be detachable or hinged. Hinges shall
be made of die cast aluminium with stainless steel pivots. Handles shall be made of hard
nylon and be operational from both inside and outside of the unit. Units supplied with
various sections shall be suitable for on-site assembly match drilled, with bolts, nuts and
continuous neoprene rubber gaskets. All fixing and gaskets shall be concealed.
Floor and roof panels shall be double skin type and shall be of same construction as the
wall panels.
AHUs shall have hinged quick-opening insulated access door on fan and filter sections.
Access doors shall be double skin type and shall be of same construction as the wall panels.
Four (4) lifting lugs shall be bolted to each base section for lifting or placing the AHU in
place.
All connecting fasteners and related hardware and its accessories shall be in stainless steel.
3.2.3 Sloping condensate drain pan shall be fabricated from 18G GSS. It shall be isolated from bottom floor
panel through 25 mm thick heavy duty Treated for Fire (TF) quality expanded polystyrene or polyurethane foam.
Drain pan shall extend beyond the coil.
3.2.4 Casing shall be of air-tight construction and sufficiently rigid to exclude vibrations, throughout the
working capacity range of the AHU.
5.6.4 FILTERS
5.6.4.1 Pre-filter
Each unit shall be provided with a factory assembled filter section containing air filters of
washable synthetic fibre or High Density Polyethylene (HDPE) media having 18G GSS
frame. The media shall be supported with HDPE mesh on one side and aluminium on the
other side. Filter banks shall be easily accessible and designed for easy withdrawal and
replacement of filter cells. Filter bank frame work shall be fully sealed and constructed
from GSS. The efficiency of the filters shall be 90% down to particle size of 20 microns as
per IS 7613.
5.6.4.2 Fine-filter

335
 Flanged microvee filters with HDPE filter media shall be provided. The filter frame and
filter bank framework shall be of 18G GSS construction with neoprene rubber gasket. The
efficiency of the filters shall be 99% down to particle size of 5 microns as per IS 7613.
Preferably, fine filters shall be located at the downstream side of fan section inside the
AHU.
5.6.4.3 HEPA filter
Flanged HEPA filters having cold Di-Octyl-Phthalate (DOP) test efficiency of 99.97%
down to particle size of 0.3 microns, shall be located at the downstream side of fan section
inside the AHU. HEPA filters made of sub-micron glass fibre paper shall be designed for
velocities of 1.25 metres per second. The filter frame work shall be of aluminium and filter
bank shall be of GSS construction. Three (3) mm thick neoprene rubber gaskets shall be
provided to prevent any air leakage.
5.6.5 COOLING COILS AND HEATING COILS
5.6.5.1 Cooling and heating coils shall have 12.5 to 15 mm diameter tubes of minimum 24G
thickness with sine wave aluminium fins firmly bonded to copper tubes assembled in zinc
coated steel frame of 1.5 mm thick. Face and surface areas shall be such as to ensure rated
capacity from each AHU. The coil face air velocity across the coil shall not exceed 2.54
metres per second for cooling coil and 4 metres per second for heating coil. The coil shall
be pitched in the AHU casing to ensure proper drainage. Each coil shall be factory tested to
21 Kg/cm2(g) air pressure under water. Tube shall be mechanically expanded for minimum
thermal contact resistance with fins. Fin spacing shall be 4 to 5 fins per cm. Coil piping
shall be extended through the casing wall approximately 150 mm and provided with 1034
kPa raised face flange connection. In case, multiple coil sections are provided, the coil inlet
and outlet connections shall be headered inside or outside the AHU and only one (1)
common inlet and outlet connections shall be provided for the coils outside the AHU. The
companion flanges with gaskets, nuts and bolts shall be provided for piping connections.
Pipe extension shall be IS 1239 heavy class. A packing gland is required at the casing wall
to provide an air tight seal around the opening. Coil piping connection side shall be
determined by final layout and design arrangement.
5.6.5.2 Coils shall be sealed in polythene bags and packed in crates properly. Coils with damaged
fins shall not be accepted.
5.6.6 FAN SECTION
5.6.6.1 Fans shall be Double Width Double Inlet (DWDI) centrifugal type. Fans shall have forward
curved or backward curved blades as specified in data sheet A. The fan speed shall not
exceed 1000 RPM and fan outlet air velocity shall not be more than 11 metres per second.
Fan casing and impeller shall be made of galvanised steel or epoxy painted carbon steel.
Fan shaft shall be made from EN 8 steel and supported in self aligning plummer block,
operating at less than 75% of first critical speed with grease lubricated bearings. Impellers
and pulleys shall be individually tested and precision balanced statically and dynamically.
Fans shall be tested for performance at manufacturer‟s works as per AMCA 210 and at site.

5.6.6.2 Motors shall drive heavy duty V-belt, constant speed, fixed pitch drive sheaves, selected at
1.5 service factor with a minimum of two (2) grooves to prevent start-up slippage and pre-

336
 mature belt failure. Motors shall be specially designed for quiet operation and motor speed
shall not exceed 1440 rpm. Belts shall be of oil resistant type. Belt guard shall be provided
with enough space on motor side to fit in the largest pulley for maximum speed. Also
provision shall be made for adjusting the motor side of the belt guard in relation with the
motor adjustment.
In case of single skin AHU, motor shall be mounted outside the casing on slide rails for
easy belt tensioning. Fan and motor shall be mounted on aluminium alloy or galvanised
steel base frames. Isolation shall be provided from the AHU casing by combination spring
and rubber anti-vibration mounts having a 70 to 80% vibration dampening efficiency and
flame retardant, water proof neoprene impregnated flexible connection on fan discharge.
5.6.6.3 In case of double skin AHU, motors shall be mounted inside the casing on slide rails for
easy belt tensioning. The entire fan and motor assembly shall be mounted on a common
deep section aluminium alloy or galvanised steel base frame. Isolation shall be provided
from the AHU casing by combination spring and rubber anti-vibration mounts having a 70
to 80% vibration dampening efficiency and flame retardant, water proof neoprene
impregnated flexible connection on fan discharge.
5.6.7 MIXING BOX
Mixing box shall be complete with fresh and return air dampers. Mixing box shall be
provided whenever the return air is ducted back to the AHU.
5.6.8 DAMPERS
Dampers shall be opposed blade type. Blades shall be made of double skin airfoil extruded
aluminium sections with integral gasket and assembled within a rigid extruded aluminium
alloy frame. All linkages and supporting spindles shall be made of aluminium or nylon,
turning in teflon bushes. In case of automatic dampers, sealed ball bearings shall be provided,
in place of teflon bushes. Manual dampers shall be provided with a bakelite knob for locking
the damper blades in position. Linkages shall be extended for motorised operation if specified
in data sheet A. Damper frames shall be sectionalised to minimise blade warping. Air leakage
through dampers when in the closed position shall not exceed 1.5% of the maximum design
air volume flow rate at the maximum design air total pressure.
5.6.9 GENERAL
5.6.9.1 Each AHU shall be provided with manual air vent at high point in cooling and heating coil
and drain plug in bottom of the coil. Vent and drain shall be provided with 15 mm NB gate
valves. Condensate drain line size shall be 40 mm NB.
5.6.9.2 Shop coats of paint that have become marred during shipment or erection shall be cleaned off
with mineral spirits, wire brushed and spot primed over the affected areas, then coated with
paint to match the finish over the adjoining shop painted surface.
(Eliminator plates, if specified in data sheet A, shall be of aluminium alloy or PVC fill with three (3) bends.
Blow through AHU shall have diffuser section at the downstream of fan. The diffuser provided shall be of
18G perforated aluminium sheet having minimum 50% free area.
Ribbed neoprene rubber pads as vibration isolators shall be provided for AHUs.)
5.6.9.3 Power and control cabling for fan motors and any other electric consumers inside the AHU
shall be provided by the AHU CONTRACTOR and the same shall be brought outside the

337
 AHU and terminated in junction boxes provided by the AHU CONTRACTOR. Lockable
on/off push button for each motor shall be provided outside the AHU.
5.6.9.4 Marine lights shall be provided in AHU sections for maintenance, if specified in data sheet
A. One (1) light switch shall be provided on the exterior of the AHU to control all the
fixtures. The lighting switch shall be completely pre-wired to a junction box on the top of
the AHU. Lighting wire shall be carried out with PVC insulated, 600 volts grade, 2.5 mm2
stranded copper conductor wires. The purchaser shall provide 240V, single phase supply to
the junction box.

338
DATA SHEET -A
SL UNIT
ITEM SL NO.
NO.
1. DESIGNATION : AIR HANDLING UNITS 15. PRE-FILTER REQUIRED :
YES
2. NUMBER REQUIRED : AS PER AHU 15.1 MAXIMUM FACE VELOCITY : 2.5
TABLE M/Sec
3. TAG NUMBERS : 15.2 MAXIMUM PRESSURE DROP AT
RATED CAPACITY
4. TYPE : DRAW / BLOW THROUGH 15.2.2 CLEAN CONDITION : mmWC
5. CASING: SINGLE SKIN / DOUBLE SKIN 16. FINE FILTER REQUIRED :
YES/NO
6. LOCATION : INDOOR / OUTDOOR 16.1 MAXIMUM FACE VELOCITY : 2.5
M/Sec
7. DUTY : CONTINUOUS / INTERMITTENT 16.2 MAXIMUM PRESSURE DROP AT
GENERAL

Hrs/DAY FILTERS RATED CAPACITY

8. VIBRATION ISOLATORS : YES 16.2.1 CLEAN CONDITION : 9 mmWC
9. COMPANION FLANGES AS PER ANSI B 16.2.2 CLOGGED CONDITION :
16.5 CLASS WITH NUTS BOLTS AND 16 mmW C
GASKETS : YES
10. NOISE LEVEL AT A DISTANCE OF 17. HEPA FILTER REQUIRED :
1.5 METRES : 65 dB(A) YES/NO
11. MARINE LIGHTS : YES / NO 17.1 MAXIMUM PRESSURE DROP AT
RATED CAPACITY
12. PAINTING OF FAN AND MS 17.1.1 CLEAN CONDITION :
STRUCTURAL FRAME WORK : EPOXY mmWC
PAINTED / MANUFACTURER'S STD.

13. LIMIT SWITCH: YES/NO 17.1.2 CLOGGED CONDITION : mmWC

14. THERMAL BREAK: YES/NO 17.1.3 MAXIMUM FACE VELOCITY :

M/Sec
FILE NAME:M4-122-03-Rev-R2(1).DOCX
Proprietary rights of the information contained herein belong to Tata Consulting Engineers Limited (TCE). This
information is intended to be used for the mentioned purpose/project only. In case of misuse of information and any claim
arising thereof, cost and consequence will be on the party misusing the information.

SL UNIT
ITEM SL NO.
NO.
18. COOLING CAPACITY : (AS PER 44. TYPE : PAN HUMIDIFIER /
COOLING COIL

AHU TABLE) TR STEAM HUMIDIFIER

HUMIDIFIER

19. APPARATUS DEW POINT 45. CAPACITY : KW

TEMPERATURE : (AS PER AHU
TABLE)OC
20. ENTERING AIR TEMPERATURE

339
 SL UNIT
ITEM SL NO.
NO.
21. DRY BULB : (AS PER AHU TABLE) 46. MINIMUM NUMBER OF STEPS:
O
C
22. WET BULB : (AS PER AHU TABLE) 47. CAPACITY : (AS PER AHU TABLE)
O
C M3/Hr
23. LEAVING AIR TEMPERATURE 48. STATIC PRESSURE :
(AS PER AHU TABLE) mmWC
O
24. DRY BULB : (AS PER AHU TABLE) C 49. TYPE : FORWARD / BACKWARD
CURVED/CENTRIFUGAL/PLUG
TYPE
25. WET BULB : (AS PER AHU TABLE) 50. DISCHARGE DIRECTION : TOP
O
C HORIZONTAL /BOTTOM
HORIZONTAL/ VERTICAL

FAN
UPWARDS/VERTICAL
DOWNWARDS
26. NUMBER OF ROWS DEEP : 6 (MIN.) 51. MOTOR : BY PURCHASER /
VENDOR

27. TYPE OF COIL : CHILLED WATER / 52. STARTER : BY PURCHASER /

CHILLED BRINE / DX VENDOR
28. CHILLED WATER/BRINE FLOW RATE : 53. MOTOR TO CONFORM TO :
(SEE SHEET 5) M3/Hr TCE.M4-203-01
29. CHILLEDWATER/BRINE ENTERING 54. MOTOR PROVIDED WITH VFD:
TEMPERATURE : 6.67 OC YES/NO
30. CHILLED WATER/BRINE LEAVING 55. MIXING BOX REQUIRED : YES /
TEMPERATURE : 12.22 OC (MAX.) NO
MIXING BOX

31. CHILLED WATER/BRINE PRESSURE AT 56. FRESH AIR DAMPER REQUIRED :

COIL INLET : 5.0 Kg/cm2g YES / NO
(MAX.)
32. MAXIMUM PERMISSIBLE CHILLED 57. SIZE : mm x mm
WATER/BRINE PRESSURE DROP : 0.7
Kg/cm2
33. ELIMINATOR PLATES REQUIRED 58. RETURN AIR DAMPER REQUIRED :
MIXING BOX AND DAMPER (CONTD).

AFTER COOLING COIL : YES / NO YES / NO

34. AIR PRESSURE DROP: mmWC
35. HEATING CAPACITY : 59. SIZE : mm x mm
(SEE SHEET 5) KW
36. TYPE : STEAM/HOT WATER/ELECTRIC 60. TYPE OF FRESH AIR AND RETURN
HEATING COIL

STRIP HEATERS WITH CONTROLS IN AIR DAMPER : MANUAL /

STEPS PNEUMATIC / ELECTRIC

37. NUMBER OF ROWS DEEP : 61. SUPPLY AIR DAMPER REQUIRED

:YES
38. FLOW RATE : M 3/Hr 62. SIZE : mm x mm
39. STEAM/HOT WATER ENTERING 63. TYPE OF SUPPLY AIR DAMPER :
340
 SL UNIT
ITEM SL NO.
NO.
O
TEMPERATURE : C MANUAL / PNEUMATIC / ELECTRIC
40. HOT WATER LEAVING TEMPERATURE:
O
C
41. STEAM/HOT WATER PRESSURE AT
COIL INLET : Kg/cm2g
REFER TCE.M4-981 „ SCHEDULE OF

COST LOADING & SPARES & MAINTENANCE TOOLS & TACKLES

42. MAXIMUM PERMISSIBLE HOT WATER 64.
PRESSURE DROP: 0.7 ESSENTIAL & RECOMMENDED
Kg/cm2 SPARES‟
43. MINIMUM NUMBER OF STEPS
REQUIRED FOR ELECTRIC STRIP
HEATER : THREE (3)
65. REFER TCE.M4-982 „ SCHEDULE OF
MAINTENANCE TOOLS &
TACKLES‟

TESTS & INSPECTION

66. REFER TCE.M4-983 „ SCHEDULE of
START-UP & COMMISSIONING
SPARES‟
67. DEHUMIDIFIED AIR QUANTITY: (AS 77.
PER AHU TABLE) M3/HR
68. STATIC PRESSURE: 78.
(SEE SHEET 5) MMWC
69. ENTERING DRY BULB TEMPERATURE: 79. POWER CONSUMPTION; RS/KW
(AS PER AHU TABLE) ○ C
PERFORMANCE GUARANTEES

70. ENTERING WET BULB TEMPERATURE: 80. CHILLED WATER/BRINE

PENALTY

(SEE SHEET 5) ○ C CONSUMPTION: RS/M3/HR

71. LEAVING DRY BULB TEMPERATURE: 81.
(AS PER AHU TABLE) ○ C
72. LEAVING WET BULB TEMPERATURE: 82.
(AS PER AHU TABLE) ○ C
INSPECTION

73. CHILLED WATER / BRINE FLOW: 83.

(AS PER AHU TABLE) CMH
TESTS &

74. CHILLED WATER / BRINE INLET 84.

○
TEMPERATURE: C
75. CHILLED WATER / BRINE OUTLET
○
TEMPERATURE: C
76. NOISE LEVEL AT ADISTANCE OF 1.5
METRES: 65 dB(A)

341
AHU DETAILS:

Entering Air Leaving Air

Sl. Cooling Fan Static
AHU for Tag Nos. Qty temperature temperature Fan capacity
No Capacity Pressure
DBT WBT DBT WBT
811-
Nos TR °F °F °F °F CFM mm WC
AHU-
BIDDER TO SPECIFY
1 Treated Fresh Air G01 2 5.5 2600 50

342
5.7 CONDENSING UNITS FOR AIR-CONDITIONING APPLICATION

5.7.1 SCOPE
This specification covers the general design, materials, construction features, manufacture,
shop inspection and testing at manufacturer's works, delivery at site, handling at site,
installation, testing, commissioning and carrying out performance test at site and handing
over of Condensing Units of capacities 5 TR to 100 TR used for Air Conditioning
application . Type of refrigerant shall be R 22 or R 134a.

5.7.2 CODES AND STANDARDS

The design, materials, manufacture, inspection, testing and performance of Condensing

Units shall comply with all currently applicable statutes, regulations, safety codes and
standards in the locality where the equipment is to be installed. Nothing in this
specification shall be construed to relieve the CONTRACTOR of this responsibility. In
particular, the Condensing Units shall conform to the latest edition of the following
standards:

ASHRAE 15 Safety Code for Mechanical Refrigeration

ASHRAE 23 Methods of Testing for Rating Positive Displacement

Refrigerant Compressors and Condensing Units

ANSI B 31.5 Code for Refrigeration Piping

ARI 575 Standard for Method of Measuring Machinery Sound

within an Equipment Space

ISO 1940 Mechanical Vibration - Balance Quality Requirements

of Rigid Rotors

5.7.3 CONSTRUCTION FEATURES

5.7.3.1 COMPRESSOR

The compressor shall be either hermetic / semi hermetic reciprocating, screw or scroll type as specified in
data sheet A and shall be mounted on vibration isolators. Necessary crankcase heaters shall be provided in
the compressor for capacities exceeding 10 TR.

343
5.7.3.2 CONDENSER

Water Cooled Condenser shall be of shell & tube type with carbon steel shell and
integrally finned copper tubes as per TEMA-B.

Air Cooled Condenser shall be with copper tubes and aluminium fins with low noise
fans. Speed of the fans shall not exceed 960 RPM for fans with impeller diameter above
450 mm & 1440 RPM for fans with impeller diameter 450 mm and less. The impeller
shall be statically and dynamically balanced. The air cooled condenser motor shall have
IP:55 or better protection.

5.7.4 REFRIGERATION PIPING AND CONTROLS

5.7.4.1 The refrigeration piping shall be complete with liquid line strainer, dehydrator, sight glass, liquid line shut-off
valve, pilot solenoid valve and thermostatic expansion valve.

5.7.4.2 For refrigerants R 22 and R 134a, copper tubes conforming to IS:10773 shall be used. Fittings, flanges and pipe
joints shall conform to the requirements of ANSI B 31.5.

5.7.4.3 Piping shall be designed for not less than the internal pressure given in the table.

REFRIGERANT REFRIGERANT MINIMUM INTERNAL DESIGN PRESSURE

NUMBER NAME HIGH PRESSURE SIDE LOW PRESSURE
(Kg/cm2g) SIDE
(Kg/cm2g)
WATER AIR
COOLED COOLED

R 22 Monochloro
difluoro 20 25 13/full
methane vacuum

R 134a Tetrafluoro 13.5 17.5 8.55/full

ethane vacuum

5.7.4.4 Test pressure for piping shall be 1.1 times of design pressure. The pressure shall be gradually increased until a
gauge pressure which is the lesser of one-half of the test pressure or 1.75 Kg/cm2g is attained and preliminary
leak checks shall be carried out. Thereafter, the pressure shall be gradually increased in steps until the test
pressure is reached. The pressure shall then be reduced to the design pressure and leakage examination shall
be made. The design pressure shall be maintained for 48 to 72 hours. A pressure relief valve/device shall be
provided on test pressure line having a set pressure slightly above the test pressure. Nitrogen shall be used as
test medium. Oxygen or any combustible mixture of gases shall not be used within the piping for testing.
Water or water solutions shall not be used as a test medium.

344
5.7.4.5 Vacuum testing shall be done for medium vacuum of around 40 mm Hg absolute and held with vacuum pump
in operation for at least 4 hours. Thereafter unit shall be sealed and vacuum held for at least 12 hours.
Vacuum break shall be done using refrigerant and pressure raised to standing pressure in refrigerant cylinder.

5.7.4.6 Provision for interlock in the control panel shall be provided such that compressor can start only after starting
the air handling fan of evaporator unit. Provision shall also be made to interlock the compressor with
condenser water circulation pump or the air cooled condenser fan motor / air flow switch. Safety devices
such as high/low pressure (HP/LP) cut out, hermetic motor winding thermostat etc. shall be provided. HP cut
out shall be manual reset type while LP cut out shall be auto reset type.

5.7.4.7 The water cooled unit shall be factory piped with adequate charge of refrigerant and oil. The refrigerant piping
and refrigerant charging for air cooled units shall be carried out at site. Refrigerant and oil shall be supplied
along with the unit till the unit is handed over to the PURCHASER.

5.7.5 ELECTRICAL

5.8.5.1 A terminal box suitable for connecting external 3 phase, 4 wire cable shall be provided.

5.8.5.2 The unit shall be provided with single phase preventer.

5.8.5.3 The control panel shall be complete with starters for compressor and condenser fan/pump
motors and shall be prewired.

5.8.5.4 The wiring between the Condensing Unit and Indoor Unit shall be carried out at site.

5.8.5.5 Control panel shall be suitable for ambient temperature of 50OC.

5.7.6 PAINTING

As the Condensing Units (CNU) are normally located outside, painting used shall be of
corrosion resistant type and shall be as per manufacturer's standards.
5.7.7 GENERAL

5.8.7.1 The compressor and condenser of the condensing unit shall have a common base frame.

5.8.7.2 The condensing unit shall be mounted on suitable vibration isolators.

345
5.7.8 PERFORMANCE GUARANTEES

Performance parameters to be guaranteed by the Contractor and tolerances permitted

shall be as indicated in Section C and/or Data Sheet - A. The Bidder shall confirm
acceptance of these by indicating values in Data Sheet - B. Condensing Units or any
portion thereof is liable for rejection, if it fails to give any of the guaranteed
performance parameters.

346
DATA SHEET - A

SL.
NO. ITEM
1. DESIGNATION
2. NUMBERS OFFERED 2NOS
3. TAG NUMBERS
4. MAKE /MODEL NUMBER
5. PLACE OF MANUFACTURE
6. NOMINAL CAPACITY OF EACH CONDENSING
UNIT(CNU) TR 55
7. CAPACITY OF EACH CNU AT SPECIFIED TR 5.5
DESIGN CONDITION
8. REFRIGERANT R 134a
9. OVERALL SIZE OF EACH CNU Lx Dx H mm x x
10. CLEARANCE REQUIRED ON ALL SIDES OF mm FRONT BACK SIDES TOP
EACH CNU
11. OPERATING WEIGHT Kg
12. NOISE LEVEL AT 1.86 M DISTANCE :
12.1 COMPRESSOR dBA
12.2 CONDENSER FAN(IF AIR COOLED) dBA
13. NUMBER OF REFRIGERATION CIRCUITS/ CNU Nos.
14. TOTAL INPUT POWER AT SPECIFIED DESIGN
CONDITIONS PER CNU kW
15. TYPE OF VIBRATION ISOLATORS
16. TYPE , MAKE AND MODEL NUMBER

17. NUMBER OF COMPRESSORS PER CNU Nos. 1 NO

18. PLACE OF MANUFACTURE
O
19. SUCTION TEMPERATURE C
20. SUCTION PRESSURE Kg/cm2
g
O
21. CONDENSING TEMPERATURE C AMBIENT

347
 22. CONDENSING PRESSURE Kg/cm2g
23. OPERATING SPEED AT SPECIFIED DESIGN RPM
CONDITION
COMPRESSOR (CONTD.)

24. CAPACITY AT SPECIFIED DESIGN TR

CONDITION PER COMPRESSOR
25. BKW AT SPECIFIED DESIGN CONDITION PER BKW
COMPRESSOR
26. MOTOR RATING PER COMPRESSOR kW
27. CAPACITY CONTROL AVAILABLE YES / NO
28 IN STEPS OF
29. TYPE , MAKE AND MODEL NUMBER

30. WATER COOLED CONDENSER

30.1 NUMBER OF CONDENSERS PER CNU Nos.
30.2 HEAT REJECTION CAPACITY AT SPECIFIED KCal/Hr
DESIGN CONDITIONS PER CONDENSER
30.3 TOTAL HEAT REJECTION CAPACITY AT KCal/Hr
SPECIFIED DESIGN CONDITIONS PER CNU
30.4 CONDENSER COOLING WATER FOULING HR.SQ
FACTOR FTOF/
CONDENSER

BTU
30.5 COOLING WATER FLOW RATE/ CONDENSER M3/Hr
O
30.6 COOLING WATER INLET TEMPERATURE C
O
30.7 COOLING WATER OUTLET TEMPERATURE C
30.8 WATER VELOCITY IN TUBES M/Sec
30.9 WATER SIDE PRESSURE DROP Kg/cm2
31. AIR COOLED CONDENSER
31.1 NUMBER OF CONDENSERS PER CNU Nos.
31.2 HEAT REJECTION CAPACITY AT SPECIFIED KCal/Hr
DESIGN CONDITIONS PER CONDENSER
31.3 TOTAL HEAT REJECTION CAPACITY AT KCal/Hr
SPECIFIED DESIGN CONDITIONS PER CNU

348
 31.4 MAXIMUM PERMISSIBLE DISTANCE M VERTICAL TOTAL
BETWEEN CNU AND INDOOR UNIT
31.5 CONDENSER FANS
31.5.1 NUMBERS IN EACH CONDENSER
31.5.2 CAPACITY OF EACH FAN M3/Hr
31.5.3 STATIC PRESSURE mmWC
31.5.4 IMPELLER MATERIAL
31.5.5 BRAKE POWER OF EACH FAN kW
31.5.6 INPUT POWER OF EACH FAN kW
31.5.7 MOTOR RATING OF EACH FAN kW
32. HIGH AND LOW PRESSURE CUT OUTS
MAKE OF ACCESSORIES

33. THERMOSTAT
34. SOLENIOD VALVE
35. SINGLE PHASE PREVENTOR
36. STARTERS
37. VIBRATION ISOLATORS
38. CONTROL PANEL
39. CAPACITY OF EACH CNU AT DESIGN TR
PERFORMANCE

CONDITIONS
GUARANTEE

40. TOTAL POWER INPUT AT DESIGN kW

CONDITIONS
41. NOISE LEVEL AT 1.86 M DISTANCE FROM dBA
CNU
42. CONFIRM THAT UNITS CAN BE INSTALLED,
OPERATED AND SERVICED IN AVAILABLE
PLANT ROOM SPACE YES/NO
GENERAL

43. CONFIRM THAT UNITS ARE SUITABLE FOR

SPECIFICIED VOLTAGE AND FREQUENCY YES/NO
44. PERFORMANCE CURVE/RATING CHARTS
ENCLOSED. YES/NO

349
5.8 APPROVED MAKE LIST OF HVAC EQUIPMENTS
NOTE:
- All materials and products shall conform to the relevant standards and shall be of approved
make and design. A list of manufacturers/ vendors is given separately herein below for
guidance. The Engineer shall give the approval of a manufacturer/ vendor/ only after review
of the sample/ specimen. In case the same is not available in the market or in case of change
in trade name, equivalent makes/ re-designated manufacturer then an equivalent approved
make shall be used with the approval of Employer/ Engineer. The complete system and
installation shall also be in conformity with applicable Codes & Standards and Tender
specifications.
- Only “First” class quality materials shall be used.
- Employer reserves the right to choose any of the approved make / vendors as per this list.
- In case of products not indicated in this list, bis marked products shall be preferred.
- Specification of manufacturer‟s item shall be checked against tender item / specifications
before selecting any product or brand name. In case of any discrepancy, tender item/
specifications shall prevail, and any such brand of item shall not be used which is not
conforming to tender specifications even if it is listed in this list.
- For use of material from a bis listed/ certified manufacturer, the contractor shall furnish a
copy of the BIS certificate to Employer before procuring the material.
- In case non-availability of any item/ material among approved manufacturers/ brands at a
particular site/ region, alternate manufacturers/ brands conforming to BIS/ BS etc. shall be
used subject to approval by Employer.
- In case of non-availability of any manufacturer among approved manufacturers at a particular
site/ region, alternate manufacturer‟s name shall be proposed along-with required credentials
for Employer‟s approval.
- In case of any item/ product neither covered in this list nor having A BIS specifications, the
contractor shall submit the proposed item/ product along-with technical details/ specifications
(as per bid), test certificates etc. And other credentials of the manufacturer for Employers
approval.

350
LIST OF APPROVED MAKES FOR PRODUCTS AND MATERIALS FOR HVAC WORKS
ARE INDICATED IN THE TABLE BELOW. HOWEVER, ANY OTHER MAKE WHICH IS
EQUIVALENT AND MEETING THE TENDER SPECIFICATIONS ARE ALSO
ACCEPTABLEWITH PRIOR APPROVAL OF THE ENGINEER

S.No. Details of Materials / Manufacturer

Equipment

1 Variable Refrigerant Flow Daikin

System Hitachi
LG
O General
Daikin
Mitsubishi
Sanyo
Toshiba
Voltas
Blue Star
Carrier
2 Air Handling Unit Carrier
Ciat
Climaveneta
Euroclima
Novair
Saiver
Trane
VTS
Blue Star
Carrier
Citizen
Edgetech
ETA
ETHOS
Flaktwoods
Nutech
Suvidha – Saiver
Voltas
Zeco
3 Split Unit O General
Daikin
Hitachi
Blue Star
Carrier
ETA
Voltas
351
4 Ductable Split Unit (with Toshiba
Refrigerant R-410A/R-407c)
Trane
York
O General
Blue Star
Carrier
ETA
Voltas
5 Centrifugal Fan Chaysol
Comefri
Flaktwoods
Greenheck
Wolter
Blowtech
Nadi
Nicotra
Kruger
Humidin
6 Plug fans Kruger
Greenheck
Wolter
7 Axial Flow Fan Greenheck
Nicotra
Nuaire
Systemair
Wolter
Air flow
Humidin
Kruger
Nadi
Nicotra
8 Inline / Propeller Fan / Roof Chaysol
extractor Fan Nuaire
Ostberg
Systemair
Air flow
Alstom
Nadi
Air washer (Wetting Pad type / Ambassador
Nozzle type scrubber) Emerald
Humidin
Roots Air
9
Roots Cooling

352
 Weather Master
10 Kitchen Scrubber (Dry Type) Flanders Air seal
Trion
11 GI Sheet ESSAR
Jindal
Lloyd
SAIL
TATA

12 Factory Made Duct Alpha duct

Ductofab
Nuaire Engineers
Radient air systems
Rolastar
Seven star
Techno Aircon
Zeco
13 Factory Made Spiral Duct Atco
Karthila Industries
Seven Star
Spiral Tubes Pvt. Ltd.

Western Air Duct

14 Flexible duct Atco

Caryaire
Seven star
UP Twiga
15 Pre-insulated duct ALP
Nutech
Radient air systems
16 Pre-insulated Pipe Perma pipe
Seven Star
17 Passivation system for Western Air Duct
hydraulic systems Biocide
(CHW/CDW/Hot water)

Chemtex

18 Grille/diffuser/dampers Airflow
Air Master
Caryaire
Cosmic

353
 Cosmos
Dynacraft
Ravistar
19 Smoke / Fire Damper (Actuator Greenheck
shall be UL listed) Ruskin
Airmaster
Caryaire
Cosmic
George Rao
Ravistar(Systemair)

20 Sound Attenuator Greenheck

Systemair
Trox
Caryaire
George Rao
Ravistar (Systemair)
Unifair
21 Anchor Fastener Fischer
Hilti
Power Fastener
22 Insulation

22.1 Closed Cell Elastomeric nitrile Eurobatex – Union

rubber/EPDM along with Foam
adhesive Aeroflex
A flex
Armacell
22.2 Microban Closed Cell A flex
Elastomeric nitrile rubber along Armacell
with adhesive

22.3 Cross link polyethylene foam Trocellen

with adhesive
22.4 Fibreglass (Al. Foil Faced) Kimmco
Owens Corning
Lloyd insulation
UP Twiga
23 Acoustic insulation
a. Fibre glass Kimmco
Owens Corning
b. Nitrile rubber with Armacell - Armasound
Antimicrobial property Lloyd insulation

354
 UP Twiga
A Flex
Armacell - Armasound
24 Expanded Polystyrene (TF Beardsell
Quality) Coolite
Styrene Packaging
Tosiba
25 Humidistat Honeywell
Invensys
Johnson Control
Sauter
Siemens
26 Vibration Isolator Cori
Flexionics
Kanwal Industrial
Corporation
Resistoflex
27 Flexible Pipe Connection Mason
Weico
28 Plug fans Kruger
Greenheck
Wolter
HDPE Tanks Sintax
29
Local approval

355
TECHNICAL SPECIFICATION

COMPRESSOR WORKS

356
 COMPRESSOR WORKS

6.1 SCOPE OF SUPPLY

6.1.1 INTRODUCTION

This section covers the requirements for compressed air generation facilities to be supplied at
technical centre at Pudi. This system package shall be modularised / pre-assembled as much as
possible, aiming for the shortest construction period.

6.1.2 EQUIPMENT AND SERVICES TO BE PROVIDED BY CONTRACTOR

The equipment to be supplied and erected under this specification are shown in the flow diagram
enclosed with this specification, as detailed in section Schedule of quantities and these shall be in
accordance relevant Data sheet A of this section. Any item which may not have been specifically
mentioned herein but are needed to complete the equipment / system shall also be treated as
included and the same shall also be furnished and erected, unless otherwise specifically excluded
as indicated.

6.1.3 ENGINEERING / DESIGN

a) Supply of engineering information for interface points with other piping.

b) Operation philosophy and control logic for instrumentation and controls.

c) General arrangement and equipment layout drawings of compressors, receiver and air
drying plant in compressor room.

d) P&ID of compressor system.

6.1.4 SUPPLY ALL MATERIALS TO SITE INCLUDING, BUT NOT LIMITED TO

a) Two nos (1W+1S ) motor driven, lubricated air cooled screw compressor inbuilt with
refrigerant type dryer, capable of delivering 170CFM (FAD) each at a discharge pressure
of 8.5 Kg/cm² (g) with associated accessories as per enclosed datasheets.

357
b) One set of filters consisting of pre-filter and fine filter to restrict oil carry over to 1
mg/m3. Differential pressure gauge with root isolation valve shall be provided at
appropriate locations.

c) One no. Vertical air receiver as per enclosed datasheet with all accessories having capacity
of 1 M³. Receiver shall be provided with two (2) suitably sized safety valves to relieve the
full compressor discharge capacity and shall be set at a pressure 1.25 times the operating
pressure. Receivers shall be provided with one no. pressure indicator and auto drain trap
assembly.

d) All instruments for the compressor as indicated (but not limited to) in attached flow
diagram & data sheets required for proper operation & monitoring of the compressor
along with all instrument impulse piping, fittings and erection hardware.

e) Completely wired microprocessor based panel along with operator interface unit with
LCD screen with push buttons for compressor operation and all necessary accessories
shall be supplied fully wired for each compressor for load-un-load / start-stop & other
controls for the compressor along with complete earthing.

f) All instruments for the air dryer required for proper operation & monitoring of the air
dryer along with all instrument impulse piping, fittings and erection hardware.

g) Completely wired skid mounted microprocessor based panel for the air dryer for operation
and monitoring along with complete earthing.

h) Control and instrumentation cables for connection between instrument / equipment/ MCC
and the control panels for the compressor & air dryer along with all cable trays, conduits,
glands, termination accessories etc..

i) One lot of base plates, foundation bolts, nuts and washers etc. required for each equipment

j) Counter flanges with bolts, nuts, washers and gaskets for all equipment at all terminal
points of equipment covered under Contractor‟s scope of supply.

k) First fill of all lubricants and consumables

l) One set of commissioning and start – up spares. (Price for the same shall be included in
the total quoted price only).

358
 m) One set of recommended spares for 2 years of trouble free operation. (Contractor shall list
the recommended spares and furnish the unit rates separately)

n) One set of recommended maintenance tools and tackles. (Contractor shall list the same
and furnish the unit rates separately)

o) Painting

p) Installation, operation and maintenance manual for the complete system

6.1.5 OTHER SERVICES BY CONTRACTOR

a) Necessary in-house Inspection

b) Supervision of Erection

c) Erection, Testing, Commissioning and Start-up at site

d) Performance Testing of Equipment

e) Training of Employer‟s personnel

f) Documentation.

6.1.6 EQUIPMENT & SERVICES TO BE PROVIDED BY CONTRACTOR.

The following are the equipment and services that shall be provided contractor:

a) Supply & laying of power cable up to the vendor panel shall be done by electrical works
contractor.

b) Earthing pits and the earthing cables from the compressor control skid /dryer control panel
to the earthing pits.

c) All inter-connecting piping with valves, fitting & specialities, as indicated on flow
diagram TCE.10106A-6047-PI-60684.

d) Civil construction, buildings, equipment foundations by civil contactor.

e) Electrical trenches and drain by civil contactor.

359
6.2 CODES AND STANDARDS
All equipment, systems and works covered under this specification shall comply with all
currently applicable statutes, regulations, standards and safety codes in the locality where the
equipment will be installed. All equipment and systems shall comply in all respects with
requirements of latest editions of codes and standards as indicated in this specification.

In the event of any conflict between the codes and standards referred to in the specification and
the requirements of this specification, the more stringent of this requirement shall govern.

a) ASME SEC. VIII DIV.1-2015 - Boiler and Pressure Vessel Code

b) IS 5456:2006 Code of Practice for Testing of Positive Displacement Type Air

Compressors and Exhausters

c) IS 6206:2012 Guide for Selection, Installation and Maintenance of Air Compressor

Plants with Operating Pressures up to 10 bar (g)

d) IS 7938:1976 Air Receivers for Compressed Air Installation

e) IS 11780:1986 Code for Selection and Testing of Rotary Screw Air Compressors (Oil
Flooded)

f) ISO 8573:1: 2001 Compressed Air Contaminants and purity classes

6.3 SPECIFIC REQUIREMENTS / INSTRUCTION TO CONTRACTOR

6.3.1 All equipment supplied shall have capacities not less than those specified in the in the
specification and necessary test certificates shall be furnished in this regard. However, if the
CONTRACTOR feels that higher capacity equipment is required meet guarantee
requirements, he should offer the same and substantiate the same by calculations.
6.3.2 Any conflict between the requirements of this section and related specification, codes,
standards and other documents, shall be referred to Project Manager‟s for clarification.
6.3.3 Fabrication of package unit equipment shall be executed in a controlled manner. This means
that all executed checks, tests and inspections are documented in the manufacturing report
6.3.4 Equipment design shall be aimed at maximum standardization of components and
subassemblies to ensure lowest possible inventory of replacement of parts.
6.3.5 The equipment within the package unit shall be easily accessible for operation and
maintenance.
6.3.6 The motor rating indicated in the bid shall be final and the CONTRACTOR is not permitted
to change this after the award of contract.

360
6.3.7 If required, vibration isolators, mounting / installation structural frames for all equipment
shall be part of the CONTRACTOR‟s scope of work.
6.3.8 The CONTRACTOR shall quote unit rates for each type of equipment viz. Compressors,
dryers and receivers etc. so that if Employer desires to add or delete the same from
CONTRACTOR‟s scope of work, then the total price shall be adjusted based on the unit rates
furnished by the CONTRACTOR.
6.3.9 Two nos of compressors (1W+1S) of 170 CFM(FAD) capacity each are in operation at
present.
6.3.10 The scope of work shall also include guarantee for trouble free operation of the complete
system and equipment/accessories therein for a period of 18 months from the date of supply
at site OR 12 months from date of successful commissioning of the system, whichever is
earlier.
6.3.11 This guarantee shall also include overall performance guarantee of the entire` system to
achieve design conditions stated in specification along with all necessary safety and
statutory requirements.
6.3.12 During the guarantee period the CONTRACTOR shall rectify free of cost of all defects
which may develop due to faulty design, material, construction and workmanship inclusive
of free replacement of defective parts.
6.3.13 During the guarantee period the parts of the equipment requiring repairs or replacement shall
be fitted at site by the CONTRACTOR such that the functioning of the system is not
compromised for any reason whatsoever.
6.3.14 All expenses involved in fulfilling the above guarantee obligations like replacement of
spares, consumables, deputation of service experts, their travel/lodging/boarding shall be
borne by the CONTRACTOR.
6.3.15 Damages occurred to ceiling/floors/walls or any other parts of the building
construction/maintenance shall be made good free of cost with approved fire rated materials
failing which, the cost shall be debited to the CONTRACTOR.

6.4 SPECIFIC ELECTRICAL REQUIREMENT

6.4.1 Electric supply for motors covered under this package shall be made at 415 V, 3 phase by
EMPLOYER.
6.4.2 CONTRACTOR shall carryout all interconnecting control cabling inside the compressed air
system panel. Necessary cable conduits / trays shall be provided by CONTRACTOR.
6.4.3 Control cables shall be stranded copper conductor PVC insulated and extruded PVC inner
sheathed, galvanised steel stripwire armoured overall extruded PVC outer sheathed
conforming to latest IS.
6.4.4 Employer will provide only power supply (415 V, 3 Ph) at one point. Further distribution to
each panel / motor shall be by CONTRACTOR. Any further stepping down of supply shall
be done by CONTACTOR inside the control panel.
6.4.5 CONTRACTOR to include supply and installation of Star-Delta feeder for the compressor in
the compressor panel.
6.4.6 The Star-Delta feeder shall include the starter, over-load relay, CTs ammeter and all
necessary auxiliary relays, controls and on/off/trip indications on the panel.
6.4.7 Earthing for all equipment shall be by EMPLOYER.

361
6.5 SPECIFIC REQUIREMENT OF I & C SYSTEM
6.5.1 This specification shall be read in conjunction with the data sheets, enclosed as part of of this
Section.

6.5.2 I&C SYSTEM FOR COMPRESSOR

6.5.2.1 The Air Compressor Package Unit shall be supplied complete with all instruments and
control equipment/systems, both field and panel mounted. It shall include but not be limited
to the following :
(a) Pressure indicators as per data sheet for :
i. Discharge of each compressor
ii. Each air receiver pressure
iii. Lube oil pressure
(b) Pressure Switches as per data sheet for Lube oil pressure low.
(c) Pressure transmitter as per data sheet for Pressure transmitter on each air receiver for:
i. Air receiver pressure high & low alarms
ii. Loading/unloading of each air compressor
iii. Auto start/stop action of each compressor
(d) Thermometers as per data sheet or :
i. Air temperature for inter stage of each compressor (where multistage compressors
are required).
ii. Air temperature at the discharge of each compressor.
iii. Air temperature in outlet of the dryer
(e) Temperature Switches as per data sheet No. for :
i. Air temperature at discharge of each compressor high
ii. Air temperature after cooler high
iii. Lube oil temperature high
(f) Safety Relief valves as per data sheet for air receiver pressure very high.
6.5.2.2 Control Panel
Microprocessor based control panel shall be provided for compressor. It shall be provided
with operator interface unit (OIU) with 4 line LCD display. It shall display all the process
parameters and alarms on the screen. Alarms shall be provided with audible and visual
362
 indication. Push button shall be provided for start/stop operation of the dryer. All logic
and interlocks for sequential operations shall be programmed in the controller unit.

The panel shall be prefabricated type with enclosure protection of IP 52 as per IS 13947.
The panel shall be made of CRCA cold rolled sheet of 2mm thickness. The panel shall be
painted with exterior colour 631 of IS-5 & interior paint shall be glossy white. 3 pin
receptacle for 230 V AC, 1P, 50 Hz shall be provided inside the panel. All internal wiring
shall be carried out with 1100V grade, stranded tinned copper conductors with PVC
insulation. The panel shall be provided with a proper earthing bus made of copper
securely fixed along the inside base of the panels. This bus shall be typically of 25 mm
wide and 6 mm thick of copper.

(a) Each compressor unit shall be provided with necessary controllers for the safe &
reliable operation of the compressor.

(b) A two position selector switch shall be provided on the control panel for selection of
the compressor AUTO/MANUAL

(c) Each compressor panel shall be provided with a three position selector switch marked
Auto-Off-On for the following functions :

i. Auto - The compressor shall be selected as „Working‟ in load / unload mode.

ii. Off Stops the respective motor.
iii. On For manual start of the respective compressor by push buttons with load
/ unload regulation.
(d) Pushbuttons shall be provided on the front facia of the control panel for manual
start/stop operation of the compressor. An emergency stop pushbuttons shall also be
provided.

(e) One potential free contact will be made available at the terminals of the each
compressor control panel for remote alarm under trip condition.

(f) The control system shall permit operation of each compressor in either of the following
two regulations:
363
 i. Continuous Run-Load-Unload Regulation.
ii. Automatic Start-Stop Regulation.
(g) Under continuous Run-Load-Unload Regulation, the drive motor shall run continuously
while the compressor shall be loaded at pre-set (adjustable) cut-in pressure as the
receiver pressure falls and unloaded at a higher pre-set (adjustable) cut-out pressure, as
the receiver pressure rises. With automatic Start-Stop Regulation, the drive motor shall
automatically start at pre-set (adjustable) cut-in pressure as the receiver pressure falls
and automatically stop at a pre-set (adjustable) higher cut-out pressure as the receiver
pressure rises.

(h) With either system, the compressor shall always be unloaded when the drive motor
starts. The unloaders shall keep the compressor unloaded till the drive motor comes to
full speed.

(i) Following are the minimum alarm annunciation required to be provided on the operator
interface unit screen. In addition to the alarms mentioned below vendor shall provide
the necessary alarms for safe operation of compressors:

i. Tripping of individual air compressors

ii. Each air receiver pressure high
iii. Each air receiver pressure low
iv. Lube oil pressure low
v. Air temperature at discharge of inter stage of each compressor high
vi. Air temperature at discharge of each compressor high
vii. Air temperature after each after cooler high
viii. Lube oil temperature high
(j) 1 no. of hooter shall be provided on the panel for the sound identification of the Alarm
condition. Facility for the Test / Acknowledge / Reset for Alarms shall be provided on
the PLC panel.
(k) All inter cubical and internal wiring for the panel shall be carried out with 1100V
grade, stranded tinned copper conductors with PVC insulation.

364
6.5.2.3 The panel shall be provided with a proper earthing bus made of copper securely fixed along
the inside base of the panels. These buses shall be typically of 25 mm wide and 6 mm thick
of copper.

6.5.2.4 Operator Interface Unit

Unless otherwise specified all set points, control parameters, alarm limits and timers shall
be adjustable through the Operator Interface Unit (OIU) with suitable password
protection.
(a) It shall also provide following facilities:
i. Selection of particular control sequences and actions
ii. Display and acknowledgement of alarms with an alarm log giving individual status.
iii. Provide data storage
iv. Provide data downloading facility
(b) Alarms shall be raised on the OIU as described above.

6.5.2.5 INSTRUMENT POWER SUPPLY

The power supply made available for instrumentation system for both compressor shall be
230V AC. Converters or power supply units required to derive the necessary operating
voltages other than 230V AC for the instrumentation system shall be in the scope of
contractor. MCBs shall be provided in the panel for each power supply distribution feeder to
field & panel mounted instruments and PLC.

6.5.2.6 CABLES
Cabling from control panels to electrical panel and cabling between instruments & panels
supplied by the Contractor shall be by Contractor. Necessary cable trays, conduits shall be
provided by contractor. The specifications for the cables shall be as per data sheet.

6.5.2.7 INSTALLATION & COMMISSIONING

CONTRACTOR's scope of work includes, erection of instruments and control panel,
instrument cabling, loop checking and commissioning. All instruments shall be erected in
such a manner that they are easily read and maintenance can be carried out easily without
shutting down the plant. Prior to guarantee run of the plant, all the instruments shall be
recalibrated and the results shall be recorded. Erection of instruments shall be carried out as

365
 per the CONTRACTOR's instrument installation drawings after getting Project Manager's /
Employer‟s approval.

6.5.2.8 TESTING & INSPECTION

All the instruments & panels shall be tested and calibrated at manufacturer's works in an
approved manner. Inspection shall be carried out in the presence of Employer‟s inspector. All
test certificates for testing instruments shall have calibration certificates from approved test
house, valid for minimum 6 months.

6.6 GUARANTEES AND PERFORMANCE REQUIREMENT

6.6.1 GENERAL
The compressed air system shall perform satisfactorily to meet the guarantee requirements
specified to the entire satisfaction of the EMPLOYER / ENGINEER.

6.6.2 COMPRESSED AIR SYSTEM

i. The CONTRACTOR shall guarantee the capacities of various equipment as specified in
this section and schedule of quantities.
ii. Allowable tolerances on capacity (FAD) of compressors: (-) Zero
(+) Anything
iii. Allowable tolerances on discharge pressure at compressor outlet: (+) 0.5 bar
(-) Zero
iv. Allowable tolerances on dew point temperature at atmospheric pressure of compressed air
at battery limit shall be: (-) Anything, (+) Zero

v. Allowable noise level measured at a distance of 1.5 metres from the source in any
direction: (+) Zero , (-) Anything

vi. The above allowable tolerance requirements are excluding instrument tolerances.

6.6.3 POWER CONSUMPTION

 Tolerance on Power consumption: (+) Zero
(-) Anything

366
6.7 ACCEPTANCE TEST

6.7.1 After the entire installation work has been completed, the CONTRACTOR shall make all
required adjustments until all guaranteed performance requirements are met. All instruments,
services required for the above tests shall be furnished by the CONTRACTOR. The test
reports shall be handed over for EMPLOYER‟s approval before handing over the plant.

6.7.2 If the stipulated performance requirements are not fulfilled, the CONTRACTOR shall make
good the deficiency by providing it in every case, by altering and/ or replacing the parts or
the whole equipment / system free of charge to the EMPLOYER immediately. All rejected
equipment shall be removed from the site at CONTRACTOR‟s expense.

6.8 PAINTING
All the non-insulated exposed carbon steel surfaces of equipment and piping shall be painted
as indicated below:
6.8.1 Surface preparation – Removal of dust, dirt, oil, grease, scale and other foreign material by
manual or power tools.
6.8.2 Primer – 2 coat of red oxide primer (conforming to IS: 2074) with minimum dry film
thickness (DFT) 25 microns per coat.
6.8.3 Finish – 2 coat of synthetic enamel (conforming to IS: 2932) with minimum dry film
thickness (DFT) 25 microns per coat.

6.9 TENDER EVALUATION AND PENALTY FACTOR

6.9.1 Tender Evaluation
a) The CONTRACTOR shall comply with all systems / parameters wherever they are
specified in specification and in data sheets A . Evaluation factor as indicated in para
below for power consumption shall apply. The evaluation factor shall be applicable to the
differential power consumption of all installed equipment, calculated with the lowest
quoted parameter as the base. The CONTRACTOR shall indicate under section schedule
of quantities the guaranteed power consumption for each equipment separately.
b) Deviation from the specifications, if acceptable to the EMPLOYER insofar as practicable
will be converted to rupee value and added to the bid price to compensate for the
deviation from the specification. In determining the rupee value of the deviations, the
EMPLOYER will use the parameters consistent with those specific in the documents and
specifications and other information as necessary and available to the EMPLOYER.

367
6.10 MAINTENANCE REQUIREMENTS
6.10.1 In order to carry out preventive maintenance, it should be possible to readily disassemble,
repair, re-assemble the equipment in the shortest period and to attend to any defect by a
minimum disassembly.
6.10.2 The CONTRACTOR shall furnish one complete set of any special maintenance tools
required for normal maintenance of equipment. The prices for the same shall be indicated in–
Schedule of prices and delivery.
6.10.3 The CONTRACTOR shall confirm that space shown for the equipment is adequate from
point of view of access, easy maintenance and for day to day operation.
6.10.4 All system must have convenient maintenance characteristics including :
a) Minimum disturbance to production during preventive maintenance.
b) Easy access to replacement part which can be installed by personnel with minimum
skill.

6.11 SUMMARY OF DATA TO BE FURNISHED ALONG WITH BID AND AFTER

ACCEPTANCE OF PURCHASE ORDER

The CONTRACTOR shall ensure the following documentation are prepared and submitted
to EMPLOYER for his review / record.
6.11.1 ALONG WITH BID

Sl. No. Details

1.0 Description of the systems offered along with

catalogues, leaflets, drawings, etc.

2.0 All data sheet B of the tender specification, duly filled

in.

3.0 Confirmation on layout drawing enclosed for locations

of equipment & provision of space for operation &
maintenance.

4.0 Performance curves / rating charts used for selection of

equipment for all the systems shall be furnished along
with the bid, with the duty points duly marked on them.

5.0 Bar chart schedule indicating the date of completion of

various activities so as to complete the contract within

368
 Sl. No. Details

the time frame stipulated in the tender specification.

6.0 All section Schedule of quantities duly filled in.

7.0 Electrical load list indicating rating and quantity.

6.11.2 After Award of Contract

Sl. No. Details

1.0 Instrument list with tag numbers, Makes and Model nos.,
Service, Type of instrument

2.0 Data sheets & catalogues for instruments & cables.

3.0 Following drawings for Control Panels for both compressor &
air dryer:

i. Drawings and data sheets for all equipment as listed in

various data sheet enclosed with specification.

ii. Front facia layout of showing all instruments with cut-

outs, bezel dimensions, construction details, foundation
details, interior G.A. drawings

iii. Internal wiring diagrams indicating termination details

of each component

iv. Bill of Material (B.O.M) indicating tag No., quantity,

service & model no. of each controller/PLC
module/instrument/item.

4.0 Catalogues for PLC system and Operator Interface Units

5.0 Writeup on the controls provided for the compressor & dryer

6.0 List of annunciation

7.0 QAP for all the items.

369
 Sl. No. Details

8.0 „As Built‟ drawings

9.0 Instruction manual for installation and start-up.

6.11.3 FINAL DOCUMENTS

6.11.3.1 CONTRACTOR shall submit the copies of operation and maintenance manuals well
before the despatch of the equipment. The manual shall be in sufficient detail with step by
step instructions to enable others to inspect erect, commission, maintain, dismantle, repair,
reassemble and adjust all parts of the equipment. Each manual shall also include a complete
set of approved as built drawings together with performance / rating curves / charts of the
equipment, maintenance schedule and test certificates wherever applicable.

6.11.3.2 Quality assurance documentation specific for the project.

6.11.3.3 PIPING MATERIAL SPECIFICATION

370
 BUTT WELDING
SW SOCKET WELDING
CS CARBON STEEL
SS STAINLESS STEEL
CI CAST IRON
CL CLASS
ERW ELECTRIC RESISTANT WELDED
EFW ELECTRIC FUSION WELDED
SMLS SEAMLESS
LEG
PE PLAIN ENDS
BE BEVELLED ENDS
END
TE THREADED ENDS
BW
SO SLIP-ON
WN WELDING NECK
LJ LAP JOINT
RF FLANGED RAISED FACE
FF FLANGED FLAT FACE
SCH SCHEDULE
GALV GALVANISED
IBR INDIAN BOILER REGULATION
EPDM ETHYLENE PROPYLENE DIENE MONOMER
U-PVC UNPLASTICISED POLYVINYLCHLORIDE
C-PVC CHLORINATED POLYVINYLCHLORIDE
HDPE HIGH DESNSITY POLYETHYLENE
NPT AMERICAN STD. PIPE THREAD (NATIONAL PIPE TAPER)
Gr GRADE
TOE THREADED ONE END
TBE THREADED BOTH END
PSE PLAIN SMALL END
BLE BEVELLED LARGE END
THK THICKNESS

371
NOTES:

1. SPECIFIC REQUIREMENTS GIVEN IN PIPING DRAWINGS OR IN ISOMETRICS

SUPERSEDES REQUIREMENTS GIVEN HERE.

2. USE PTFE TAPE FOR THREADED JOINTS FOR TEMPERATURE  200 0C

SERVICE : : COMPRESSED AIR

CORR. ALL. inch/

TEMP. º F / º C 60 1.5
mm
DESIGN

PR. psig/ kg/ cm2 g 10 FLANGE FACING RF, CONC. SERR. FINISH (NOTE-5)

NOM. PIPE SIZE 15 20 25 32 40 50 65 80 100 150

mm

OUTSIDE DIA. 21.8 27.3 34.2 42.9 48.8 60.8 76.6 89.5 115 166.5
mm

HV HVY HVY HVY HVY HVY HVY HVY HVY HVY CL

CLASS/
mm Y CL CL CL CL CL CL CL CL
THICKNESS
CL

 40 < 40 - SW TO ANSI B16.11

LINE JOINT
 50 > 50 - BW TO ANSI B16.25

MAINTENANCE
ALL FLANGED. TO BE KEPT MINIMUM
JOINTS

NOMINAL
DIMENSION
PIPE MATERIAL
ITEM AL REMARKS
SIZE RANGE SPECIFICATION
STANDARD
inch / mm

CS, IS 1239 PT-1 ERW, GALVANISED,  40 –

PIPES < 150 IS 1239 PT-1
(GALVANISED) PE,  50 - BE

CS, IS 3589 Gr. FE 410

> 150 IS 3589 ERW, GALVANISED
(GALVANISED)

372
 TYPE-E, POE-
CS, IS 1239 PT-1
PIPE NIPPLE 15 TO 40 IS 1239 PT-1 TOE,PBE,TBE,SCH TO
(GALVANISED)
MATCH PIPE

ELBOWS,
CAPS, ASTM A 234 Gr. WPB
> 40 TO 150 ANSI B 16.9 SCH 40, SMLS
REDUCERS,TEE (GALVANISED)
S
B.W. FITTINGS

ELBOWS,
SCH MATCH TO PIPE
CAPS, ASTM A 234 Gr. WPBW
> 150 ANSI B 16.9 THICKNESS, WELDED (SEE
REDUCERS,TEE (GALVANISED)
NOTE –1)
S

ASTM A 105
S.W . FITTINGS  40 ANSI B 16.11 3000CL.
(GALVANISED)

SWAGES( ASTM A 234 Gr. WPB PSE & BLE,THICKNESS TO

15 TO 100 MSS SP 95
ECC/CONC) (GALVANISED) MATCH PIPE

BRANCH SEE BRANCH

ALL
CONNECTION CONNECTION CHART

ASTM A 105
 150 ANSI B 16.5 SO, 150 CL
(GALVANISED)

IS 2062 Gr. A
FLANGES 200 TO 300 ANSI B 16.5 SO, 150 CL
(GALVANISED)

IS 2062 Gr. A SO, 150 CL LIGHT WEIGHT

 350 ANSI B 16.5
(GALVANISED) (SEE NOTE-2)

ASTM A 105
 150 ANSI B 16.5 150 CL
(GALVANISED)

IS 2062 Gr. A
BLIND FLANGES 200 TO 300 ANSI B 16.5 150 CL
(GALVANISED)

IS 2062 Gr. A 150 CL LIGHT WEIGHT

 350 ANSI B 16.5
(GALVANISED) (SEE NOTE-2)

MACHINE / STUD ASTM A 307 GR.B ANSI B

ALL CL. 2A
BOLTS (GALVANISED) 18.2.1
ASTM A 194, Gr.2 ANSI B
HEAVY HEX. NUTS ALL CL.2B REF NOTE 2
(GALVANISED) 18.2.2
ANSI B 16.21 SELF-CENTERING RING, 2
GASKETS ALL NOTE-4
CL.150 MM THK. (NOTE-5)

373
 ASTM A 105
UNIONS < 40 ANSI B 16.11 SW 3000 CL
(GALVANISED)
THREADED ASTM A 105
 40 ANSI B 16.11 3000 CL
FITTINGS (GALVANISED)
NPT / IS 554 ( TAPER) AS
REQUIRED
TYPE SIZE TYPE
PRESSUR SPECIFICATI
OF RANG MATERIAL OF REMARKS
E RATING ON OR
VALVE E ENDS
inch./
BODY TRIM ANSI/ IS -
mm.
CHECK
(LIFT
ASTM A 13% Cr.
TYPE)  40 800 SW -
105 STEEL
GATE
GLOBE
SCREWED, TWO
15 TO ASTM A PIECE, REGULAR
BALL SS 304 150 TE -
40 105 PORT TYPE WITH
PTFE SEAT, SCREWED
FLANGE END, TWO
ASTM A PIECE, REGULAR
BALL  50 216 SS 304 150 RF - PORT TYPE WITH
Gr.WCB PTFE SEAT ,
FLANGED ENDS
CHECK DISC: ASTM
(DUAL A 216 GR. WAFE
 50 SG IRON 150 -
PLATE WCB, R
) SEAT:EPDM
NOTES:
1. USE FLAT END COVERS INSTEAD OF CAPS FOR SIZE  200
2. NUT SHALL BE ALONG WITH WASHER.
3. GASKETS SHALL BE OF ASBESTOS FREE NBR DULY REINFORCED WITH ARMID FIBRES
4. USE FLAT FACE FLANGES & FULL FACE GASKETS WITH CAST IRON FLANGED VALVES.
5. PRIOR TO WELDING OF GALVANISED PIPING, GALVANISING SHALL BE LOCALLY REMOVED FOR A
LENGTH OF 50 mm FROM
EACH END. EXTERNAL SURFACE SHALL BE COATED WITH ZINC-RICH PAINT AFTER COMPLETION OF
WELDING OPERATION.

374
 BRANCH CONNECTION CHART

SIZE BRANCH

inch / mm

RUN 15 20 25 32 40 50 65 80 100 150

15 T

20 RT T

25 RT RT T

32 RT RT RT T

40 RT RT RT RT T

50 H H H H H S

65 H H H H H S S

80 H H H H H S S S

100 H H H H H S S S S

150 H H H H H S S S S S

375
LEGEND :
T - EQUAL TEE RT - REDUCING TEE
H - HALF COUPLING TL -THREADOLET
SL - SOCKOLET WL - WELDOLET
S - STUB –IN N - NIPOLET
SR - STUB-IN WITH R-PAD

376
6.12 SPECIFICATION FOR AIR COMPRESSORS

6.12.1 SCOPE

This specification covers the general design, materials, construction features, manufacture,
shop inspection and testing at manufacturer‟s works, delivery at site, handling at site,
erection, testing, commissioning, performance testing and handing over of Air / Gas
Compressors and Accessories.

6.12.2 CODES AND STANDARDS

The design, materials, construction, manufacture, inspection, testing and performance of the
air/ gas compressors and accessories shall comply with all currently applicable statutes,
regulations and safety codes in the locality where the equipment is to be installed. The
equipment shall also conform to the latest applicable Indian or equivalent standards. Other
international standards are also acceptable, if these are established to be equal or superior to
the listed standards. Nothing in this specification shall be construed to relieve the
CONTRACTOR of this responsibility.

The following are some of the important codes and standards relevant to this specification.
a) API 617 Centrifugal Compressors for Petroleum, Chemical, and Gas Service Industry
Services
b) API 618 Reciprocating Compressors for Petroleum, Chemical, and Gas Industry Services

c) API 619 Rotary Type Positive Displacement Compressors for Petroleum, Chemical,
and Gas Industry Services
d) API 672 Packaged, Integrally Geared Centrifugal Air Compressors for Petroleum,
Chemical, and Gas Industry Services
e) ASME SEC. Boiler and Pressure Vessel Code VIII DIV.1
f) TEMA Standards of the Tubular Exchanger Manufacturers Association
g) IS 2825 Code for Unfired Pressure Vessels
h) IS 5456 Code of Practice for Testing of Positive Displacement Type Air Compressors
and Exhausters
377
 i) IS 6206 Guide for Selection, Installation and Maintenance of Air Compressor
Plants with Operating Pressures up to 10 bars
j) IS 7938 Air Receivers for Compressed Air Installation IS 11780 Code for Selection
and Testing of Rotary Screw Air Compressors (Oil Flooded)
k) IS 13124 Reciprocating Gas Compressors - Technical Supply Conditions

6.12.3 DESIGN AND CONSTRUCTION FEATURES

The compressor shall be of reciprocating or centrifugal or screw type as specified in data

sheet A.

6.12.4 RECIPROCATING COMPRESSORS

a) Frame
The frame shall be a single casting and robust in construction. It shall be provided with
sufficiently large and easily removable inspection doors so that the bearings and other parts
are readily accessible for checking and adjustments. Inspection doors shall be dust-proof and
oil-tight.

b) Cylinder
The cylinder shall be made of cast iron or stainless steel or as specified in data sheet A. The
cylinder heads and barrels shall be provided with cooling water jackets. The design of jackets
shall be such that low air discharge temperature and minimum carbon formation are ensured.
The water jackets shall be so constructed that the flow of water is uniform throughout the
cooling surface and no stagnant water pockets are formed. The walls of the cylinder shall
have sufficient thickness suitable for maximum working pressure and temperature and shall
be suitable for reboring. It shall be provided with liberally sized valve openings and stream-
lined passages. The internal surface of the cylinder shall be highly polished to reduce wear of
the piston rings.

378
c) Piston and Piston Rod

The piston shall be of such a design and construction that the piston rings exert equal
pressure at all points of the cylinder bore. The piston rod shall be designed to take up the full
thrust acting on the piston. The piston rings for non- lubricated type compressor shall be of
self lubricating type. Piston speed shall be maximum 300 M/Min for large capacity
compressors and 350 M/Min for small capacity compressors.

d) Cross Head

The cross head shall be of solid box type with the faces ground to work closely with the
groove of the guides. The cross head pin shall be case hardened and ground.

e) Connecting Rod and Crank Shaft

The connecting rod shall be of I cross-section providing adequate strength and rigidity. The
crank shaft shall be adequately designed so as to ensure smooth running, without vibrations.
It shall be accurately finished to size and shall have sufficient length so as to be fitted to main
bearing and flywheel.

f) Flywheel
The flywheel shall be designed such that it is well balanced and is of sufficient weight to give
an even turning moment. The wheel shall be of robust construction. The spokes shall have
oval cross-section and the boss shall have split construction such that the wheel runs true
with the shaft. The flywheel shall be suitable for type of power transmission i.e. flat belt, V-
belt, direct coupling etc. between the driver and compressor.

g) Main Bearings
The main bearings shall be of robust construction assuring long bearing life and shall have
sufficiently large diameter and adequate length. The bearing at the crank pin end of
connecting rod shall be fitted with bronze lined with best quality white metal. The bearing at
the cross head end shall be fitted with a bushing made of bronze. The bearings shall be made
in halves and shall have forced feed lubrication.
379
 h) Valves
The valves shall have straight and uniform lift and maximum effective area so as to ensure
low air velocity and minimum valve clearance. The valve plate discs shall be heat treated,
tempered and ground and the valve seat shall be case hardened. The valve springs shall be
capable of effecting quick opening and closing and shall also provide the required cushioning
effect. The valve design shall be such that the valve can be easily removed for checking and
maintenance.

i) Lubrication
(i) Frame Lubrication
Frame lubrication for small compressors with motor rating upto 55 kW shall be of
splash type. The pressurised i.e. forced feed system shall be used for compressors
with higher motor rating. In case of force feed lubrication, the oil pump shall be either
driven by crank shaft of the compressor or shall be separately driven. The pump shall
draw the oil from the adequately sized oil well

(ii) Cylinder Lubrication

For lubricated type of compressors, multi plunger pump or metering pump shall be
used for cylinder lubrication. In case of non-lubricated type air compressors, a wiper
ring shall be provided such that the crank case oil is not carried to the cylinder along
with the piston rod.

6.12.5 SCREW COMPRESSORS

a) Casing
Casing shall be of barrel type made of cast iron or fabricated steel for moderate pressure
applications, cast steel or stainless steel for high pressure applications or as specified in data
sheet A. For water injected applications the casing shall be of stainless steel or as specified in
data sheet A. Casing shall have built-in air passages either as cast or machined.

b) Rotors
Rotors shall be of asymmetric profile. The material of construction of rotors shall be as
specified in data sheet A. The rotors shall be dynamically balanced before and after mounting
380
 timing gears and thrust collars. The rotors shall be ultrasonically tested. For non-lubricated
screw compressors rotors shall be lined with PTFE.

c) Gears
Gear pair shall be used to step up speed of the compressor. Helical gear hardened to
minimum 55 RC shall be used. Gear shall be shrink fit on drive shaft and shall mesh with
pinion mounted on extended portion of male rotor. Gears shall be designed as per AGMA
standards.

d) Bearings
The rotors shall be carried in heavy duty ball and roller bearings to take radial and axial loads
or journal bearings with thin babbitt metal lining.

e) Air- Oil Separator

In case of lubricated screw compressors, high efficiency air-oil separation system shall be
provided to ensure removal of oil.

6.12.6 ACCESSORIES
Accessories such as intake filter, silencer, inter-coolers, after -coolers, oil-coolers, receivers,
control cabinet etc. shall be supplied to make the system complete in all respects.

6.12.7 INTAKE FILTER

The intake filter shall be generally as per IS 6206. The type of intake filter shall be as
specified in data sheet A. The filter shall be designed to retain particles of one (1) micron and
above with ninety-seven (97) percent efficiency. In case of cloth filter, the filter element may
be of nylon, polypropylene or woollen cloth attached to the wire netting .

6.12.8 INTER-COOLERS
For multi stage compressors, inter-coolers shall be provided. These shall be of shell and tube
type, with removable tube bundles. The tubes shall have sufficient thickness to withstand the
operating pressure and shall be carefully expanded into the tube sheets. Capacity of inter-
coolers shall be twenty (20) percent more than the compressor capacity or as specified in data
sheet A. Design pressure shall be twenty-five (25) percent more than the working pressure or

381
 as specified in data sheet A. The material of construction and design shall be as specified in
data sheet A.

6.12.9 AFTER-COOLERS AND OIL-COOLERS

The construction features, design etc. shall be as per inter-coolers described above. Capacity
of after-coolers and oil-coolers shall be twenty (20) percent more than the compressor
capacity or as specified in data sheet A. Design pressure shall be twenty-five (25) percent
more than the working pressure or as specified in data sheet A.

6.12.10 RECEIVERS
Receivers shall generally conform to IS 7938. Receivers shall be provided with two (2)
suitably sized safety valves to relieve the full compressor discharge capacity individually and
shall be set at a pressure 1.25 times the operating pressure. The material of construction and
design shall be as specified in data sheet A.

6.12.11 MOTOR RATING

Motor shall be of suitable rating considering compressor power requirements. Motor rating
shall be calculated as follows:

(a) If compressor shaft input power requirement is 100 KW and above,

SKW
Motor rating in KW shall be = 1.10 
t
(b) If compressor shaft input power requirement is less than 100 KW,

SKW
Motor rating in KW shall be = 1.12 
t
Where,
SKW = Shaft Power at selected speed in KW
t = Efficiency of transmission

6.12.12 CAPACITY CONTROL

Capacity control shall be achieved either by speed variation or at constant speed as specified
in data sheet A. In case where capacity control is to be achieved at constant speed, following
methods are generally available. Data sheet A shall be referred for method to be actually
employed.
(a) Automatic start-stop of the compressor
382
 (b) Automatic load-unload of the compressor
(c) Throttling of suction valve
(d) By-passing air or gas from delivery to suction inlet
(e) Increasing clearance volume by a clearance pocket
(f) Variable filling using a by-pass valve.
(g) Movable inlet guide vanes.

6.12.13 DUAL TYPE CONTROL

Capacity control by start-stop and load-unload of compressors is also known as „dual type
control‟, and same is described below.
The dual type control system shall permit operation of each compressor in either of the
following two regulations :

(a) Continuous Run-Load-Unload Regulation.

(b) Automatic Start-Stop Regulation.

Under continuous Run-Load-Unload Regulation, the drive motor shall run continuously
while the compressor shall be loaded at pre-set (adjustable) cut-in pressure as the receiver
pressure falls and unloaded at a higher pre-set (adjustable) cut-out pressure, as the receiver
pressure rises. With automatic Start-Stop Regulation, the drive motor shall automatically start
at pre-set (adjustable) cut-in pressure as the receiver pressure falls and automatically stop at a
pre-set (adjustable) higher cut-out pressure as the receiver pressure rises.

With either system, the compressor shall always be unloaded when the drive motor starts.
The unloaders shall keep the compressor unloaded till the drive motor comes to full speed.

Compressor shall be provided with one selector switch having three positions marked
AUTO-OFF-ON for the following functions :
(a) OFF -Stops the motor.

383
 (b) AUTO -Keeps the compressor(s) in load / unload mode as
selected by master selector switch. Starts the motor of the compressor in
strart-stop regulation as selected by master selector switch.
(c) ON -For manual start up by push buttons with load /unload regulation.

a) Pressure switches shall be provided to monitor receiver pressure of compressor, one for load-
unload control and the other for start-stop control considering two (2) steps regulation for
load-unload mode. In case number of steps are more as indicated in data sheet A, number of
pressure switches provided shall be sufficient to meet the requirement.
b) Pressure switches with alarm initiating contacts shall be provided for the receiver
c) high and low pressures.
d) The dual control units shall be complete with pressure switches, solenoid valves, control air
tubing, air filter (if required) and other accessories as required for the afore-mentioned
operations.
e) For centrifugal compressors anti-surge control shall also be provided to protect compressor
from surging.
f) One potential free contact shall be made available for each compressor for remote alarm
under trip condition and a common contact for compressor auto start.
g) Green and red lamps shall be provided to indicate motor running and stop conditions
respectively.
h) Motors shall be provided with motor winding over-heat sensors and bearing temperature
sensors for alarm indication and to trip the motor.
i) For compressors driven with turbine, the required turbine control and instrumentation shall
be provided.
j) For air / gas compressors, depending on the hazardous area classification, motors and
instrument enclosures shall be explosion-proof certified for the specific area.

384
6.12.14 NOISE AND VIBRATIONS
a) Noise level produced by any rotating equipment individually or collectively shall not exceed
85 dB(A) measured at a distance of 1.5 metres from the source in any direction.
b) The overall vibration level shall be as per zones A and B of ISO 10816-1. Vibration
dampening pads if required, shall be provided.

6.12.15 PERFORMANCE GUARANTEES

Performance parameters to be guaranteed by the CONTRACTOR and tolerances permitted

shall be as indicated in data sheet A. CONTRACTOR shall confirm acceptance of these by
indicating values in data sheet B. Compressor or any portion thereof is liable for rejection, if it
fails to give any of the guaranteed performance parameters.

DATA SHEET A: AIR COMPRESSORS

19.2 FOR INTER-COOLER, AFTER-
1. DESIGNATION : COMPRESSORS FOR
COOLER
COMPRESSED AIR SYSTEM AIR
2. NUMBER REQUIRED : 1 (1W + 1S) 20. COOLING WATER QUALITY : NA
21. COOLING WATER INLET
3. TAG NUMBERS :
TEMPERATURE: NA
22. MAXIMUM COOLING WATER
4. LOCATION : INDOOR / OUTDOOR
OUTLET TEMPERATURE: NA
5. OPERATION : CONTINUOUS / 23. COOLING WATER PRESSURE AT
INTERMITTENT 12 Hrs/Day AT INLET: NA
24. MAXIMUM ALLOWABLE COOLING
WATER PRESSURE DROP IN THE
6. TYPE OF DRIVE : ELECTRIC MOTOR / COMPRESSOR, INTER-COOLER,
AFTER-COOLER AND OIL- COOLER :
NA
7. APPLICABLE STANDARDS : IS 6206 /
GENERAL

IS11780
8. SITE DATA :
25. COMPRESSOR FRAME
DESIGN DATA (CONTD.)

9. LUBRICATION :
10. TYPE : OIL INJECTED AIR - COOLED
SPLASH / PRESSURISED
SCREW COMPRESSOR
DESIGN DATA

11. FLUID TO BE COMPRESSED : AIR 26. TYPE OF CAPACITY CONTROL :

BY SPEED VARIATION / AT
12. CAPACITY (FAD) : 170 CFM CONSTANT SPEED
27.
28.

385
 29.
30. ADJUSTABLE RANGE FOR
15. SUCTION PRESSURE : AMBIENT PRESSURE
16. SUCTION TEMPERATURE - AMBIENT SWITCHES : 6.0 TO 9.0 Kg/ cm 2
31. EXPECTED SETTING OF PRESSURE

TYPE
17. DISCHARGE PRESSURE: 8.5 Kg/ cm 2 (g) SWITCHES FOR : (NOTE-3)
18. MAXIMUM COMPRESSOR SPEED : * 31.1 AUTO LOAD-UNLOAD
RPM

CONTROLS
REGULATION :
19. COOLING MEDIUM : FOR (a) LOAD : 7.5 Kg / cm
2

DUAL
COMPRESSOR : AIR (g)
(b) UNLOAD : 8.5 Kg / cm
2
(g)
31.2 AUTO START-STOP REGULATION: 31.4 HIGH RECEIVER PRESSURE
ALARM : 9.35 Kg/ cm 2
(a) START : 7.5 Kg/ cm 2 (g)
(g)
32. NUMBER OF STEPS FOR
(b) STOP : 8.5 Kg/ cm 2 (g)
LOAD -
31.3 VERY LOW RECEIVER PRESSURE UNLOAD REGULATION : 2 / 3 / 4 /
49. CASING : CI IS 210 OR ASTM A 278
ALARM : 6.8 Kg/ cm 2 (g)
DUAL TYPE CONTROLS (CONTD.)

CL
50. ROTOR BODY : CI ASTM A 395 /
FORGED STEEL AISI 1030-1045 / CAST
40 / FABRICATED STEEL ASTM A 353 / SCREW COMPRESSORS ALUMINIUM ASTM B 26 ALLOY 355
CONSTRUCTION FOR

CAST STEEL ASTM A 216 GR WCB

OR C 355
MATERIALS OF

NORMALIZED / CAST SS ASTM A 743 AND

744 CA6-NM

51. SHAFT : FORGED STEEL AISI 1030-

1035/ FORGED SS ASTM A151 TYPE 410
SS

69. DESIGNATION : INTER-COOLERS /

52. INTAKE FILTER TYPE : PAPER /
AFTER-COOLERS
INTER-COOLERS /AFTER-COOLERS / OIL-

70. TAG NUMBERS FOR INTER-

52.1 MATERIAL OF CONSTRUCTION
COOLERS :
71. AFTER-COOLERS REQUIRED : YES /
CASING : MS / ALUMINIUM
NO
53. SILENCER REQUIRED : YES
DESIGN DATA

72. TAG NUMBERS FOR AFTER-

54. DRIVE PULLEYS WITH V-BELT AND
COOLERS
COMPRESSOR ACCESSORIES

COOLERS :
BELT GUARDS REQUIRED : YES 73. CAPACITY OF :
55. COUPLINGS AND COUPLING
73.1 INTER-COOLERS : 170 CFM
GUARDS REQUIRED : YES
FOR DIRECT COUPLED COMPRESSORS 73.2 AFTER-COOLERS : 170 CFM
56. SLIDE RAILS FOR MOTOR REQUIRED:
74. TYPE : *
YES
57. CONTROL CABINET REQUIRED : YES 75. TYPE OF FLOW : COUNTER-
CURRENT
58. IMPULSE TUBING : COPPER / 76. OPERATING PRESSURE FOR AFTER
386
 ADMIRALITY BRASS AS PER BS EN
1057 COOLERS :
2
EXCEPT FOR EDDY CURRENT TEST/ 76.1 AIR SIDE: 7.0 (MAX.)Kg/ cm
(g)
STAINLESS STEEL 76.2 WATER SIDE : NA
59. MOTOR BY : CONTRACTOR / 77. DESIGN PRESSURE FOR AFTER-
EMPLOYER COOLERS
60. STARTER BY : CONTRACTOR / 77.1 AIR SIDE : *
EMPLOYER 77.2 WATER SIDE : NA
78. MAXIMUM ACCEPTABLE OUTLET
61.
AIR
62. TEMPERATURE : 400 C (NOTE-2)
79. ALLOWABLE PRESSURE DROP OF
63.
AIR
64. THROUGH AFTER-COOLER :
65. 0.2 Kg/ cm 2
80. DESIGN CODE : ASME SEC.
66.
VIII DIV. 1 AND TEMA
67.
81. CORROSION ALLOWANCE :
68.
1.5 mm
90. DESIGNATION : RECEIVER FOR
82. SHELL : CS SA 106 GR B / IS 2002
COOLERS/AFTERCOOLERS/

AIR COMPRESSOR
/
91. NUMBER REQUIRED: ONE (1 W) /
OIL-COOLERS – M O C

83. TUBES : COPPER/ ADMIRALITY BRASS

ONE(1W)
AS PER BS EN 1057 EXCEPT FOR EDDY
92. TAG NUMBERS : LATER
CURRENT TEST / SS 316
84. TUBE SHEETS : CS / BRASS 93. TYPE : HORIZONTAL/ VERTICAL /
CYLINDRICAL WITH WELDED
85. TUBE SUPPORT PLATES : IS 2062 /
INTER-

DISHED ENDS
86. 94. OPERATING PRESSURE : 7.5 Kg/ cm
2
(g)
87. MOISTURE AND OIL SEPARATOR
WITH AUTO DRAIN TRAP TO BE
INTER-COOLERS / AFTER-COOLERS

PROVIDED WITH EACH INTER- COOLER 95. DESIGN PRESSURE : 10 Kg / cm 2

AND AFTER-COOLER TO (g)
DISCHARGE MOISTURE AND OIL TO
DRAIN
ACCESSORIES

96. DESIGN TEMPERATURE : 60

RECEIVER DESIGN DATA

°C
97. NOMINAL VOLUME : 2.0 M 3
98. DIMENSIONS :
98.1 HEIGHT TAN TO TAN : * mm
98.2 DIAMETER : * mm
87.1 TYPE OF MOISTURE AND OIL
99. APPLICABLE CODE : ASME SEC
SEPARATOR : CENTRIFUGAL/ DEMISTER
VIII DIV 1
PAD / BAFFLE

387
 100. CORROSION ALLOWANCE :
1.5 mm
87.2 TYPE OF AUTO DRAIN TRAP : 101. SHELL AND DISHED END
/ BALL FLOAT / SOLENOID OPERATED / MATERIAL : IS 2002 / IS 2062
ELECTRONIC LEVEL CONTROLLED
88. MATERIAL OF CONSTRUCTION OF 102. INTERNAL PAINTING : BLACK
MOISTURE AND OIL SEPARATOR BITUMIINOUS
88.1 BODY/ SHELL : ASTM A 216 103. INSULATION : YES /
Gr. B NO
104. SKIRT REQUIRED : LEG SUPPORT
105.
106. MANHOLE WITH COVER FOR
89. MATERIAL OF CONSTRUCTION OF
INSPECTION AND CLEANING

ACCESSORIES
AUTO DRAIN TRAP
REQUIRED : YES

RECEIVER
89.1 BODY : ASTM A 216 Gr. B

89.2 TRIM : BRONZE /SS

109. ALL THE VALVES, SPECIALITIES

INSTRUMENTS AND ACCESSORIES
REQUIRED : YES
110. COUNTER FLANGES FOR ALL THE 124. ESSENTIAL SPARES
AND
MAINTENANCE TOOLS AND
CONNECTIONS AT BATTERY LIMITS
MISCELLANEOUS

WITH NUTS, STUDS, BOLTS, GASKETS

AND WASHERS REQUIRED : YES / NO
124.1
124.2
124.3
TACKLES

110.1 FLANGES : REF. PIPING MATERIAL 124.4

SPARES

SPECIFICATION - GRADE GA
111. FOUNDATION BOLTS FOR ALL THE
EQUIPMENT REQUIRED : YES / NO
112. ERECTION BY CONTRACTOR :YES/NO
126. PERFORMANCE TEST AT SITE
115. PRIMER : EPOXY
TESTS AND INSPECTION

REQUIRED : YES
115.1 NUMBER OF COATS : 2
PAINTING

127. APPLICABLE STANDARDS : IS

115.2 DRY FILM THICKNESS : 25 µ COAT 5456 / API 618 / API 617 / API 672 / API
619 / IS 11780 /
116. FINISH PAINT : EPOXY
116.1. NUMBER OF COATS : 2 128.
116.2 DRY FILM THICKNESS : 50 µ COAT 129.
117. 130. CAPACITY OF EACH
PERFORMANC

GUARANTEES
SPECIFICATIO

COMPRESSOR : 170CFM (FAD)

COMPANION

118. 131. DISCHARGE PRESSURE : 8.5 Kg/

cm 2 (g)
NS

119. : 132. POWER CONSUMPTION :

E

388
 (+) 0 () * KW
120. 133. TEMPERATURE OF AIR AT
OUTLET OF AFTER COOLER

121. 134. COOLING WATER FLOW RATE :

NA
122.
135. 139.
PERFORMNCE
GUARANTEES

136. 140.
(CONTD.)

137. 141.
138. 142.

143. BEARINGS SKF / FAG

LIST OF SUB-VENDORS FOR BOUGHT-

144. MOTORS CG / BB / KEC

OUT AND CRITICAL ITEMS

145. TURBINE ---

146. ENGINE ----
147. COUPLINGS FENNER
148. V- BELTS FENNER
149. VALVES & SPECIALITIES
150. AUTO DRAIN TRAPS SPIRAX
151. VIBRATION DAMPENING PADS DUNLOP
152. CONTROL PANEL &
RITTAL / PERO PRESIDENT / ENCLOTEK
INSTRUMENTS
153. MCC *
NOTES
1. * VENDOR TO SPECIFY
2. CONTRACTOR TO CONFIRM. THE SAME SHALL BE CONSIDERED IN AIR DRIER DESIGN.
3. COMPRESSOR SHALL BE PROVIDED WITH BOTH ON/OFF REGULATION AND LOAD /
UNLOAD
REGULATION. A TOGGLE SWITCH SHALL BE PROVIDED TO SELECT THE MODE OF
REGULATION.
HOWEVER THE MOTOR SHALL BE SUITABLE FOR CONTINUOUS OPERATION DUTY.

6.13 SPECIFICATION FOR WELDED UNFIRED PRESSURE VESSEL

6.13.1 SCOPE

This specification covers the general design, preparation of detailed fabrication drawings for
review and approval, supply of materials, fabrication, stage-wise inspection, final inspection,
389
 testing, packing, forwarding, transportation and delivery at site of welded unfired pressure
vessels.
6.13.2 CODES AND STANDARDS
a) The design, materials, fabrication, inspection, testing and performance of welded
unfired pressure vessels shall comply with all currently applicable design codes and
standards, statutes, regulations and safety codes in the locality where the equipment is
to be installed. The equipment shall also conform to the latest applicable Indian or
equivalent standards. Other international standards are also acceptable, if these are
established to be equal, or superior to the listed standards. Nothing in this
specification shall be construed to relieve the VENDOR of this responsibility.
b) If statutory approvals are specified in data sheet A, the VENDOR shall be responsible
for obtaining all approvals on design, materials, stage-wise inspection, final
inspection and testing of the vessel.

6.13.3 MATERIALS

6.13.3.1 All materials used in the fabrication of pressure vessels shall be as specified in the
data sheets. Equivalent materials are acceptable only when approved by the EMPLOYER in
writing.
6.13.3.2 All plates shall be ultrasonically tested as follows :
(a) For nominal thickness 20 mm and higher when used for fabrication of dished ends
(b) For nominal thickness 40 mm and higher when used for fabrication of shells
(c) For nominal thickness 50 mm and higher when used for blind flanges
(d) All thicknesses, when used for body flanges
6.13.3.3 The VENDOR shall ensure that code mandatory requirements of impact testing are
met in accordance with the minimum design temperatures specified in the data sheets.
6.13.3.4 Any non-pressure parts such as cleats, pads at support lugs or legs, wear plates at
saddles and pads at pipe supports etc., welded directly on to the pressure parts, shall be of the
same material as the pressure parts.
6.13.3.5 Reinforcement pads at nozzles and other load bearing locations shall be of the same
material and nominal thickness as the pressure part.
6.13.3.6 Material for skirt in case of alloy steel vessels and columns shall be the same as that
of pressure part at least for a minimum length of 500 mm from bottom tan-line.

6.13.4 ALLOY STEEL PROTECTIVE LINING AND CLADDING

6.13.4.1 Lining is defined as loose strip lining and bush lining. Cladding may be by weld
deposit overlay or explosion bonding or roll bonding.
6.13.4.2 Clad plate or lining shall conform to the following requirements :
390
 (a) Clad plate thickness shall be minimum 3 mm, unless specified otherwise.
(b) Clad plate made either by the explosion bonding process or reduction roll bonding
process is acceptable.
(c) Clad plate shall meet the ASME code requirements of SA263, SA264, SA265
including bond test or AD-Merkblatter W-8.The shear bond test shall be executed as
per SA264, Figure 1.Ultrasonic inspection shall be carried out in accordance with SA
578, acceptance level S-6.
(d) For the purpose of ensuring that cladding thickness of reduction roll-bonded clad
plates is not less than 3 mm, each plate shall be inspected at the mill using a "coating
gauge". Plates shall be scanned on at least three edges and one across the width of
the plate. Thickness shall be plotted at points not more than 600 mm apart. The
VENDOR shall furnish a mill certificate, showing an outline of the plate and the
points at which readings were taken together with the results.
(e) Instead of lining, weld deposit overlay may also be considered.
(f) At weld deposit overlay or clad-restoring welds, at least the same chemical
composition shall be present at 3 mm depth, to be analysed by the welding procedure
qualification in advance.
(g) Weld deposit overlay and clad-restoring welds shall be dye penetrant tested and
crack-free.
(h) Weld deposit overlay and clad-restoring welds as a minimum, shall be qualified as per
ASME Section IX.

6.13.4.3 Alloy steel lining shall not be used when cladding is specified. Alloy steel lining,
when specified, shall be so designed that the distance between attachments does not
exceed 150 mm.
6.13.4.4 The minimum required thickness of pressure parts shall exclude cladding or lining.
6.13.4.5 Cladding or lining requirements discussed in this specification are using low and
high alloy steels only. For cladding or lining using non-ferrous and other materials,
when specified, the VENDOR shall furnish on his drawings all details, including
Welding Procedure Specification (WPS), for review and approval.

6.13.5 MINIMUM THICKNESS

6.13.5.1 The thicknesses of the pressure parts as shown in the data sheets or drawings are the
minimum acceptable thicknesses after manufacture, even though the code may permit a
lesser thickness. The minimum acceptable thickness includes specified corrosion allowance.

391
6.13.5.2 The VENDOR shall be responsible for proper selection of plate thickness considering
the fabrication and forming allowances, mill under-tolerances etc., to meet the minimum
thickness requirements as specified.

6.13.6 SHELLS

Shell courses shall be of the largest possible dimensions to minimise the number of weld
seams.

6.13.7 HEADS AND REDUCING SECTIONS

a) Heads shall be of 2:1 ellipsoidal or equivalent ellipsodial type (crown radius R = 0.9D,
knuckle radius r = 0.17D), unless specified otherwise, where D is the inside diameter of the shell.
b) Reducing sections or conical bottoms shall have a knuckle radius of r = 0.06D, unless
specified otherwise. However, knuckle radius shall not be less than 50 mm.
c) Dished ends shall be seamless or 100% radiographed when made from more than one piece.

6.13.8 AGITATOR ASSEMBLY

a) Agitator assembly shall be complete with drive motor, mechanical seal with seal housing,
bearings, gear box, agitator shaft with impellers, foot-step bearing with support, rigid
coupling between agitator shaft and gear box output shaft with spool piece, flexible couplings
between gear box and drive motor, suitable base plate and supporting structure for agitator
drive arrangement and necessary fasteners etc. so as to make it complete in all respects.
b) Drive motor and gear box shall be mounted on a common base frame and duly coupled and
aligned through flexible couplings.
c) Agitator shaft and gear box output shaft shall be coupled through a rigid coupling with split
ring locking arrangement in order to ensure that agitator shaft does not fall into the vessel
during operation.
d) Agitator, shaft and impeller assembly shall be statically and dynamically balanced.
e) The VENDOR shall obtain necessary approvals from the seal manufacturer regarding
arrangement of assembly and application of API cooling plan etc. for the mechanical seal.
f) The gear box shall be rated for heavy duty agitator service, continuously working for 24
hours a day and shall be suitable to withstand static and dynamic loads and bending moment
on the gear box due to agitator shaft.
g) Drive motor and gear box unit shall be provided with a suitable lifting eye hook.
h) There shall be no oil spillage from gear box on to the vessel.
392
 i) Base frame shall be provided with suitable lifting lugs suitably designed for lifting complete
agitator assembly.

6.13.9 NOZZLES AND MANHOLES

a) Nozzles fabricated from plates are acceptable for sizes larger than 250 mm NB in case of
carbon and low alloy steels and 150 mm NB in case of high alloy steels. However, this is to
be done with prior approval and subject to all welds being 100% radiographed.
b) All nozzle sizes and quantities indicated in the data sheets are tentative and for bid purpose
only. Final sizes and quantities are subject to confirmation during review of drawings. The
CONTRACTOR shall include and confirm in his BID, that changes, to the extent of one
size lower or higher for each nozzle and quantities plus or minus one number for each size,
are acceptable at no extra cost to the EMPLOYER.
c) All nozzles with butt-welding end connections shall have edge preparation as per ANSI
B16.25 suitable for connected piping inside diameter. Such nozzles shall have 100 mm extra
stub length with pipe caps for hydrotest purpose.
d) All nozzles of sizes 40 mm NB and below shall be gusseted as per the companion
specification
e) All openings in pressure parts shall be compensated for the area of opening as per code.
Minimum width of pad shall be 50 mm.
f) All load bearing areas in pressure parts shall be verified for buckling and local stresses.
Adequate reinforcement shall be provided.
g) Nozzle and manhole necks shall be flush with the inside surface of vessel, unless specified
otherwise. Inside edges of manholes shall be smooth and rounded-off with a radius of 3 mm.

6.13.10 FLANGES
a) Unless specified otherwise, all nozzles shall be provided with rated flanges only, from
consideration of interchangeability, as per the dimensional standards indicated in the data
sheets.
b) Bolt holes shall straddle the main vessel axes, unless specified otherwise.
c) All flanges on nozzles shall be of forged construction with integral hubs. Plate or plate type
forged flanges are not acceptable in place of forged flanges with integral hubs.
d) All slip-on type flanges of sizes larger than 50 mm NB and girth flanges shall be provided
with adequate venting arrangement during welding.
393
 e) Girth flanges, if made out of multiple plates, shall be a maximum of three segments. All
welds shall be 100% radiographed. Pre-heating and postweld heat treatment shall be carried
out as per code.
f) Companion flanges specified with alloy steel liner shall be supplied with 100 mm long alloy
steel stub ends with butt-welding edge preparation to suit connected pipe thickness.
g) When companion flanges are of welding neck type, the same shall be to suit bore of
connected pipe.However,this information shall be provided by the EMPLOYER, during
review of drawings.
h) Blind flanges and covers intended for inspection or access openings shall be provided with
adequate arrangement to facilitate opening and closing without undue effort.
i) Unless specified otherwise, seating surfaces for non-metallic gaskets shall have stock or
serrated finish. For other types of gaskets, the type of finish shall be furnished by the
VENDOR on the drawings for review and approval.
j) When flanges specified are of tongue and groove or male and female type, groove or female
face shall be on the nozzle flanges and tongue or male face on the companion flanges.

6.13.11 SUPPORTS
a) All skirt supports shall have at least one access opening and adequate vent holes at the top of
skirt.
b) Skirt shall be provided with adequate holding and climbing rungs inside, above and below
the skirt opening. Details shall be furnished by the VENDOR on the drawings for review and
approval.

6.13.12 MISCELLANEOUS
a) The sizing of vessel internals shall be such that all removable parts can be removed through
manholes.
b) Wherever applicable and unless specified otherwise in data sheets all support rings, bolting
bar for internals such as trays, tower packings, downcomers etc. shall be in the scope of the
VENDOR.
c) Internal baffles, tray support beams of other internals spanning a chord or diameter of the
vessel shall be provided with a means for allowing differential expansion between the part
and the vessel shell.

394
 d) Unless specified otherwise, baffles or weir plates shall not be welded directly to the shell or
dished end of the vessel. These shall be bolted to the support attachments which are welded
to the shell or dished end.
e) The CONTRACTOR shall include two (2) numbers stainless steel name plates in his scope.
This requirement is exclusive of manufacturer's name plate. The details on name plate shall
be furnished during review of drawings.
f) Lifting lugs shall be provided for all vessels. Details are subject to review and approval.
g) Earthing cleats as per companion specification shall be provided at the approved locations.
h) All pads at nozzles, supports etc. shall be provided with a tell-tale hole at the bottom-most
location, which shall be tested with air at 1.0 kg/cm²(g) and checked with soap solution for
leakage. Such tall-tale holes shall be plugged after satisfactory testing.
i) For insulated or fire proofed vessels, insulation or fire proofing supports as per enclosed
companion specification shall be provided by the VENDOR.
j) Wherever platforms and ladders are specified in the data sheets, necessary supports shall be
provided by the VENDOR as per details which shall be made available during review of
drawings.
k) Where materials are “free issue” as indicated in the enquiry specification or data sheet, the
CONTRACTOR shall furnish along with the technical BID, a firm Bill of Materials (BOM)
of all “free issue” items and also indicate cutting and wastage allowances both accountable
and unaccountable.

6.13.13 ANCHOR BOLTS

Anchor bolts are not included in the scope of supply of the VENDOR, unless specified
otherwise in the data sheets.
6.13.14 FABRICATION
a) All welders, WPS and Procedure Qualification Records (PQR) shall meet the
b) requirements of the specified code irrespective of pressure service or non-pressure service.
c) Before welding, edges shall be checked in order to ascertain the absence of flaking,
irregularities or serious defects.
d) Stainless steel and high alloy steel fabrication shall have independent set of tools, grinding
wheels and wire brushes etc.
e) Welding shall be executed by qualified welders.

395
 f) Butt-welds shall have full penetration. Single sided welds shall be chipped back to sound
metal and rewelded from the other side. Wherever chipping is not possible, root run shall be
by TIG. Backing strip shall not be used without prior approval.
g) Openings, reinforcing pads and attachments shall clear longitudinal and circumferential weld
seams.
h) Circumferential welds shall be situated 100 mm above or below the support rings and
packing support rings meant for supporting internals, if specified.
i) Circumferential and longitudinal weld seams shall clear saddles and support lugs.
Longitudinal seams, in case of horizontal vessels, shall be at least 150 mm above saddle
wear plate.
j) Nozzle and reinforcement pads, where applicable, shall be set-in type and attached to the
vessel by full penetration welds.
k) Skirt to vessel heads joints shall have continuous flat-faced weld matching with outer
diameter of the vessel. The width of the weld shall be equal to skirt thickness and height of
weld shall be twice the width.
l) All welds shall be deburred, free from under cuts, overlap ridges and valleys.
m) No welding shall be carried out after stress relieving and/or postweld heat treatment. All
flange faces shall be suitably protected against oxidation during heat treatment.

6.13.15 FIELD ERECTION

a) Where size or shape of vessel makes it impossible to ship it in one piece for erection by
others, the VENDOR shall ship largest shop fabricated sections suitable for shipment and
ease of handling for field erection and assembly. Fabrication and erection shall be completed
at the site by the VENDOR.
b) All pieces shall be shop fit-up into sections and each sections shall be fit to adjacent section
and all pieces shall be match marked.
c) The width of permissible gap during fit-up shall be in accordance with approved drawings
and welding procedures and shall generally be 3 mm maximum with a tolerance of plus 0.8
mm to minus 0.0 mm.
d) Flame cut edges shall be ground by the VENDOR as required to remove slag, detrimental
discoloration and non-uniformity of edges.

396
 e) All radiographic requirements for welds completed in shop shall be made by the VENDOR
before the parts of section leave the shop.

6.13.16 PAINTING
All carbon steel exteriors shall be descaled, edges deburred and wire brushed. Subsequently,
all such surfaces shall be painted with two coats of red oxide primer.

6.13.17 ESSENTIAL AND RECOMMENDED SPARES

The CONTRACTOR shall include following essential spares in his scope of supply :
a) Two (2) gaskets as spares for each nozzle
b) Three (3) gaskets as spares for body flanges
c) 10% spare fasteners of each size and length. However, the minimum quantity shall be
four (4) for each size and length.

397
 398

SHOP INSPECTION REQUIREMENTSUNFIRED PRESSURE VESSELS

SERIAL NO.

VISUAL EXAMINATION

DIMENSIONS

MATERIAL TEST CERT.

CORRELATION
IDENTIFICATION AND
ULTRASONIC TEST
QUALIFICATION
WELDING
FIT UP

BACKCHIP - PT

PT / MT

RADIOGRAPHY
COUPON TEST
PRODUCTION WELD
OVALITY, THINNING
HEAT TREATMENT

SURFACE FINISH
TEST
HYDROSTATIC LEAK
PNEUMATIC LEAK TEST

HARDNESS TEST

SPARK, ADHESION TEST

THICKNESS CHECK
OUT TESTS
OPERATION AND RUN
DESCRIPTION

MATERIAL FOR PRESSURE PARTS, FLANGES,

1 D D C D D
PADS, LUGS
2 FORMED SHELLS, HEADS D D D D C
BUTT, GROOVE WELDS ON PRESSURE PARTS, , A/
3 D D B D D B B B
FLANGES , PADS, LIFTING LUGS C
4 FILLET WELDS ON ABOVE MATERIALS D D A/ D D
C
5 OVERLAY WELDS D D D A/ A
C
6 INTERNAL SUPPORTS WELDING IF ANY D D
7 INTERNAL FITTINGS, IF ANY D D
8 COMPLETED VESSEL A A C A A B
9 MOUNTED AGITATORS, IF ANY A A C D B C/ B A
A
10 LININGS, IF ANY A A A A
11 COATINGS, IF ANY A A

SHEET
A - WITNESSED BY TCE. 1 - ALL STAGES SHALL BE CHECKED 100 % BY VENDOR AND RECORDS THEREOF SHOWN TO TCE.
B - WITNESSED BY TCE IF REQUIREMENT IS 2 - WITNESSING BY TCE MAY BE 100 % OR ON RANDOM SAMPLES.
SPECIFIED.
3 - THIS DOCUMENT SHALL BE READ IN CONJUNCTION WITH INSPECTION REQUIREMENTS
C - RECORDS VERIFIED BY TCE WHEREVER MENTIONED IN RELEVANT TECHNICAL SPECIFICATIONS.
APPLICABLE.
4 - THE PRESSURE GAUGES AND INSTRUMENTS FOR MEASURING CRITICAL PARAMETERS SHALL

1 OF 1
D - A OR C, AT TCE'S DISCRETION WHEREVER HAVE VALID CALIBRATION CERTIFICATE TRACEABLE TO NATIONAL LABORATORY.
APPLICABLE.

398
 MACHINES-MECHANICAL
SHOP INSPECTION REQUIREMENTS ROTATING
SERIAL NO.

VISUAL EXAMINATION

DIMENSIONS

MATERIAL TEST CERT.

CORRELATION
IDENTIFICATION AND
POURING

PT / MT

RADIOGRAPHY

ULTRASONIC TEST

HEAT TREATMENT

SURFACE FINISH

LEAK TEST
CE
ALIGNMENT/CLEARAN
BALANCING
STATIC / DYNAMIC
OPERATION
PERFORMANCE /
TEMPERATURE RISE
VIBRATION, NOISE,
STRIP DOWN

TYPE TESTS

ROUTINE TESTS

NPSH TEST FOR PUMPS

LINING TESTS
DESCRIPTION

1 MATERIALS FOR PRESSURE PARTS, SHAFTS, D C D D B B C

IMPELLER / LOBES
2 MACHINED SHAFT, IMPELLER / LOBES B D
3 ROTOR ASSEMBLY D
4 MOTORS D D B D
5 COMPLETED ITEM A A D D A A D B
6 LININGS, IF ANY A A

LEGEND: NOTES:
A - WITNESSED BY TCE. 1 - ALL STAGES SHALL BE CHECKED 100 % BY VENDOR AND RECORDS THEREOF SHOWN TO TCE.
B - WITNESSED BY TCE IF REQUIREMENT IS 2 - WITNESSING BY TCE MAY BE 100 % OR ON RANDOM SAMPLES.
SPECIFIED.
3 - THIS DOCUMENT SHALL BE READ IN CONJUNCTION WITH INSPECTION REQUIREMENTS
C - RECORDS VERIFIED BY TCE WHEREVER MENTIONED IN RELEVANT TECHNICAL SPECIFICATIONS.
APPLICABLE.
D - A OR C, AT TCE'S DISCRETION WHEREVER 4 - THE PRESSURE GAUGES AND INSTRUMENTS FOR MEASURING CRITICAL PARAMETERS SHALL
APPLICABLE. HAVE VALID CALIBRATION CERTIFICATE TRACEABLE TO NATIONAL LABORATORY.

399
 SHOP INSPECTION REQUIREMENTSAIR FILTERS
SERIAL NUMBER

VISUAL EXAMINATION

DIMENSIONS

CERTIFICATE
MATERIAL TEST
IN CLEAN CONDITION
CHARACTERISTIC TEST
INITIAL RESISTANCE
CAPACITY TEST
DUST HOLDING

EFFICIENCY TEST

CONDITION
IN SATURATED
PRESSURE DROP TEST
- LEAK TEST
FILTER TO FRAME SEAL
DESCRIPTION

1 CABINET / FILTER FRAME C

2 FILTER MEDIUM A A C

3 DUST FOR EFFICIENCY TEST C

4 AIR FILTER ASSEMBLY A A AX A AY AX A

SHEET
NOTES:
LEGEND: 1 - ALL STAGES SHALL BE CHECKED 100 % BY VENDOR AND RECORDS THEREOF SHOWN TO TCE.
A - WITNESSED BY TCE. 2 - WITNESSING BY TCE MAY BE 100 % OR ON RANDOM SAMPLES.
B - WITNESSED BY TCE IF REQUIREMENT IS SPECIFIED. 3 - THIS DOCUMENT SHALL BE READ IN CONJUNCTION WITH INSPECTION REQUIREMENTS
C - RECORDS VERIFIED BY TCE WHEREVER APPLICABLE. MENTIONED IN RELEVANT TECHNICAL SPECIFICATIONS.

1 OF 1
4 - THE PRESSURE GAUGES AND INSTRUMENTS FOR MEASURING CRITICAL PARAMETERS SHALL
D - A OR C, AT TCE'S DISCRETION WHEREVER APPLICABLE HAVE VALID CALIBRATION CERTIFICATE TRACEABLE TO NATIONAL LABORATORY.

400
 SHOP INSPECTION REQUIREMENTS AIR DRYING PLANTS
SERIAL NUMBERS

VISUAL EXAMINATION

DIMENSIONS
CERTIFICATE
MATERIAL TEST
CORRELATION
IDENTIFICATION AND
ULTRASONIC TEST
QUALIFICATIONS
WELDING
FIT UP

BACK CHIP - PT

PT / MT

RADIOGRAPHY
TEST
HYDROSTATIC LEAK
PNEUMATIC LEAK TEST

OPERATION TEST

PERFORMANCE TEST

SIMULATED PERF. TEST

TYPE TESTS

ROUTINE TESTS
CERTIFICATE
PRODUCT
MANUFACTURER'S
DESCRIPTION

ADSORBER, FILTER, COOLERS / CHILLERS, HEAT

1 EXCHANGERS, CONDENSER, MOISTURE SEPARATOR A A C D B C/A D D B B A B
AND OTHER FABRICATED ITEMS

2 BLOWER / COMPRESSOR A A C C A C

3 VALVES - TWO WAY , FOUR WAY, SAFETY D D C D D C

4 PIPES AND FITTINGS A A C A

INSTRUMENTS, DEW POINT APPARATUS, VALVE
5 C D C
ACTUATOR
6 HEATER C D C

7 MOTORS > 30 KW / < 30 KW D D C A/C

8 CONTROL PANEL A A C A A C

9 COMPLETE ASSEMBLY A A A A

10 MISC., SUCH AS SILICA JEL C

SHEET
LEGEND: NOTES:
A - WITNESSED BY TCE. 1 - ALL STAGES SHALL BE CHECKED 100 % BY VENDOR AND RECORDS THEREOF SHOWN TO TCE.
B - WITNESSED BY TCE IF REQUIREMENT IS SPECIFIED. 2 - WITNESSING BY TCE MAY BE 100 % OR ON RANDOM SAMPLES.
C - RECORDS VERIFIED BY TCE WHEREVER APPLICABLE. 3 - THIS DOCUMENT SHALL BE READ IN CONJUNCTION WITH INSPECTION REQUIREMENTS
MENTIONED IN RELEVANT TECHNICAL SPECIFICATIONS.

1 OF 1
D - A OR C, AT TCE'S DISCRETION WHEREVER APPLICABLE.
4 - THE PRESSURE GAUGES AND INSTRUMENTS FOR MEASURING CRITICAL PARAMETERS SHALL
HAVE VALID CALIBRATION CERTIFICATE TRACEABLE TO NATIONAL LABORATORY.

401
402
 6.14 SPECIFICATION FOR LOW VOLTAGE INDUCTION MOTORS

6.14.1 SCOPE
The specification covers the design, material, constructional features, manufacture,
inspection and testing at the VENDOR'S/his SUB-VENDOR'S works, delivery to site
and performance testing of Low Voltage induction motors rated up to 1000V.
6.14.2 CODES AND STANDARDS
The design, material, construction, manufacture, inspection, testing and performance of
induction motors shall comply with all currently applicable statutes, regulations and
safety codes in the locality where the equipment will be installed. The equipment shall
also conform to the applicable standards specified in data sheet A1 latest revision as on
the date of offer. Nothing in this specification shall be construed to relieve the
VENDOR of this responsibility. In case of conflict between the standards and this
specification, this specification shall govern.
6.14.3 DRIVEN EQUIPMENT
a) When this specification forms part of the driven equipment specification,
information not given in the Data Sheet-A will be governed by the driven
equipment specification.
b) Motors shall be capable of satisfactory operation for the application and duty as
specified in the motor Data Sheet-A and as specified for the driven equipment.

6.14.4 PERFORMANCE AND CHARACTERISTICS

i) Motors shall be capable of giving rated output without reduction in the expected life
span when operated continuously under either of the following supply
conditions as specified in Data Sheet-A1.

Supply Condition

I II

a) Variation of supply voltage from rated voltage +/- 6% +/-10%

b) Variation in supply frequency from rated frequency +/-3% +/- 5%

c) Combined voltage and frequency variation +/- 6% +/-10%

ii) Motors shall be suitable for the method of starting specified in the Data Sheet-A.
iii) The minimum permissible voltage shall be 85% of the rated voltage during motor
starting

403
 iv) Motors shall be capable of starting and accelerating the load with the applicable
method of starting, without winding temperatures reaching injurious levels, when the
supply voltage is in the range of 85% of the rated motor voltage to maximum
permissible voltage specified in Data Sheet-A1.
v) The locked rotor current of the motor shall not exceed 600% of full load current
(subject to tolerances as per the applicable standard) unless otherwise specified.
vi) Motors shall be capable of developing the rated full load torque even if the supply
voltage drops to 70% of the rated voltage. The pull out torque of the motor shall be
atleast 205% of full load torque.
vii) Motors when started with the driven equipment coupled shall be capable of
withstanding at least two successive starts from cold conditions & one start from hot
condition without injurious heating of windings. The motors shall also be suitable for
three equally spread starts per hour under the above referred supply conditions.
viii) Motors shall be of Energy Efficient type if specified in Data sheet-A1. Category of
Energy efficiency shall be as mentioned in data sheet-A1
6.14.5 INSULATION
i) The insulation shall be given tropical and fungicidal treatment for successful operation
of the motor in hot, humid and tropical climate.
ii) Insulation of VFD controlled Motors shall be designed to withstand a dv/dt of 0.1
micro sec rise from 10 % to 90 % of steady voltage and a maximum peak of 1600 volts
as per NEMA standard MG1 Part 31.40.4.2
6.14.6 TEMPERATURE RISE
i) The temperature rises shall not exceed the values given in IS 12802. Under extremes
of supply condition (clause 4.1 above), the temperature rise shall not exceed the value
indicated in IS by 10oC.
ii) For motors specified for outdoor installation heating due to direct exposure to solar
radiation shall be considered.
6.14.7 CONSTRUCTIONAL FEATURES
i) All windings shall be of Copper.

ii) Motors weighing more than 25 kg. shall be provided with eyebolts, lugs or other means
to facilitate safe lifting.
6.14.8 BEARINGS
i) Unless otherwise specified in data sheet-A, motor bearings shall not be subjected to any
external thrust load.

404
 ii) Unless otherwise specified, motor bearings shall have an estimated life of atleast 40,000
hrs.
iii) The bearings shall permit running of the motor in either direction of rotation.

iv) When forced oil lubrication or water cooling is required, prior approval from the
Employer shall be obtained.
v) It shall be possible to lubricate the bearings without dismantling any part of the motor.
vi) On line Greasing shall be provided for motors of 15kW and above.

vii) VFD controlled Motors shall have their bearings insulated to prevent motor shaft
currents from entering the bearing race.
6.14.9 TERMINAL BOX
i) Terminal boxes shall have a degree of protection of atleast IP 55 for out door applicable

ii) Unless otherwise approved, the terminal box shall be capable of being turned through
3600 in steps of 900.
iii) Terminals shall be of stud type & the terminal box shall be complete with necessary
lugs, nuts, washers.
iv) When single core cables are to be used the gland plates shall be of non magnetic
material.
v) Sizes of terminal boxes and lugs shall be as given in Table-I, unless specified otherwise
in data sheet A
vi) TABLE-I

415 V MOTORS - SIZES OF CABLES, STUDS, TERMINAL LUGS &

TERMINAL BOXES
(TO BE PROVIDED ON MOTORS BY VENDOR)

Sr. No. Motor Rating 1100V Al Conductor, armoured

( kW) PVC/XLPE Cable
Cores x mm2

1 Upto 3 3x4

2 3.1 – 7.5 3x6

3 7.6 – 15 3x16

4 16 – 25 3x35

5 26 – 40 3x70

405
 6 41 – 55 3x120

7 56 – 70 3x185

8 71 – 85 3x240

9. 86 – 110 3x400

10 111 – 200 3x1Cx500

6.14.10 PAINT AND FINISH

All motor parts exposed directly to atmosphere shall be finished and painted to produce
a neat and durable surface which would prevent rusting and corrosion. The equipment
shall be thoroughly degreased, all rust, sharp edges and scale removed and treated with
one coat of primer and finished with two coats of grey enamel paint.
6.14.11 HEATING DURING IDLE PERIODS
Motors rated above 30 kW shall have space heaters suitable for 240V, single phase, 50
Hz, AC supply. Space heaters shall have adequate capacity to maintain motor internal
temperature above dew point to prevent moisture condensation during idle period. The
space heaters shall be placed in easily accessible positions in the lowest part of the
motor frame.
6.14.12 ACCESSORIES
i) Two independent earthing points shall be provided on opposite sides of the motor, for
bolted connection of the EMPLOYER'S earthing conductors as specified in data sheet-
A. These earthing points shall be in addition to earthing stud provided in the terminal
box.
ii) Except when otherwise specified, the motors shall be provided with a bare shaft
extension having a key slot and a key at the driving end.
6.14.13 TESTS
i) All Motors shall be subjected to all the routine tests as per applicable standard in the
presence of the EMPLOYER‟s representative.
ii) Type tests Certificates shall be furnished for motors below 37kW. If type tests have
not been carried out on similar Motors, or if the type test reports submitted are not
found in order, then VENDOR shall carry out these tests without any extra cost to the
Employer.
iii) Following Type tests shall be performed in the presence of the EMPLOYER‟s
representative for motor rating of 37kW and above, one of each rating:

406
  Temperature rise test

 Full load test to determine efficiency, power factor and slip

 Momentary overload test

 Test for vibration severity of motor

 Test for Noise level of motor

 Overspeed test

 Pull out torque measurement (Direct/ Calculations)

 Starting torque measurement (Direct/ Calculations)

iv) For other type tests, certificates shall be provided for similar rating of the motors.

v) Type and routine tests, as specified in the distribution schedule, shall be furnished for
the EMPLOYER‟s approval.
vi) All the meters, instruments, devices used for the testing purpose shall be properly
calibrated by standard authorised agencies which shall be traceable to National
standards. For each such instrument proper validity of calibration shall be
documented by Vendor.
2.0 DATASHEET: MOTOR

1.0 GENERAL
1.1 APPLICATION: FAN
1.2 NUMBER OF UNITS: (*)
1.3 TYPE OF MOTOR SQUIRREL CAGE (Energy efficient –
EFF-1) type.
1.4 SUPPLY SYSTEM FAULT MVA 38MVA,50kA
LEVEL
1.5 SUPPLY NEUTRAL – TYPE EFFECTIVELY EARTHED SYSTEM
OF EARTHING
2.0 RATING
2.1 RATED OUTPUT kW (*)
2.2 RATED VOLTAGE 415V
2.3 NUMBER OF PHASES & 3 PHASE, 50 Hz
FREQUENCY:
2.4 VOLTAGE AND Voltage variation - +/-10%, Frequency
FREQUENCY VARIATION Variation - +/-3%, Combined - 10%
2.5 SYNCHRONOUS SPEED RPM(*)
3.0 DUTY
3.1 TYPE OF DUTY(CLAUSE (*)

407
 10.2 OF IS 325 OR CL9.3 OF IS
4722)
3.2 POWER REQUIRED BY (*)
LOAD
4.0 METHOD OF STARTING: D.O.L.
5.0 INSULATION
5.1 CLASS OF INSULATION: F WITH TEMP. RISE CLASS-B
5.2 PEF AMBIENT 45 0C
TEMPERATURE
5.3 TEMPERATURE RISE BY
5.3.1 BY THEROMOMETER 650C
METHOD
5.3.2 BY WINDING RESISTANCE 750C (CLASS B)
METHOD
6.0 INSTALLATION
6.1 LOCATION Indoor/Outdoor (*)
6.2 HAZARDOUS AREA NOT APPLICABLE
DIVISION
(IS: 5572 OR
EQUIVALENT:)
6.3 ATMOSPHERE REFER SEC.B
7.0 ENCLOSURE
7.1 TYPE OF COOLING (IS 6362) TEFC
7.2 DESIGNATION OF DEGREE IP 55
OF PROTECTION (IS 4691)
8.0 MAIN TERMINAL BOX
8.1 LOCATION AS SEEN FROM RIGHT/LEFT/TOP (*)
NON- DRIVE END
8.2 RATING (*)
1, SHORT TIME
CURRENT: 50kA (RMS)
DURATION: 0.25 SECS
2. DYNAMIC kA (PEAK)
8.3 EXTERNAL CABLE DETAILS (#)
8.3.1 TYPE
8.3.2 SIZE AND NUMBER OF
CORES
8.4 EARTHING CONDUCTORS
8.4.1 MATERIAL Copper Insulated cable
8.4.2 SIZE (#)
408
9.0 MISCELLANEOUS
REQUIREMENT
9.1 SHAFT ORIENTATION: HORIZONTAL/VERTICAL/HOLLOW
VERTICAL (*)
9.2 MOUNTING SYMBOL (*)
(IS :2253 OR EQUIVALENT)
9.3 ROTATION AS SEEN FROM CLOCKWISE/ANTICLOCKWISE(*)
NON-DRIVEN END
9.4 TYPE OF BEARING DRIVE END/NON DRIVE END(*)
9.5 WHETHER BED PLATE YES/NO (#)
REQUIRED
10.0 COLOUR SHADES OF PLANT Light Gray – Shade 631 of IS-5. Special
IF SPECIAL varnishing and painting treatment to be
given as the atmosphere is highly
corrosive.
11.0 CTS FOR DIFFERENTIAL NO
PROTECTION REQUIRED
11.1 $ CT PARTICULARS NOT APPLICABLE
A) 3 CTS, ONE IN THE
NEUTRAL LEAD OF EACH
PHASE
B) RATIO
C) CLASS P. S.
D) KNEE POINT VOLTAGE
E) MAX. R. C. T.
SECONDARY WINDING,
F) MAX. EXCITING
CURRENT AT 1/2 KPV
G) CLASS OF INSULATION
11.2 VIBRATION PADS (#)
REQUIRED
12.0 TEMPERATURE
DETECTORS / INDICATORS
12.1.1 EMBEDDED TEMPERATURE NO
DETECTORS FOR WINDING
REQUIRED
12.1.2 EMBEDDED TEMPERATURE NO
DETECTORS FOR BEARINGS
REQUIRED
12.1.3 BEARING THERMOMETERS NO
FOR DRIVING END & NON
DRIVING ENDS REQUIRED
12.1.4 THERMISTERS FOR YES FOR MOTORS ABOVE 110 kW

409
 MOTORS REQUIRED AND VFD DRIVEN MOTORS
13.0 SPACE HEATERS FOR YES FOR MOTORS ABOVE 30 KW
MOTORS REQUIRED
NOTES:

7. DETAILS MARKED THUS (*) WILL BE DECIDED AND INTIMATED BY

THE CONTRACTOR BASED ON DRIVEN EQUIPMENT
CHARACTERISTICS

2. DATA MARKED THUS (#) WILL BE INTIMATED TO VENDOR AFTER

PLACEMENT OF ORDER.

1. INDUCTION MOTORS – THREE PHASE IS-325 BS EN- IEC-

60034-1 60034-
1
2. ROTATING ELECTRICAL MACHINES IS-4722
3. SINGLE PHASE INDUCTION MOTOR IS-996
4. CODE OF PRACTICE FOR CLIMATE BS EN- IEC-
PROOFING 60034-5 60034-
5
5. DESIGNATIONS FOR TYPES OF IS-2253 BS EN- IEC-
CONSTRUCTION AND MOUNTING 60034-7 60034-
ARRANGEMENTS OF ROTATING 7
ELECTRICAL MACHINES
6. TERMINAL MARKING FOR ROTATING IS-4728 BS EN- IEC-
ELECTRICAL MACHINERY 60034-8 60034-
8
7. DESIGNATION OF METHODS OF COOLING IS-6362 BS EN- IEC-
FOR ROTATING ELECTRICAL MACHINES 60034-6 60034-
6
8. DEGREE OF PROTECTION PROVIDED BY IS-4691 BS EN- IEC-
ENCLOSURE FOR ROTATING ELECTRICAL 60034-3 60034-
MACHINERY 3
9. GUIDE FOR TESTING THREE PHASE IS-4029 BS EN- IEC-
INDUCTION MOTORS 60079-1 60034-
1
10. MEASUREMENT AND EVALUATION OF IS-12075 BS EN- IEC-
VIBRATION OF ROTATING ELECTRICAL 60034-14 60034-
MACHINES 14
11. CLASSIFICATION OF HAZARDOUS AREAS IS-5572 BS EN- IEC-
FOR ELECTRICAL INSTALLATION 60079-10 60079-
10
12. DESIGNATION OF SLIDE RAILS FOR IS-2968 BS EN-
ELECTRIC MOTOR 60034-1
13. PERMISSIBLE LIMITS FOR NOISE LEVEL FOR IS-12065 BS EN- IEC-
60034-
410
 ROTATING ELECTRICAL MACHINES 60034-9 9
14. GUIDE FOR TESTING INSULATION IS-7816
RESISTANCE OF ROTATING MACHINE
15. TEST PROCEDURES FOR MEASUREMENT OF IS-13508
LOSS TANGENT ANGLE OF COIL AND BAR
FOR MACHINE WINDING - GUIDE
16. IMPULSE VOLTAGE WITHSTAND LEVEL IEC-
60034-
15
17. INDUCTION MOTORS - ENERGY EFFICIENT IS-12615
18. TEMPERATURE RISE MEASUREMENT OF IS-12802
ROTATING ELECTRICAL MACHINES
19. TYPE OF DUTY AND CLASSES OF RATING IS-12824
ASSIGNED TO ROTATING ELECTRICAL
MACHINES
20. ADJUSTABLE SPEED ELECTRICAL POWER BS-EN- IEC-
DRIVE SYSTEM- EMC REQUIREMENTS AND 61800 61800
SPECIFIC TEST METHODS.
21. DIMENSIONS AND OUTPUT SERIES FOR IS-1231 BS-4999- IEC-
ROTATING ELECTRICAL MACHINES. 141 60072-
1
22. ELECTRICAL APPARATUS FOR EXPLOSIVE
GAS ATMOSPHERE – CLASSIFICATION OF IS-5571 BS-EN- IEC-
HAZARDOUS AREA. 60079 60079-
10
23. TEMPERATURE RISE MEASUREMENT OF
ROTATING ELECTRICAL MACHINES IS-12802
NOTE : EQUIPMENT, ASSOCIATED ACCESSORIES, COMPONENTS/PARTS, RAW
MATERIAL AND TESTS SHALL IN GENERAL CONFORM TO IS.

411
DATASHEET : PRESSURE INDICATORS

412
DATASHEET : PRESSURE SWITCHES

413
DATASHEET : PRESSURE RELIEF VALVE

414
DATASHEET : TEMPERATURE SWITCH

415
DATASHEET : PRESSURE TRANSMITTER
62. MANUFACTURER : *
63. MODEL NO.: *
64. FEATURES:
65. TYPE: INDICATING SMART TYPE
66. ELECTRIC (TWO WIRE)
67. MOUNTING : FIELD RACK
68. EXTERNAL ZERO AND SPAN ADJ. :REQUIRED
69. ACCURACY : + 0.1% OF SPAN
70. OVER RANGE PROTECTION : 130% OF SPAN
71. LOCAL DISPLAY : LCD REQUIRED.
72. QUANTITY: 3 Nos
73. TAG NOS.: LATER
74. SERVICE: AIR
75. ENCLOSURE PROTECTION
76. CASE : EX PROOF ZONE __ GR._____
77. WEATHER PROTECTION: IP 65 AS PER IS 13947
78. CASE COLOUR : GREY BLACK *
79. POWER SUPPLY / SIGNAL:
80. OUTPUR SIGNAL: 4 TO 20 mA
81. POWER SUPPLY: 230 VAC / 24 V DC *
82. HART COMMUNICATION PROTOCOL: NOT REQUIRED
83.
84. MATERIAL OF CONSTRUCTION
85. HOUSING: DIE CAST ALUMINIUM
SS 316
86. SENSING ELEMENT : SS 316
87. BODY: ALUMINIUM ALLOY
88. CAPILLARY AND ARMOUR: NOT REQUIRED
89. SYPHON:

90. CONNECTION & DIMENSIONS

91. PROCESS CONNECTION: THREADED
FLANGED
92. THREADED PROCESS CONNECTION:
½ “NPT (M) ¼ “NPT (M)
1” NPT(M) 3/8 INCH BSP
93. FLANGED PROCESS CONNECTION:
FLANGE RATING :
FLANGE SIZE :
94. PROCESS CONNECTION LOCATION:
BOTTOM BACK

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95. CABLE ENTRY: ½” NPT (F)
96. ACCESSORIES (REFER NOTE 3)
97. NAME PLATE / METAL TAG : REQUIRED, SS
98. MOUNTING BRACKET: REQUIRED
99. CAPILLARY :NA
100. CABLE GRAND : REQUIRED
101. CHEMICAL SEAL :NA
102. ALL INSTALLATION HARDWARE: REQUIRED
103. SYPHON: NA
104. ISOLATION & DRAIN VALVES : REQUIRED
105. CODES AND STANDARDS (REFER NOTE 2)
106. WEATHER PROOF – IS 13947 PART I
107. EXPL. PROOF–IS 2148/ BS EN 50014/ BS EN 50020
108.
109. TESTS :
110. CALIBRATION : REQUIRED
111. HYDRO TEST : REQUIRED
112. LEAK TEST: REQUIRED
113. OVER RANGE TEST: REQUIRED
114. REPEATABILITY: REQUIRED

DRAWINGS / DOCUMENTS
1. THE VENDOR SHALL SUBMIT CATALOGUES, DATA SHEET AND
ERECTION SKETCH FOR REVIEW AND COMMENTS BY EMPLOYER/
PROJECT MANAGER.
2. THE VENDOR SHALL SUBMIT INSTRUCTION MANUAL FOR RECORDS.

TEST CERTIFICATES
1. VENDOR SHALL SUBMIT ALL ROUTINE TEST CERTIFICATES FOR
EMPLOYER/PROJECT MANAGER'S REVIEW.
2. VENDOR SHALL SUBMIT TYPE TEST CERTIFICATES FOR PROTECTION
CLASS.
Notes :

1.0 * CONTRACTOR TO FURNISH DETAILS

2.0 THE CONTRACTOR SHALL INDICATE ALL APPLICABLE CODES
AND STANDARDS.
3.0 ALL ACCESSORIES SHALL BE SUPPLIED AS APPLICABLE.

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TECHNICAL SPECIFICATION

ELECTRICAL WORKS

418
 ELECTRICAL WORKS

7.1 INTRODUCTION – ELECTRICAL

7.1.1 Followings CPWD Specification for Electrical shall take precedence over provisions
of relevant I.S. Codes.
 CPWD specification for electrical works part I internal 2013
 CPWD general specifications for electrical works - part ii (external) 1994
 CPWD general specifications for electrical works part-iv substation 2013

7.1.2 All Electrical works shall be carried out in accordance with the provisions of National
Electrical Code 2011 and Central Electricity Authority 2010.

7.1.3 Refer following Detailed Technical specifications for items which are not covered in
above mentioned CPWD Specifications. This specification is to be read along with
SLDs and BOQs. In case of any conflict in specification, BOQ spec/ description will
be followed.

7.2 HIGH VOLTAGE METAL ENCLOSED SWITCHGEAR

7.2.1 Scope
Supply, Manufacturing , installation, testing commissioning of integrated cubicle
type metal clad, form 3 a, floor mounted and draw out type free standing, front
operated indoor type 33 kV switchgear as per following specifications :
7.2.1.1 General
The switchgear enclosure shall conform to degree of protection IP -52.
The switchgear shall be made from MS sheet steel 2 mm thick (CRGO) and shall be
folded and braced as necessary to provide a rigid support for all components.
The switchgear assembly shall form a continuous dead front line up of free standing
vertical cubicles. Each cubicle shall have a lockable front hinged door and a
removable bolted back cover. All covers and doors shall be provided with neoprene
gaskets. Suitable arrangement for lifting of each cubicle shall be provided. Design
and construction of the switchgear shall be such as to permit extension at either end.
Vacuum Circuit breaker shall be provided with surge arresting device for protection
against lightning and switching over voltage. Two separate and distinct connections
to earth shall be provided for each surge arrestor.
Suitable earthing trolley/ truck shall be provided separately for each substation.
7.2.1.2 Breaker Compartment
Vacuum Circuit Breaker shall be mounted in draw out truck with front plate which
covers the cubicle when the breaker is in service position. Draw out mechanism shall
be horizontal type. This front plate shall be provided with view glass to facilitate
observation of mechanical ON/OFF indication of Circuit breaker, Spring charged /
discharged indication and operation counter. Necessary orifice shall be provided for
manual charging of the springs. ON/OFF push button for opening and closing of the

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 circuit breaker shall also be provided. The draw out truck shall have two positions
for the circuit breaker VIZ isolated / Test & Service.
7.2.1.3 Bus Bar Compartment
Bus bars of rectangular cross section of copper conductor supported by cast epoxy
insulator to withstand full short circuit currents upto 18kA for 33 kV system shall be
provided at the rear. Bus bar chamber shall be provided with inter panel barriers with
epoxy cast seal off bushings.
7.2.1.4 CT and Cable Compartments
At the rear of the panel sufficient space shall be available to accommodate three
numbers epoxy CT‟s of double core and two numbers three core cable termination.
The cable entry shall be from the top / bottom.
7.2.1.5 Separate Compartments
Circuit breakers, instrument transformer, bus bars, cable etc shall be housed in a
district different compartments as required for form 3 a, compartmentalization. All
relays, switches, lamps, etc. comprising the control, indication and protective devices
shall be housed in a separate compartment on the front of the cubicle.
7.2.1.6 Technical Particulars of Vacuum Circuit Breaker

S.NO. DESCRIPTION 33 kV

A Rated Current 630 A

B Rated Voltage 36 kV

C Rated Frequency 50Hz

D Rated Short Circuit breaking Current 18 kA

E Rated short circuit making current (kAP) 66 kA

70 kV / 170
F Insulation level (kV rms/kVP)
kV

7.2.1.7 Isolating Contacts

The breaker isolating contacts shall consist of two parallel flat silver plated copper
bars with ball point contacts to give a vertical tolerance of ±10 mm.
7.2.1.8 Low Voltage Plug and Socket Connector
A twenty pin plug and socket connection along with flexible leads shall be provided
to connect control instrumentation and interlock circuits on the breaker truck and in
the panel. The plug and socket assembly shall be suitably interlocked with the truck
positions like service and test/isolated position.
7.2.1.9 Interlocks and Safety Devices
The following interlocks shall be provided:
a) The truck cannot be moved from either test to service position or vice versa,
when the circuit breaker is „ON‟.

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 b) The circuit breaker cannot be switched „ON‟ when the truck is in any position
between test and service position.
c) Front part of the truck cannot be removed when the breaker in „ON‟ position.
d) The truck cannot be inserted when the earthing switch is „ON‟.
e) The low voltage plug and socket cannot be disconnected in any position
except test/isolated position.
f) The truck cannot be moved inside the panel, when the LT plug and socket is
disconnected.
g) Earthing switch cannot be switched „ON‟ when the truck is inside the panel.

7.2.1.10 Safety Devices

The following Safety devices shall be provided for the safety of the operating
personnel:
a) Individual explosion vents shall be provided for breaker chamber/bus
bar/cable chambers on the top of the panel to let out the gases under pressure
generated in case of fault inside the panel.
b) Cubicle with front plate to withstand the pressure for internal arc fault as per
PEHLA recommendation.
c) Circuit breaker and sheet metal enclosure shall be fully earthed.
d) Self locking shutters shall be provided which shall close automatically when
the truck is withdrawn to „Test position‟ and no separate padlocking of the
shutter shall be required.

7.2.1.11 Protective Earthing

The earthing connection between the truck and the cubicle shall be by means of
sliding contacts so that the truck is earthed in the isolated position when inserted and
remains earthed when the truck is pushed further into the connected position or when
the truck is being withdrawn until the truck has moved part the isolated position.

7.2.1.12 Current Transformer

General Requirements
Accommodation shall be provided in the circuit breaker panel, to mount one set of
duel ratio CT. Access to the CTS for cleaning, testing or changing shall be from the
front, back or top of the panel.
Rating
Duel ratio CTS of suitable burden (but each not less than 15 VA) shall be preferred
with 5 amps secondaries.
Instrument Security Factor (ISF) of each CT shall not be more than 5.
The CTs shall conform to relevant Indian Standards. The design and construction
shall be dry type, epoxy resin cast robust to withstand thermal and dynamic stresses
during short circuits. CT terminals shall be shorting type. Current & voltage circuits
shall be laid in separate wire ways. Secondary terminals of CTS shall be brought out
to a suitable terminal block which will be easily accessible for terminal connections.
Test terminal block shall be provided in the front side of the panel for testing
purpose.

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 CT‟S shall have 2 Nos. of cores for following application:
Core -1 for metering
Core -2 for over current & earth fault protection.
Class of accuracy for winding
Metering class 0.5
Protection class 5P10
7.2.1.13 Potential Transformers
The potential transformers shall be confirming to IS 3156/ IEC 60185.The primary
windings of the potential transformers shall be insulated and shall be of the cast rest
in type.
Potential transformer (PT‟S) shall be mounted on a draw out trolley and housed in
separate metal compartment and shall have control fuses on the H.V. side and a
miniature circuit breaker on the L.V. side of the windings.HT HRC Control fuses
shall be confirming to IS – 9385/ IEC –60282.Miniature Circuit breaker shall comply
with IS – 8828/ IEC – 60898.
Padlocking facilities shall be provided for both service and isolated position.
The potential transformer shall be as specified below:
Ratio : 33000 /√3/ 110/ √3/ 110 V 110 V
V A Burdan : 100 V A for 100/√3 and 110 V winding
Class : CL –1 for both the windings.
Basic Insulation level : Same as mentioned for VCB in clause -
6.
Over voltage factor : 1.2 Continuous
Single phase PT‟S shall be used and shall be connected in Star/ Star.

7.2.1.14 Protection and Tripping Arrangement

Protection
All protection relay shall be numeric type of approved make.
The protection and tripping arrangement of circuit breaker shall be Provided as per
BOQ & as mentioned below:-
a) Numeric type instantaneous short circuit protection Device No.50 Range 500
– 2000% shall be provided on all phases.
b) Numeric type back up over current protection for Phase faults Device No.51
Range 50 – 200% shall be provided on all phases.
Numeric type ground fault protection Device No.50G. CT‟s. Range 20 – 80% shall
be provided.
Surge Arrestor
Lockout and trip supervisory relays etc shall be provided with manual reset
facility.Auxiliary relay for transformer fault.
7.2.1.15 Control Wiring

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 The control wiring shall be carried out with 1.5/2.5 sq. mm. PVC insulated copper
conductor cables. The wiring shall be securely fixed and neatly arranged to enable
easy tracing of wires. Identification PVC ferrules shall be fitted to all wire terminals
to render easy identification and facilitate checking in accordance with IS 5578 and
11353.
7.2.1.16 Metering Instrument Panel Accessories
Metering
Digital type Trivector meter of approved make (Smart demand controller) shall be
provided on the incomer feeder. Specification of the meter shall be as follows:
Accuracy : Class 0.5, compliant to revenue class certification.
: Real time measurement per phase & average
V, I, PF, kW, kVAR, kVA
: Peak demand, sliding window. Protected.
: V & I unbalance, Phase reversal
: Time of Use (TOU)
Power Quality Measurement:
: Total Harmonics
Logging & recording for all measurements:
: Interval or event-based, 32 channel measurement & recording
: Event logging
: “Bust” data recording
: Min/ Max recording
Alarming : Over & under measurement detection by 24 set point
functions.
Multiport
Communication: One each of RS 485 and RS 232 ports.
7.2.1.17 Instrument Panels
The instrument panel shall be part of the housing. Relays, meters and instruments
shall be mounted as per general arrangement drawings to be submitted by the
vendors. They shall be of flush mounting type.
7.2.1.18 Instrumentations
a) Digital type Voltmeter of class 1.0 accuracy and 96 x 96 mm square in size as
per IS-1248 shall be provided at incomer panel, with selector switch. The
instrument shall be calibrated for the ranges specified.
b) Digital type Ammeter of specified range to class 1.0 accuracy and 144 x 144 sq
mm in size as per IS - 1248 shall be provided at both incomer and outgoing
panels along with necessary selector switches.
c) Digital type frequency meter class of 1.0 accuracy conforming to IS:1248 shall
be provided at incomer panel.
d) Digital type Power factor meter of class of 1.0 accuracy conforming to IS :
1248 shall be provided at incomer panel.
The following minimum indication lamps shall be provided in the front of cubicle.

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 Breaker open / closed / tripped, spring charged, trip circuit healthy and control supply
healthy. Lamps shall be clustered LED type and trip circuit supervision scheme shall
be of continuous supervision type.
After meeting all necessary control and indication requirements 2 nos. NO and 2 nos..
NC auxiliary of the breaker shall be made available for the Employer, wired up to
terminal block.
Separate MCB‟s shall be provided for lamps, heaters and other instrumentation etc.
on each panel.
Anti-condensation space heaters suitable for operation on 240 V single phase, 50 Hz
A.C. for each cubicle and with thermostat control one incandescent lamp with switch
and 3 pin 5 amps plug socket.
7.2.1.19 Inspection and Testing
After manufacturing of switchgear panels tests shall be carried out on the equipment
as per relevant IS and Electricity Regulations.
7.2.1.20 Quality Assurance
Vendor shall submit in substantial detail a quality assurance plan indicating all
activities step by step at various manufacturing/fabrication stages to meet the
requirement of this specification and various standards/regulations/practices to enable
comprehensive assessment of its merits and reliability.

7.3 LOW VOLTAGE SWITCHGEAR

7.3.1 Scope
This Section covers the detailed requirements of medium voltage switch Panel for
433V, 3 phase 50 Hz 4 wire system. These shall be branded and/or
assembled/fabricated from a factory of repute. All switchgears shall be fully rated at
an ambient of 50° C.
Type of Panel
The medium voltage switch board panel shall comprise of any one of the following
types of switchgears or combination thereof as specified.
Air Circuit breakers draw out or fixed type, Switch Disconnector Fuse Units fixed
type, MCCBs of suitable Ics ratings. MCCBs shall invariably be Current Limiting
type. Features like Double Break, Positive Isolation functions shall be preferred.
The Panel shall be indoor type having incoming sectionalization and outgoing
switchgears as specified. The design shall be cubical type. The degree of enclosure
protection shall be IP 42 as per IS: 13947 (Part-I).
7.3.2 LT Panel
7.3.2.1 General Construction
a) The switchboard shall be floor mounted free standing totally enclosed and
extensible type of uniform height not more than 2400mm. The switch board shall
be dust & vermin proof and shall be suitable for the climate conditions as
specified. The design shall include all provisions for safety of operation and
maintenance personnel. The general construction shall conform to IS: 8623/1993
for factory assembled switch board.

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 b) LT Panels shall be provided with a metal sill frame made of structural steel
channel section properly drilled for mounting the Switchgear along with necessary
mounting hardware. Hardware shall be zinc plated and passivated, Provided with
cable entry facilities at top/bottom as per layout requirement with 3mm thick
removable gland plates on breaker panels and 2 mm thick removable gland plates
on other panels with necessary cable glands. For 1-core cables, these plates shall
be non-magnetic.
c) Switchgear shall be provided with gaskets all round the perimeter of adjacent
panels, panel and base frame, removable covers and doors,
d) Provided with busbars running at the top, as required, all along the length of the
switchgear in a separate sheet steel enclosure.
7.3.2.2 Cubical Type Panels
Cubical type panels shall be fabricated out of sheet steel not less than 2.0 mm thick.
Wherever necessary, such sheet steel members shall be stiffened by angle iron frame
work. General construction shall employ the principle of compartmentalization and
segregation for each circuit. Unless otherwise approved, incomer and bus section
panels or sections shall be separate and independent and shall not be mixed with
sections required for feeders. Each section of the rear accessible type panel shall have
hinged access doors at the rear. Overall height of the panel shall not exceed 2.4
meters. Operating levers, handle etc. of highest unit shall not be higher than 1.7
meters. Multi-tier mounting of feeder is permissible. The general arrangement for
multi tier construction shall be such that the horizontal tiers formed present a pleasing
and aesthetic look. The general arrangement shall be approved before fabrication.
Cable entries for various feeders shall be either from top or bottom. Through cable
alleys located in between two circuit sections ,either in the rear or in the front of the
panel. All cable terminations shall be through gland plates. There shall be separate
gland plate for each cable entry so that there will not be dislocation of already wired
circuits when new feeders are added. Cable entry plates shall therefore be
sectionalized. The construction shall include necessary cable supports for clamping
the cable in the cable alley or rear cable chamber.
Cubicle panels with more than 1000 Amps BUS shall be made of tested structural
modular sections.
7.3.2.3 Bus Bar and Connections
The bus bars shall be of Copper/Aluminuum of high conductivity electrolytic quality
and of adequate section. Current density shall not exceed 130 amps for Copper /sq.
cm. The bus bar system may comprise of a system of main horizontal bus bars and
ancillary vertical bus bars run in bus bar alleys on either side of which the circuit
could be arranged with front access cable entries. In the case of rear access,
horizontal bus system shall run suitably either at the top or bottom. All connections to
individual circuits from the bus bar shall preferably be solid connections; however
flexible connections shall also be permitted as per recommendations of the Panel
Manufacturer. All bus bars and connections shall be suitably sleeved / insulated with
heat shrinkable PVC with approved manner.
The insulation shall be non-inflammable and self-extinguishing and in fast colours to
indicate phases. The joints shall be insulated in such a way as to provide for
accessibility of contact bolts for maintenance. Joints shall be covered with removable
moulded shrouds made out of fibreglass-reinforced polyester.
7.3.2.4 Incomer I Termination

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 Incomer termination shall be suitable for receiving bus trunking /underground cables.
Cable terminations shall invariably be through terminal blocks (Polyamide or
superior) or brought out solid terminals.
7.3.2.5 Instruments
All voltmeters and ammeters shall be flush mounted of size minimum 96 mm
conforming to class 1,5 of IS: 1248 for accuracy. All voltmeters shall be protected
with MCB. They shall be suitable for semi-flush with only flanges projecting on
vertical panels.
7.3.2.6 Indicating Lamps
On all the incomers of M.V panels, ON/OFF indicating LED lamps shall be provided
and shall be suitable for operation on AC supply. Phase indicating LED lamps shall
be associated with necessary ON/OFF toggle switch.
7.3.2.7 Small Wiring
All small wiring for Controls, Indication etc, shall be of with suitable FRLS/HFFR
(halogen free fire retardant) copper conductor cables. Wiring shall be suitably
protected within switch board. Runs of wires shall be neatly bunched, suitably
supported and clamped. Means shall be provided for easy identifications of the wires.
Where wires are drawn through steel conduits, the works shall conform to CPWD
General Specifications for Electrical works (Part I- Internal) - 2005 and IS:732 as the
case may be. Identification ferrules shall be used at both ends of the wires. All
control wiring meant for external connections are to be brought out of terminal board.
7.3.2.8 Operational Requirements
The indoor type LT panel shall conform to the following: -
The panel shall comprise of incomers, outgoing feeders and bus coupler as specified.
The incomer shall be either a double break / contact repulsion MCCB or an Air
Circuit Breaker. The bus coupler shall be either a circuit breaker or a double break /
contact repulsion MCCB, ACB, switch disconnector fuse unit as specified. The
outgoing feeders shall be circuit breakers/MCCBs as specified.
Bus bars for phase and neutral shall have a rating as specified in SLD and BOQ.
The entire switch panel shall be cubical type generally conforming to
18:8623/1993 for factory assembled switch board.
The incomer panel shall be suitable for receiving bus trunking or LT cable of size
specified either from top or from bottom.
All incoming AIRCIRCUIT BREAKER/MCCB shall have suitable adjustable
tripping current and the time delay settings.
The entire panel shall have a common earth bar of size as specified with two
terminals for earth connections.
7.3.2.9 Rating and Requirements
Air Circuit Breaker*
All Air Circuit Breakers shall be 3/4 pole with minimum 50 KA breaking capacity
(35 MVA at 433V) conforming to IS: 13947 (Part-II). Rated current shall be as per
capacities specified. The equipment shall be complete with the following: -
a) Necessary circuit breaker carriage with 3 position (isolate, test, service) draw-out
mechanism.

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b) Necessary isolating plugs and sockets.
c) Necessary mechanism interlock and automatic safe shutters gear with
arrangement for pad locking.
d) Necessary independent manual spring mechanism with mechanical On/Off
indication as well as electrical On/Off indication,
e) Necessary bus bars with bolted type neutral links.
f) ACB shall be provided with microprocessor based releases having built in over
load, short circuit & earth fault protection. Microprocessor release shall be EMl
(electro magnetic induction)/EMC(electro magnetic compatible) certified.
g) Necessary set of auxiliary switches.
h) Necessary set of CTs with ratios as specified.
i) Necessary identification, metering requirements as specified i/c. ON/OFF
indication lamps, selector switches, fuses, ammeter, voltmeter etc.
j) In case of 4 pole breaker neutral shall be fully rated with adjustable settings from
50% to 100%ofln.
k) ACB terminals shall be suitable/suitably brought out for direct aluminum
termination as per IS 13947 Part-II.
l) Provided with „red‟, „green‟ and „amber‟ indicating lamps to indicate „closed‟
„open‟ and „auto-trip‟ conditions of the circuit breaker when breaker operation is
controlled by a control switch.
m) All indicating lamps shall be clustered LED type, with in-built short circuit, surge
protections etc. Adequate number of contacts shall be provided to have remote
annunciation of the breaker feeders:
Breaker 'ON'
Breaker 'OFF'
Breaker 'TRIP'
Breaker 'Service'
Breaker 'Test'
Note: Wherever fixed type circuit breakers are required, it shall be clearly
specified.
MCCB/ MCB etc:
MCCBs : All MCCBs shall be current limiting type with features of load line
reversibility and suitable for Horizontal/Vertical mounting without any derating.
Beyond 300 Amps capacity MCCBs shall have positive isolation and preferably
double break / contact repulsion & double insulation features.
The MCCBs shall invariably be used with terminal spreaders.
a) The MCCBs shall conform to the latest applicable standards (IS: 13947).
b) MCCBs in AC circuits shall be of TP/TPN/FP construction arranged for
simultaneous manual closing and opening. Operating mechanism shall be quick-
make, quick-break and trip-free type. The ON, OFF and TRIP positions of the
MCCB shall be clearly indicated and visible to the operator. Operating handle
for operating MCCBs from door of board shall be provided.

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 c) The instantaneous short circuit release shall be so chosen by the CONTRACTOR
as to operate at a current in excess of the peak motor inrush current and a range
of settings shall be provided for the EMPLOYER „S / ENGINEER‟S selection.
d) MCCB terminals shall be shrouded and designed to receive cable lugs for cable
sizes relevant to circuit ratings.
e) Minimum no. of additional auxiliary contacts (for Employer‟s use) shall be
provided.
f) MCCBs shall incorporate time delay devices to ensure that it will tolerate
harmless transient overload unless this is well in excess of 25% of its rated value
for a sustained period.
MCBs: Miniature circuit breakers for use on motor space heater control circuits shall
comply with the requirements of applicable standards, unless otherwise mentioned in
Data Sheet.
CONTACTORS: Motor starter contactor shall be of the electromagnetic type rated
for uninterrupted duty as defined in applicable standards.
Main contacts of motor-starter contactors shall be of silver plated copper.
Contactors shall be of the double break, non-gravity type.
Direct-on-Line Starters/Star Delta Starters : Starters shall be suitable for Class
AC 3 utilisation category as specified in applicable standards.
7.3.3 Lightning and Surge Voltage Protection
7.3.3.1 Scope
This specification describes the electrical and mechanical requirements for a high
energy Transient Voltage Surge Suppressor (TVSS).The specified TVSS/SPD system
shall be connected in parallel to the facility‟s electrical all main incoming panels. It
shall provide effective high energy surge current diversion, and shall be suitable for
application in ANSI/IEEE C62.41 Category A, B and C environments or IEC 61643-
1 Class I, II and III
7.3.3.2 Codes & Standards
The specified system shall be designed, manufactured, tested and installed in
compliance with the following codes and standards:
IEC 61643-1: Surge Protective Devices connected to low voltage power distribution
systems.
Underwriters Laboratories: (UL 1449, 2nd edition) Standard for Transient Voltage
Surge Suppressors. International Standards Organization (ISO) Company certified
ISO9001 for manufacturing, design and service and the applicable portions of the
American National Standards Institute and Institute of Electrical and Electronic
Engineers standards (ANSI/IEEE 1100 ,C62.11, C62.41, C62.45)
7.3.3.3 Electrical Requirements
a) Nominal system operating voltage
The single phase TVSS system shall be suitable for installations operating
between 220VAC and 240VAC.
The three phase TVSS system shall be suitable for installations operating
between 380VAC to 415VAC, Star (Y) Configuration: 3 Phase 4 Wire Plus
Ground or Delta Configuration: 3 phase 4 wire including Ground.

428
 b) Maximum Continuous Operating Voltage (MCOV):
The maximum continuous operating voltage of the complete TVSS, as well as
all components in the suppression path shall be greater than 125% of the
nominal system operating voltage to ensure the ability of the system to
withstand temporary RMS over voltages (swell conditions).
c) Operation Frequency:
The operating frequency range of the system shall be 50 or 60 Hz.
d) Protection Modes:
Note: L = Line, G = Ground, N = Neutral
The SPD shall provide protection in all modes (L-N or L-L, L-G and N-G
where applicable)
7.3.3.4 Surge Current Capacity:

Location Class Surge Current

Main Service Entrance Class C 200/400 KA

Main Distribution Feeders Class B 100/160 KA

Sub distribution Panels Class A 50 KA

7.3.3.5 Short-circuit Withstand Capability:

The TVSS shall be able to carry the power short circuit current until it is interrupted
by external over-current disconnect or by the backup over current protection. The
minimum Short Circuit Withstand of the TVSS shall be according to the table below:

Class Minimum Short Circuit Withstand

Capability

Class C 200KA

Class B 35 to 65KA

Class A 14KA

7.3.3.6 Over current Protection (fusing)

All components, including suppression, filtering, and monitoring components, shall
be individually fused at the component level with the fuses rated so as not to impede
maximum specified surge current capacity. The fuse shall be capable of opening in
less than one millisecond and clear both high and low impedance faults.
7.3.3.7 Clamping Voltage:
The TVSS shall able to clamp the voltage:

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 System Voltage Max Let Through
Voltage
120, 120/208 or 120/240 400 volts

208, 240, 277, 230/400 or 277/480 800 volts

346, or 346/600 1200 volts

480 1500 volts

600 2000 volts

7.3.3.8 Response Time:

Typical response time of all suppression components shall be <0.5 ns.
7.3.3.9 Noise Attenuation
The filter shall provide insertion loss with a maximum of 40dB to 50dB from 10 kHz
to 100 MHz with data obtained utilizing the 50 ohm Insertion Loss Methodology
from MIL-STD-220A.
7.3.3.10 Environmental Requirements
Operating Temperature :- 400 C to +850 C (-400 to +1870 F)
Relative humidity : - 0% to 95%
Audible Noise:- The unit shall not generate any appreciable noise. 40 DB for
RFI and EMI noise attenuation
Operating Altitude: 0 to 14,000 feet above sea level.
Magnetic Fields: The unit shall not generate any appreciable magnetic fields and
shall suitable for use directly inside computer rooms.
Connection type- Parallel
Protection lvl in kV – based on level of protection
Status indication – LED type dry contacts
7.3.3.11 Instruments & Relays
a) Indicating instruments
All electrical indicating instruments will be 96 mm square, with 240-degree scale
(Taut band type). They shall be suitable for semi-flush with only flanges
projecting on vertical panels.
Instruments shall have accuracy class of 1.0 or better. The design of the scales
shall be such that it can read to a resolution corresponding to 50% of the
accuracy class index. KWH meter mentioned in the SLDs shall have pulse output
to be integrated with the BAS system and an accuracy class of 1.
b) Protective relays
Protective relays shall conform to standard requirements. Type of relays either
static or electro-mechanical which meet the various performance requirements
are considered acceptable.
All static relays shall be adequately protected against external voltage surges and

430
 noise signals. In addition to this, all the input circuit of static relays will include
their own auxiliary current and voltage transformers with screened windings.
Where auxiliary interposing transformers are not feasible in the input circuit,
relays would have special surge suppression circuits to suppress external noise
and surges.
Output elements of all static relays shall consist of electro-mechanical relays
only.
Relays shall have at least the following electrically independent output contacts
for the following purposes:
 Tripping circuit
 Remote / local annunciation
If the main relay does not have sufficient number of output contacts inherently,
these shall be multiplied using auxiliary relays. These auxiliary relays shall be
used for annunciation, indication, etc. only. For tripping, only the contact of
main relay shall be used directly
c) Wiring And Accessories
Cubicles shall be completely wired upto equipment / terminal block. Interpanel
and inter-cubicle looping of control and cubicle space heating supplies to be
carried out by CONTRACTOR. Wiring to be carried out with 650V grade single
core PVC insulated stranded copper conductor of following sizes :
 All circuits except CT circuit :1.5 sq.mm.
 CT circuit :2.5 sq.mm.
Longitudinal troughs extending throughout the full length of the panels to be
provided for interpanel wiring, AC-DC supplies, PT circuits, annunciator
circuits, etc. Ferrules for wire termination to be provided. Wire connected to trip
circuit will have red coloured ferrule.
7.3.3.12 Terminal Blocks
a) Terminals blocks for CT and PT secondary leads shall be provided with test links
and isolating facilities.
b) All spare contacts and terminals of the panel mounted equipment and devices
shall be wired to terminal blocks. At least 10% spare terminals shall be provided.
c) Terminal blocks to be suitable for connecting the following conductors of the
EMPLOYER‟s cables on each side:

All circuits except CT circuit Minimum of two 1.5 mm2 copper

CT Circuits Minimum of four 2.5 mm2 copper

7.3.3.13 Cable Terminations

a) Power and control cable glands and crimping type lugs shall be supplied to suit
the cable sizes.
b) Glands shall be heavy duty, double compression type made of brass and plated.
7.3.3.14 Control Supply

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 230/110V AC supply be provided for the switchgear. Suitable control transformer
shall be provided to derive 110V AC control supply voltage. All inter panel wiring
required shall be included in the scope.
7.3.3.15 Tests To Be Conducted
a) Functional test, temperature rise test, high voltage test, limits of operation test,
insulation test. EMPLOYER will have the option to witness the tests at the
MANUFACTURER‟S work before dispatch.
b) TENDERER shall furnish the type test certificates along with the Tender. In the
absence of the same, the CONTRACTOR shall arrange to carry out the type test
without any cost implication to the EMPLOYER.

7.3.3.16 List Of Drawings

The CONTRACTOR shall furnish the following drawings for the switchgear:
a) Overall outline dimensions and general arrangement including plan, front
elevation, rear & side elevations, clearances recommended in front and back.
b) Switchgear layout plan including floor openings, fixing arrangements and
loading details.
c) Schematic control diagrams to cover controls, protection, interlocks,
instruments, space heaters, etc. for each type of module.
d) Detailed internal wiring diagram of each type of module, including terminal
block numbers, ferrule numbers and the external cable connection designations
e) Item wise bill of material for each module, listing all devices mounted and also
otherwise furnished like cable glands, indicating the MANUFACTURER's
type, rating, quantity & special notes, if any.
f) Inter panel interconnection wiring diagram including terminal numbers and
ferrule numbers.
g) Each type of protection relay and circuit breaker release characteristics
NOTES:
 The CONTRACTOR shall be entirely responsible for the correctness of the
internal wiring diagrams
 The CONTRACTOR shall ensure that the characteristics of the CTs, fuses,
protection relays, VTs and all other devices offered by him are such as to be
suitable for the purpose for which they are intended.
7.3.3.17 Test Certificates
Type test certificates of all standard component parts, e.g. contactors, breakers,
switches, fuses, relays, CTs, VTs, and for the standard factory built assembly shall be
submitted by the CONTRACTOR.
7.3.3.18 Instruction Manuals
The CONTRACTOR shall furnish specified number of copies of the instruction
manual which would contain detailed instructions for all operational & maintenance
requirement. The manual shall be furnished at the time of dispatch of the equipment
and shall include the following aspects:

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 a) Outline dimension drawings showing relevant cross-sectional views, earthing
details and constructional features.
b) Rated voltages, current, duty-cycle and all other technical information which
may be necessary for correct operation of the switchgear.
c) Catalogue numbers of all components liable to be replaced during the life of the
switchgear.
d) Storage for prolonged duration.
e) Unpacking.
f) Handling at site.
g) Erection.
h) Precommissioning tests.
i) Operating procedures.
j) Maintenance procedures.
k) Precautions to be taken during operation and maintenance work.
7.3.3.19 Installation
The installation work shall cover assembly of various sections of the panels lining up,
grouting the units etc. In the case of multiple panel switch boards after connecting up
the bus bars etc., all joints shall be insulated with necessary insulation tape or
approved insulation compound. A common earth bar as per these specifications shall
be run inside at the back of switch panel connecting all the sections for connection to
frame earth system. All protection and other small wirings for indication etc. shall be
completed before calibration and commissioning checks are commenced. All relays,
meters etc. shall be mounted and connected with appropriate wiring.
7.3.3.20 Testing And Commissioning
Commissioning checks and tests shall include all wiring checks and checking up of
connections. Relay adjustment/setting shall be done before commissioning in
addition to routine Megger tests. Checks and tests shall include the following: -
a) Operation checks and lubrication of all moving parts.
b) Interlock function checks.
c) Continuity checks of wiring, fuses etc. as required.
d) Insulation test: When measured with 500V Megger the insulation resistance
shall not be less than 100 mega ohms.
e) Trip tests and protection gear test.

7.4 POWER FACTOR CORRECTION SYSTEM

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7.4.1 Scope
Design, manufacture, supply, erection, testing and commissioning of Indoor type
power correction capacitor banks for power factor improvement as per specification
given below.
7.4.2 Rating
50 KVAR (or less) capacitor units as specified in the BOQ shall be used to form a
bank of capacitors of designed capacity.
7.4.3 Enclosure
The panel shall be indoor type, free standing, and floor mounting with IP42 degree of
protection. It shall be completely made of CRCA sheet steel. The enclosure shall
have sturdy support structure with angle supports as necessary and shall be finished
with powder coating in the approved colour shade/s to match the colour of the other
panels. The thickness of powder coating should be minimum 80 microns.
Suitable provisions shall be made in the panel for proper heat dissipation. Air
aspiration louvers for heat dissipation shall be provided as a necessary.
The front portion shall house the switchgear and the rear portion shall house
capacitors . The enclosure is to be suitably sized to accommodate all the
components, providing necessary air clearance between live and non-live parts,
providing necessary working clearance.
7.4.4 APFC Relay / Controller
Microprocessor based APFC relay (Intelligent VAr controller) shall sense the PF in
the system and automatically switch ON / OFF the capacitor unit or stage to achieve
the preset target PF. The controller shall have the following features :
a) Digital settings of parameters like PF, Switching time delay, Step limit etc.
b) Indication of PF, preset parameters.
c) Minimum threshold setting of 1% of CT current.
d) No-volt release.
e) Protective shut down in case of harmonic overload.
f) Indication for Failure to achieve the target PF, Harmonic overloading, Step
failure etc.
g) All electricity supplies exceeding 100 A,3 phase shall maintain their power
factor between 0.95 lag and unity at the point of connection.
7.4.5 Capacitor Unit
Each basic unit of mixed dielectric extra low loss heavy duty capacitor shall be built
with a number of elements. These elements shall be combination of capacitor tissue
paper and biaxially oriented polypropylene film impregnated with non PCB bio-
degradable impregnant or Film Foil capacitor manufactured using Poly propylene
film placed between 2 layers of metal foil and winding. The elements shall be
connected to the external bus bars through these leads in a series parallel connection
to form a three phase unit.
The capacitor units shall be floor mounting type using minimum floor space. The
container of capacitors shall be made out of 2 mm thick M S sheet steel of polyster
paint coated finish. Each standard unit shall be provided with internal fuses
(operation co-ordinated with case-rupture characteristics to avoid rusting).
Total Harmonic Distortion (THD) of upto 5% on voltage and current waveforms
shall not affect the life of capacitors. ±10% variation in line voltage shall not affect
the life of the capacitors.
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7.4.6 Capacitors
General specifications : 3 phase, delta connected, 50 Hz.
Voltage : Shall be designed for minimum 520V and shall withstand system over
voltage, increased voltage due to series reactor and harmonics.
Capacitor type : Super heavy duty with double side metallised capacitor tissue paper.
Oil impregnated and self-healing type with bi-axially oriented polypropylene film
shall be fitted with pressure sensitive disconnector in each individual capacitor cell.
Overvoltage +10% (12h / 24h), + 15% (30m / 24h), + 20% (5m), +30% (1m) as per
Clause 6.1 of IS 13340-1993.
Over current : 2.5 x In
Pak Inrush current withstand : 350 x In
Total watt-losses including discharge resistors : < 0.45 W / k V Ar.
Temperature category : -25 deg.C to 70 deg.C.
Capacitor shall be self-heating type and oil impregnated for longer life. The
impregnant shall be non-PCB, biodegradable type, must be properly treated and de-
gasified, so as not to have any degeneration properties and shall be non-oxidizing.
The design shall be modular for simple mechanical assembly, no extra accessories /
metal parts to be required. Unit must be free standing with an IP 41 protection level.
7.4.7 Discharge Resistance
Capacitors shall be provided with permanently connected discharge resistors so that
residual voltage of capacitors is reduced to 50 volts or less within one minute after
the capacitors are disconnected from the source of supply.
7.4.8 Terminals
Each capacitor bank shall be provided with a terminal chamber and cable glands
suitable for PVC insulated aluminum conductor armoured cables as specified.
7.4.9 Earthing
Two separate earthing terminals shall be provided for earth connection of each
bank.
7.4.10 Testing
The reactor shall be tested `using a separate source voltage test of 3 KV (coil to core)
for one minute as per IEC 76/3. The reactor shall be fitted with a temperature
sensitive micro-switch in the centre coil (normally open) for connection to trip circuit
in case of high operating temperature.
7.4.11 Switchgear & Protection
Incomer switchgear shall be TP&N breaker appropriate rating (minimum 1.8 times
the normal current to take care of inrush switching current). Suitable contactor for
each step shall be used and must be capable of capacitor switching duty at each step
for short circuit protection.
Busbars shall be suitably colour coded and must be mounted on appropriate insulator
supports.
Power cables used shall have superior mechanical, electrical and thermal properties,
and shall have the capability to continuously operate at very high temperatures up to
125 deg.C.
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 Internal wiring between main bus-bars, breaker, contactor and capacitors shall be
made with 1100 V grade, PVC insulated, copper conductor cable of appropriate size,
by using suitable copper crimping terminal ends etc.
Suitable bus links for input supply cable termination shall be provided.
7.4.12 Control Circuit & General Protection
The control circuit shall be duly protected by using suitable rating MCB.
Wiring of the control circuit shall be done by using 1.5 sq.mm, 1100 V grade, PVC
insulated, multi-stranded copper control wire.
Inspection terminal strip, number ferruling, labeling etc. shall be provided.
440 V caution board on the panel shall be provided.
7.4.13 Installation
Capacitors banks shall be installed as per installation manual of supplier and
shall conform to relevant Indian Standards.
All interconnections in the control panel shall be checked before commissioning.
Cable end boxes shall be sealed after cable connections to prevent absorption of
moisture.
7.4.14 Testing & Commissioning
The capacitor bank shall be subject to tests as specified in relevant Indian
Standards at the factory and the test certificates shall be furnished in quadruplicate.
Insulation resistance shall be tested with a 1000 volts meagger between phases and
phase to earth.
Residual voltage shall be measured after switching of the capacitors and the same
shall not be more than 50 volts after one minute.
Each discharge resistor shall be tested for its working.

7.5 TRANSFORMER - OIL TYPE:

7.5.1 Scope:
Design, manufacture, testing, supply, Installation, testing and commissioning of
outdoor type 33 kV /0.415 kV transformers with ONAN cooling complete with all
the accessories and fittings for efficient and trouble free operation. The details are
given in the data sheet. All other specifications shall be followed as per CPWD. First
filling of oil shall be at site by contractor.
7.5.2 Standards:
7.5.2.1 The equipment and accessories covered by this specification shall be designed,
manufactured and tested in compliance with the latest relevant standards published
by the Indian Standards institution wherever available in order that specific aspects
under Indian conditions are taken care of.
7.5.2.2 The equipment and accessories for which Indian Standards are not available shall be
designed, manufactured and tested in accordance with the latest standards published
by any other recognized national standards institution.

436
7.5.2.3 The equipment shall also conform to the latest Indian Electricity Rules as regards
safety, earthing and other essential provisions specified therein for installation and
operation of electrical plants.
7.5.3 General Design And Constructional Features:
7.5.3.1 All materials used shall be of best quality and of the class most suitable for working
under the site conditions and shall withstand the variations of temperature and
atmospheric conditions, overloads, over-excitation, short circuits as per applicable
standards, without distortion or deterioration or the setting up of undue stresses in any
part, and also without affecting the strength and suitability of the various parts for the
work which they have to perform.
7.5.3.2 The design shall be such that the risks of accidental short-circuit due to birds or
vermin‟s are obviated. All apparatus, including bushing insulators and fittings shall
be so designed that water cannot collect at any point. Marshaling kiosks, boxes etc.
shall be adequately ventilated to prevent condensation of moisture and so treated
internally as to prevent growth of fungi on any coils, wires and insulating materials
used.
7.5.3.3 The transformers shall operate with minimum noise and vibration. The cores, tank
and other structural parts shall be properly constructed so that the mechanical
vibrations are kept to the minimum, thus reducing the noise.
7.5.3.4 The design of the transformer shall be such that changes in transformer connection
can be made by a simple change of link connection inside the tank. The transformers
shall be designed to suppress harmonic voltages, specially the third and fifth, so as to
eliminate distortion in wave form, and the possibility of circulating currents between
the neutrals at different transformer stations.
7.5.3.5 All transformers shall be of the latest design, oil filled as called for in the main
specification. All transformers shall be suitable for outdoor installation. The type of
cooling and the corresponding ratings for each transformer shall be as indicated in the
BOQ.
7.5.3.6 The magnetic circuit of each transformer shall be so designed as to minimize eddy-
current and hysteresis losses in the core.
7.5.3.7 All electrical connections and contacts shall be of ample section for carrying the rated
current without excessive heating.
7.5.3.8 All mechanisms shall be of stainless steel, brass, gunmetal, or other suitable material
to prevent sticking due to rust or corrosion.
7.5.4 Tank:
7.5.4.1 The transformer tank shall be made of steel plate, shaped in such a way that
minimum of welding is required. The tank shall be electrically welded and all
welding stresses shall be properly relieved. Tank walls shall be reinforced by
adequate stiffeners to ensure mechanical rigidity permitting hoisting of complete
transformers filled with oil and also to damp transformer noise. The tank shall be
sufficiently strong to withstand shocks likely to be encountered during transport of
the transformer without any deformation or weakening of joints. The joints shall be
oil tight. Guides shall be welded on the inner side of the tank to facilitate tanking and
untanking of the transformer core and coil assembly.
7.5.4.2 Tank cover shall be bolted on to the flanged rim of the tank with a suitable
weather-proof, hot-oil-resistant gasket in between for oil tightness. The bolted tank
cover shall be so arranged that it can be removed and the core inspected without
removal of the radiators. All requisite access and inspection holes shall be provided
with bolted oil tight, gasket seated cover plates. Bushing turrets, covers of access
holes, covers of pockets to prevent leakage of water into the tank shall be provided.
7.5.4.3 The exterior of tank and other steel surface exposed to the weather shall be
thoroughly cleaned and have a priming coat of zinc chromate applied. The second

437
 coat shall be of an oil and weather resistant nature preferably of distinct colour from
the prime and finish coats. The final coat shall be of a glossy, oil and weather
resisting non-fading paint of specified shade. The interior of the tank shall be
cleaned by shot blasting and painted with two coats of heat resistant and oil insoluble
paint.
7.5.4.4 Steel bolts and nuts exposed to atmosphere shall be galvanized however; surfaces of
the transformer or other parts of the transformer or auxiliary equipment which are in
contact with oil shall not be galvanized.
7.5.4.5 The transformer tank, auxiliary equipment and fittings shall be provided with
necessary devices for lifting and haulage facilities. The tank shall be mounted on a
substantial under-carriage.
7.5.4.6 Unless otherwise stated the tank together with radiators, conservator, bushings and
other fittings shall be designed to withstand without permanent distortion the
following conditions.
a) Full vacuum of 760mm of Hg for filling oil by vacuum.
b) Internal gas pressure of 0.35 Kg/Sq.cm. with oil at operating level.
c) Valves shall not leak nor any welded joints sweat under above conditions.
7.5.4.7 Adequate space shall be provided at the bottom of the tank for collection of
sediments.
7.5.5 Core:
7.5.5.1 The magnetic circuit shall be built of transformer grade cold rolled grain oriented low
loss steel stampings having high permeability and conforming to adopted standards.
Stampings shall be insulated from each other with material having high inter-
lamination insulation resistance and rust inhibiting property and also capable of
withstanding pressure, mechanical vibration and action of heat and oil, thus reducing
the possibility of sludge formation to a minimum.
7.5.5.2 The framework, clamping arrangement and general structure of the cores of each
transformer shall be of robust construction and shall be capable of withstanding any
shock to which they may be subjected during transport, installation and service. The
assembled core shall be securely clamped, on the limbs and the yoke, to build up a
rigid structure. The clamping pressure shall be uniform over the whole of the core
and so adjusted as to minimize noise and vibration in the core when the transformer
is in service. The framework and the core bolts shall be efficiently insulated from
the core so as to reduce the circulating currents to a minimum.
7.5.5.3 The core clamping frame shall be provided with lifting eyes for the purpose of
tanking and untanking the core with winding mounted thereon and shall have ample
strength to take the full weight of the core and winding assembly.
7.5.5.4 An approved type of core grounding system shall be used; the grounding connections
being located at the top of the core for easy access from the inspection hole.
7.5.6 Winding:
7.5.6.1 The coils used for transformer winding shall be flat in shape, made of paper
insulated, continuous and smooth, tinned or enameled electrolytic copper conductors
of high conductivity.
7.5.6.2 The transformer winding shall be designed for basic impulse insulation level not
lower than that specified in the main specification.
7.5.6.3 Liberal ducts shall be provided to prevent any hot spot temperature in the winding
that may adversely affect the life of the transformer. Adequate supports, wedges and
spacers of hard insulating material shall be so fitted that they will neither move nor
permit relative movement of any part of winding during transit of normal service or
under terminal short circuit, nor damage the winding insulation in any way. All leads
and connections shall be robust, adequately insulated, protected and clamped. The
winding assembly shall be dried in vacuum with tested insulating oil of approved

438
 standard. The windings shall be subjected to a thorough shrinking and seasoning
process so that no further shrinkage of windings occur during service at site.
However adjustable devices shall be provided for taking up any possible shrinkage of
coils in service. The assembly shall be held in position under adequate axial
compression to withstand the axial thrust likely to occur under terminal short circuit.
7.5.6.4 The end turns on the high voltage winding shall have reinforced insulation to take
care of the voltage surges likely to occur during switching or any other abnormal
system condition.
7.5.6.5 The transformers shall be suitable for operation at full rated power on all tappings
without exceeding the specified temperature rise as indicated in the applicable
standards.
7.5.7 Insulating Materials:
The insulating oil shall conform to IS-335 and shall be suitable in all respects for
operating the transformer at the rating and under conditions specified in the main
equipment specification. Sufficient oil shall be supplied for the first filling of
transformer, the oil circulating equipment and the tank containing tap-changing
mechanism and an extra 10% shall be supplied in non-returnable drums. The tender
shall contain information about the grades of oil recommended by the transformer
manufacturer for use in the transformer. Test certificates for the oil shall be
furnished before dispatch of transformer and acceptance by Employer.
7.5.8 Transformer Tappings:
33/4.415 kV, delta / star wound, Transformers shall be with on load tap changer.
Transformer shall be provided with „ON‟ load tap changing on 33 KV side. The
tapings to be provided for variation on HV side from +7.5% to – 7.5% in steps of
1.25% each. Provision of bushing shall be made for neutral and neutral CTs shall also
be provided.
7.5.9 Cooling Equipment:
Natural cooling by means of banks of detachable type radiators made from
pressed/round tubes around transformer tank shall be provided. The radiators shall
be of seamless mild steel sheet with clean bright internal surface and shall be suitably
braced to protect them from shock.
7.5.10 Terminal Arrangement
7.5.10.1High Voltage Side (33 KV)
Cable box shall be provided suitable for terminating one no. 3C x 300 sq.mm XLPE
insulated armoured 33 KV cable complete with disconnecting chamber, compression
glands, tinned copper lugs, Armour earth clamp and body earth terminal.
Cable box shall be fitted with bushing insulators for H.T. cable termination side.
7.5.10.2Low Voltage Side (415V)
2 MVA, 33 KV / 0.415 kV delta / star Transformers – 33 kV Cable, outdoor
connections shall be made. 33/0.415 kVA Transformers shall be suitable for cable or
bus ducts as mentioned in BOQ & drawings (SLDs).
7.5.10.3Disconnecting Chamber
The disconnecting chamber shall be air insulated and complete with seal off
bushing, removable flexible connectors / links and removable covers. It shall be
possible to trail out the transformer without having disconnecting the bus duct /
cables.

439
 Phase to phase and phase to ground clearances within the chamber shall be such as
to enable either the transformer or cable to be subjected separately to H.V. test.
7.5.10.4Bushing:
Bushings shall confirm to IS: 2099 and other relevant standards.
Bushings shall be supplied with terminal connector clamp suitable for connecting the
bushing terminal to the Employer's conductor.
Creepage distance of bushing shall be (41mm/kv phase ground) adequately,
7.5.11 Marshalling Box
Whenever optional fittings, temperature indicators, with auxiliary contacts,
Buchholtz Relay and Bushing CT's are specified then the bidder shall provide a
Marshalling box and Marshall to it all the contact terminals of electrical devices
mounted on the transformer. It shall be in the contractor's scope to provide:
a) The interconnection cabling between the Marshalling box and the accessory
devices either by PVC insulated copper wire in G.I. conduits or PVC insulated
copper conductor armoured cables.
b) Necessary compression type brass cable glands at the Marshalling box for
above cables.
The Marshalling box shall be tank mounted, water/dust tight sheet steel (2mm thick)
enclosed with hinged door having padlocking facility. All doors, covers and plates
shall be fitted with neoprene gaskets. Top surface shall be sloped and bottom shall be
atleast 600mm from floor and provided with gland plate and cable glands as required.
Terminals shall be clipon type rated for 10A. All contacts for alarm/trip indication
shall be potential free, wired up to the terminal block. Wiring shall be done with
stranded copper conductor wires of sizes not less than 1.5 sq.mm for control and 2.5
sq.mm for CT circuits. C.T. terminals shall be provided with shorting facility.
7.5.12 Electrical & Performance Requirement:
Transformer shall operate without injurious heating at the rated kVA at any voltage
within +/- 10% of the rated voltage of that particular tap.
Transformer shall be designed for 110% continuous over fluxing withstand
capability.
The neutral terminals of the winding with star connection shall be designed for the
highest over current that can flow through the winding.
Overloads shall be allowed within the conditions defined in the loading guide of the
applicable standard. Under these conditions, no limitations by terminal bushings, tap
changers or other auxiliary equipment shall apply.
Temperature Rise shall be continuously rated for full load. The temperature rise shall
not exceed 45 degree C by thermometer in oil or 55 degree centigrade by resistance
over an ambient of 38 degree C.
7.5.13 Earthing:
7.5.13.1Two separate earthing terminals to be provided at the bottom of the tank on opposite
sides. The terminals shall be suitable for connection to grounding strip.
7.5.13.2Internal Earthing:
The frame work and clamping arrangements of core and oil shall be securely earthed
inside the tank by adequately sized copper strip connections to the tank.
7.5.14 Fittings And Accessories:

440
 The transformer shall be provided with all standard fittings and accessories
specified in the applicable standard for the size and type of transformer
concerned. The accessories and fittings shall generally be as specified below:
a) Lifting Lugs:
The arrangement for lifting the active part out of the transformer tank along
with the cover by means of lifting lugs without disturbing the connections.
b) Swivel Type Rollers:
The transformer to be provided with 4 No‟s Bi-Directional rollers fitted on
cross channels to facilitate the movement of the transformer in both directions.
c) Oil Conservator:
The transformer to be provided with an oil conservator with welded end plates.
It is to be bolted to the cover and can be dismounted for purpose of transport. It
has to be provided with magnetic oil level gauge and an oil filling hole 1 1/4”
BSF size with a cap, which can be used for filtering oil. For draining purpose a
plug shall provided. A connection pipe between the conservator and the main
tank is to be provided which projects inside the conservator and the main tank
is to be provided which projects inside the conservator.
d) Air release Valve:
An air release valve is to be provided on the top of the tank cover facilitate the
release of the entrapped air and filling of oil.
e) Breather:
The transformer to be provided with an indicating dehydrating silica gel
breather of sufficient capacity.
f) Drain-cum-oil Filter Valves:
The transformer to be provided with a drain-cum-oil filter valve of 1 1/4” BSF
size at the bottom of the tank.
g) Diagram and rating plate:
Diagram and rating plate shall be provided indicating the details of transformer,
connection diagram, vector group, tap changing diagram etc.
h) Dial type Magnetic thermometer (150 mm dia) with maximum set pointer at
75 deg C and electrical contacts for electrical alarm at high temperature.
i) Winding temperature indication and electrical contacts for trip / alarm (except
for below 800 kVA Transformer)
j) Buchholz relay of double float type with electrical contacts for low oil level
alarm and high gas pressure trip suitable for 24 volts DC supply.
k) Filter valve of 1 1/4” BSF at top.
l) Explosion vent.
m) Repeater for Oil and Winding Alarm and Trip for BMS connection.
n) RTD for temperature signal to BMS.
o) Surge Relay
7.5.15 Drawings And O&M Manuals:
Four copies of manual of complete instructions for the installation, operation,
maintenance and repairs circuit diagrams, foundation and trenching details shall be
provided with the transformers. List of spare parts shall also be indicated.
Two copies of the drawings incorporating the following particulars shall be submitted
with the offer for preliminary study.

441
 GA drawing showing dimension, net weight and shipping weight, quantity of
insulating oil etc.
Suitable capacity of crane requirements for assembly and dismantling of the
transformer.
Drawing indicating GA of busduct/cable box and its dimension for cable entry cut
out requirements etc.
The drawings in (four sets) to be furnished by the supplier for approval after
acceptance of his order shall include the following.
GA showing front and side elevations and plan of transformer and all accessories and
external features, detailed dimensions, crane lift for untanking, oil quantity, H.T./L.T.
clearances etc.
Drawings of Bus duct/cables termination arrangement.
HV cable box arrangement & disconnecting chamber GA & details drawings.
Drawing of each type of bushing.
Name plate and terminal making and connection diagram.
Control wiring & schematic diagram showing polarity and vector group of windings,
CTs and OTI, WTI, circuits, Alarm/trip circuits etc.
Reproducible copy of the above drawings for records
Maximum allowable Power losses shall be as per ECBC norms.
7.5.16 Testing:
The transformer shall be subjected to all routine tests in accordance with IS : 2026 at
the factory before dispatching the same and test certificates shall be furnished.
Testing at site:
a) Insulation test of HT and LT winding
b) Oil dielectric strength test
c) Ratio test of transformer
Four copies of the test reports in bound volume shall be submitted for approval.
SOAK PIT AND DRAIN PIT (Wherever required) shall be provided as per IS
10028- 2.
The transformers foundation shall be surrounded by a suitable soak pit enclosed by a
150 mm high non- combustible curb. This soak pit shall be filled with coarse crushed
stones about 25mm in diameter to a minimum depth of 300 mm. The volume of the
soak pit minus the volume of the stones should be sufficient to contain the entire oil
content of the transformer if the oil content is less than or equal to 5 kl. In case the oil
content is more than 5 kl, the volume of soak pit minus the volume of stones should
be sufficient to contain at least one third of the total oil content. The excess should be
led through two or more hume /concrete pipes (min. 150 dia.) from bottom of pit to a
central remote burnt oil tank.
7.5.17 Remote Tap Changer Control Panel (RTCC) for 33/0.415kV, 2 MVA transformer
RTCC panel shall be of sheet steel cabinet for indoor installation, floor mounting
type. The RTCC panel shall be totally enclosed, completely dust and vermin proof
and shall be with hinged doors, Neoprene gasket and padlocking arrangement.
RTCC panel shall be suitable for the climatic conditions as specified in Special
Conditions. Steel sheets used in the construction of RTCC panel shall be 14 SWG

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 CRCA sheet steel and shall be folded and braced as necessary to provide a rigid
support for all components. Joints of any kind in sheet metal shall be seam welded,
all welding, slag shall be rounded off and welding pits wiped smooth with plumber
metal. The general construction shall confirm to IS-8623-1977 (part-I) for factory
built assembled switchgear & control gear for voltage upto and including 1100 V AC.
All panels and covers shall be properly fitted and square with the frame, and holes in
the panel correctly positioned. Fixing screws shall enter into holes tapped into an
adequate thickness of metal or provided with wing nuts. Self threading screws shall
not be used in the construction of RTCC panel. A base channel of 75 mm x 40 mm x
5 mm thick shall be provided at the bottom for floor mounted panel.
The following components shall be provided in the RTCC panel:
a) Digital Tap Position Indicating Meter
b) Raise/Lower Push Buttons for Remote Control of OLTC
c) Tap Change in Progress Signal Lamp.
d) Supply on Signal Lamp
e) Local / Remote Control Indicating Lamps
f) Panel illuminating lamp with door switch.
g) Space Heater with Switch and Thermostat.
h) Automatic Voltage Relay with Time Delay Element.
i) Selectors switch for Auto/Manual Operation.
j) Undrilled Gland Plate for Cable entry.
k) Earthing Terminal
l) Lifting Eyes Bolts.

7.6 BUS DUCTS

7.6.1 Scope:
The specification covers design, manufacturing, supply, installation, testing and
commissioning of Sandwich type busbar trunking for use as feeder busbars for
interconnection between separate electrical equipment / load centers, and for use as
plug in busbar risers.
7.6.2 System details:
The busbar shall be suitable for operation in a 600V system, with frequency of 50 Hz
having 100% neutral and internal earth.
The bus duct shall conform to IEE/NEMA/BUI/JIS for seismic protection
certification.
7.6.3 Design & Construction requirements – Sandwich bus bars
7.6.3.1 General:
The busbars shall be of sandwich construction, non-ventilated design. It shall be
possible to mount the busbar system in any orientation, without affecting the current
rating.
The bus duct shall consist of three phases and neutral bus bar permanently positioned
dust and vermin proof and the degree of enclosure protection shall be IP 52 for
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 indoor installation and shall be IP-65 for outdoor installation as per schedule of
quantities.
7.6.3.2 Busbars:
The busbars shall of high conductivity Copper, or Aluminum, as specified in the
tender.
Where an earth conductor is required, it shall be a separate, integral earth conductor,
of the same high conductivity material as the phase conductors.
7.6.3.3 Insulation:
The busbars shall be insulated throughout their length by epoxy coating / Mylar. The
insulation material used shall be of Class H (180 deg. C). The insulation must comply
to UL 94 V-O. It shall be Halogen Free.
Housing: The housing shall be made of extruded Aluminum case duly enameled/
electro-galvanized sheet steel, with an epoxy powder coated paint finish. The housing
shall be profiled, to provide higher strength and efficient heat dissipation. The width
of the housing shall preferably be the same for all ratings of busbars, in order to
provide interchangeability of tap off boxes.
7.6.3.4 Joints:
The joints between sections shall be made so as to provide flexibility during
installation and expansion / contraction of busbar during operation. The joints shall
be of the single bolt type
The joint construction must have the following features.
a) Heat expansion of at least 3mm per joint.
b) The joint insulation must be of one piece molded design and not have any cut
edges which can absorb moisture.
c) The joint construction must allow a +/- 14mm adjustment at the time of
installation, for ease of adjusting to site measurement variations.
d) The joint bolt must be insulated with a bolt insulator. The bolt insulator
must be of molded one piece.
e) The joint system must be designed in a way that the installer cannot
insert the busduct length too far and damage the bolt insulator.
f) The busbar ends shall not have holes or slots at the joints – the electrical
continuity shall be through pressure plates, achieving a high area of
joint cross section and expansion capability.
g) It shall be possible to install and remove the joints without disturbing the
busbar run.
7.6.3.5 End termination:
At the termination either on the transformer side or on the panel side , bus duct shall
be provided with flange ends, adopter box and copper flexible( preferably multi
sheet types) to connect bus bar of bus duct to bus bar of panels or transformer
terminals.
7.6.3.6 Accessories:
A full range of accessories like bends, end flanges, end feed units, and support
brackets etc. shall be available.
7.6.4 Installation
Bus ducts running along the wall shall be supported at intervals not exceeding 1.5 m.
In case of branching, there shall be support on all branches at a distance of 300 mm

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 from the point of branching, Support shall not be less than 40 x 40 x 6 mm MS angle
secured in an approved manner. Supports may also be provided in the form of
brackets fixed to walls where the duct runs along the wall. In case of ceiling
suspended bus ducts, supports made out of 40x40x6 mm MS angle iron shall be
provided along with 12mm dia MS rod with threading and nut bolts. The horizontal
distance between two such supports shall not be more than 1200 mm. The ducts
supports shall be suspended from suitable approved suspension devices provided in
the ceiling. Fire barrier shall be provided at each floor/wall crossing as per relevant
IS code. Continuous earth bus of suitable size shall be provided along with
throughout the length of Bus duct. Fire barrier of 2hrs rating shall be provided on
each floor.
7.6.5 Testing
The busbars shall be type tested at a reputed international test laboratory (ASTA or
CPRI) for short circuit withstand. The test shall be for a minimum duration of 1
second. Tests shall be performed over a range of current ratings, covering the
different frame sizes of the manufacturer.
Degree of ingress protection (IP rating) shall also be tested at any reputed
independent laboratory. This test shall be for IP54 for indoor application and IP65 for
outdoor application for sandwiched busbars.
The following tests shall be carried out at site and test results to be recorded:
a) Insulation resistance shall be tested with 1000 V megger and shall be not less
than 100 mega ohms.
b) Earth continuity test

7.7 HT CABLE (UE)

7.7.1 General
Cables shall be aluminium conductor, unearth type , FRLS, cross linked polyurethane
construction and shall be supplied, inspected, laid, tested and commissioned in
accordance with drawings, specifications, relevant Standard Specifications and cable
manufacturer‟s instructions.
7.7.2 Material
Conductor
The Conductor shall be made from electrical grade aluminum, stranded wires
compacted together.
Insulation
High quality TROPOTHEN - X (XLPE) unfilled insulating compound of natural
colour shall be used for insulation. Insulation shall be provided by extrusion process
and shall be chemically cross linked in continues vulcanization process.
Shielding
Cables shall be provided with conductor shielding as well as insulation shielding and
shall consist of extruded semi-conducting compound, additionally insulation shield
shall be provided with semi-conducting and metallic tape shield over the extruded

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 insulation shield. XLPE insulation and outer core shielding shall be extruded in one
operation.
Armoring
Armoring shall be provided over the inner sheath and shall comprise of flat steel
wires (strips).
Outer Sheath (with FRLS)
Tough outer sheath of heat resisting PVC compound shall be FRLS extruded over the
armoring in case of armored cables, or over inner sheath in the case of unarmored
cables.
7.7.3 Tests
Cables shall be type tested and routine tested in accordance with IS:7098 (Part II).
The following tests shall be carried out at site for insulation between phases and
between phase and earth before and after the cable laying is complete.
a) Insulation Resistance Test.
b) Continuity resistance test.
c) Sheathing continuity test.
d) Earth test.
e) High Voltage test.
Cables shall be laid with a clearance of at least 75 mm between two cables.
Before laying of cables megger values shall be taken and shall be recorded.
7.7.4 End Termination of HT Cable
Pre-moulded cable terminations for XLPE cable shall be used as per manufacturer‟s
instructions. The heat shrinkable raychem shall consist of highly track resistant
insulating section vulcanised to a semi-conducting section. The pad material shall
have cold-flow properties and shall be flame retardant.
Each end terminal shall undergo Hi Pot Test at site. Necessary equipment shall be
arranged at site by contractor.
7.7.5 Laying of HT Cables
Direct In Ground
The work shall involve digging of outdoor trench in ground and laying cable(s) as
indicated in specifications and Schedule of Quantities.
The depth of the trenches shall not be less than 1200 mm for 33 KV , 900mm for
11kV plus radius of cable, from the upper surface of ground. Where more than one
multicore cable is laid in the same trench, a horizontal inter spacing of 250 mm shall
be left in order ro reduce mutual heating and also to ensure that fault occuring on one
cable will not damage the adjacent cable.
Cable shall be laid in cement pipes encased in concrete or hume pipes at all road
crossing. Cables shall be laid in trenches over rollers placed inside the trenches. After
the cable has been properly laid and straightened, it shall covered with 80 mm thick
layer of sand. Cable shall then be lifted and placed over the sand cushion. Again, the
cable shall be covered with 80 mm layer of sand. Over this cable protection shall be
provided by providing tiles which shall overlap cables 50 mm on either side.
Trenches shall then be back-filled with earth and shall be consolidated. Suitable
cable markers made of cast iron with aluminium paint indicating the voltage grade,
direction of run and size of cables shall be provided at regular intervals.

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7.7.6 RCC/MASONRY TRENCH
For laying of HT cable in RCC/Masonry trench refer detail on sub-station layout
drawing and IS-1255-1983.

7.8 1.1 KV GRADE CABLES AND CABLE TRAYS

7.8.1 Standards Of Codes

This chapter covers the specifications for supply and laying of Medium Voltage
XLPE insulated PVC sheathed FRLS cables for 1100 volts.

All equipments, components, materials and entire work shall be carried out in
conformity with applicable and relevant Bureau of Indian Standards and Codes of
Practice, as amended upto date. In addition, relevant clauses of the Indian Electricity
Act 1910 and Indian Electricity Rules 1956 as amended upto date shall also apply.
Wherever appropriate Indian Standards are not available, relevant British and /or IEC
Standards shall be applicable.

7.8.2 Cables

Medium voltage cables shall be aluminium/copper conductor XLPE insulated, FRLS

PVC sheathed, armoured conforming to latest IS. Cables shall be rated for 1100
Volts.

All Conductor cables shall be as per BOQ.

Conductors shall be insulated with high quality XLPE base compound. A common
covering (bedding) shall be applied over the laid up cores by extruded sheath of
unvulcanised compound. Armouring shall be applied below outer sheath of PVC
sheathing. The outer sheath shall bear the manufacturer‟s name and trade mark at
every meter length. Cores shall be provided with following colour scheme of PVC
insulation.

1 Core : Red/Black/Yellow/Blue

2 Core : Red and Black

3 Core : Red, Yellow and Blue

3 ½ /4 Core : Red, Yellow, Blue and Black

7.8.3 LAYING

Cables shall be laid as per the specifications given below :

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7.8.3.1 Duct system

Wherever specified such as road crossing, entry to building or in paved area etc.
cables shall be laid in underground ducts. The duct system shall consists of a
required number of stone ware pipes, GI, CI or spun reinforced concrete pipe with
simplex joints and all the jointing work shall be done according to the CPWD
building specifications or as per the instructions of the Engineer-In-Charge as the
case may be. The size of the pipe shall not be less than 100mm in diameter for a
single cable and shall not be less than 150mm for more than one cable and so on.
The pipe shall be laid directly in ground without making any special bed but
wherever asbestos cement pipes are used, the pipes shall be encased in concrete of
75mm thick. The ducts shall be properly anchored to prevent any movement. The
top surface of the cable ducts shall not be less than 60 cm. below the ground level.
The ducts shall be laid a gradient of at least 1:300. The duct shall be provided
manholes of adequate size at regular intervals for drawing the cables. The manhole
cover and frame shall be of cast iron and machine finished to ensure a perfect joint.
The manhole covers shall be installed flush with the ground or paved surfaces. The
duct entry to the manholes shall be made leak proof with lead-wool joints. The ducts
shall be properly plugged at the ends to prevent entry of water, rodents, etc. Suitable
duct markers shall be placed along the run of the cable ducts. The duct markers shall
at least be 15 cm. square embedded in concrete, indicating duct. Suitable cable
supports made of angle iron shall be provided in the manholes for supporting the
cables. Proper identification tags shall be provided for each cable in the manholes.

7.8.3.2 Cables in outdoor trenches

Cable shall be laid in outdoor trenches wherever called for. The depth of the trenches
shall not be less than 75cm from the final ground level. The width of the trenches
shall not be less than 45 cm. However, where more than one cable is laid, an axial
distance of not less than 15 cm. shall be allowed between the cables. The trenches
shall be excavated in reasonably straight line with vertical side walls and with
uniform depth. Wherever there is a change in direction suitable curvature shall be
provided complying with the requirements. Suitable shoring and propping may be
done to avoid caving in of trench walls. The bottom of the trench shall be level and
free from stone brick bats etc. The trench shall then be provided with a layer of
clean, dry sand cushion of not less than 8 cm. in depth.

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 The cable shall be pulled over rollers in the trench steadily and uniformly without
jerks and strains. The entire cable length shall as far as possible be paved of in one
stretch. However where this is not possible the remainder of the cable may be
removed by "Flaking" i.e. by making one long loop in the reverse direction. After the
cable has been uncoiled and laid into the trench over the rollers, the cable shall be
lifted slightly over the rollers beginning from one end by helpers standing about 10
mtrs. apart and drawn straight. The cable should then be taken off the rollers by
additional helpers lifting the cable and then laid in a reasonably straight line.

For short cut runs and sizes upto 50 sq.mm of cables upto 1.1 KV grade any other
suitable method of direct handling and laying can be adopted with the prior approval
of the Engineer-in-charge.

When the cable has been properly straightened, the cores are tested for continuity and
insulation resistance and the cable length then measured. The ends of all cables shall
be sealed immediately. In case of PVC cables suitable moisture seal tape shall be
used for this purpose.

Cable laid in trenches in a single tier formation shall have a covering of clean, dry
sand of not less 17 cms above the base cushion of sand before the protective cover is
laid. In the case of vertical multi tier formation after the first cable has been laid, a
sand cushion of 30 cms shall be provided over the initial bed before the second tier is
laid. If additional tiers
are formed, each of the subsequent tiers also shall have a sand cushion of 30 cms as
stated above. The top most cable shall have final sand covering not less than 17 cms
before the protective cover is laid.

Unless otherwise specified, the cables shall be protected by the second class bricks of
not less 20 cms x 10 cms x 10 cms (nominal size) protection covers placed on top of
the sand (bricks to be laid breadth wise) for the full length of the cable. Where more
than one cable is to be laid in the same trench, this protective covering shall cover all
the cables and project at 5 cm. over the sides of the end cables. The trenches shall be
taken back filled with excavated earth free from stones or other sharp edge debris and
shall be rammed and watered, if necessary, in successive layers not exceeding 30 cm,
unless otherwise specified.

7.8.3.3 Route Marker

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 Cable route marker marked "Cable" shall be provided alongwith the route of the
cable and location of loops. The route markers shall be of tapered concrete slab of 60
x 60cm at bottom and 50 x 50cm at top having a thickness of 10cm. Cable marker
shall be mounted parallel to and 50cm away from the edge of the trench.

7.8.3.4 Cables in indoor trenches

Cables shall be laid in indoor trenches wherever specified. The trench shall be made
of brick masonry with smooth cement mortar finish with suitable removable covers
(i.e. precasted slabs or chequred plates). The dimensions of the trenches shall be
determined depending upon the maximum number of cables that is expected to be
accommodated and can be conveniently laid. Cables shall be arranged in tier
formation in trenches and if necessary, cables may be fixed with clamps. Suitable
clamps, hooks and saddles shall be used for securing the cables in position. Spacing
between the cables shall not be less than 15 cm centre to centre. Wherever specified,
trenches shall be filled with fine sand and covered with RCC or steel chequred trench
covers.

7.8.3.5 Cable on Trays/Racks

Cable shall be laid on cable trays/racks wherever specified. Cable racks/trays shall
be of ladder, trough or channel design suitable for the purpose. The nominal depth of
the trays/racks shall be 150 mm. The width of the trays shall be made of steel or
aluminium. The trays/racks shall be completed with end plates, tees, elbows, risers,
and all necessary hardware, entire steel trays/ racks shall be hot dip galvanized
including widths & accessories. Cable trays shall be erected properly to present a
neat and clean appearance. Suitable cleats or saddles made of aluminium strips with
PVC covering shall be used for securing the cables to the cable trays. The cable trays
shall comply with the following requirements :

The tray shall have suitable strength and rigidity to provide adequate support for all
contained cables.

a) It shall not present sharp edges, burrs or projections injurious to the insulation
of wiring/cables.

b) If made of metal, it shall be adequately protected against corrosion or shall be

made of corrosion-resistant material.

c) It shall have side rails or equivalent structural members.

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 d) It shall include fittings or other suitable means for changes in direction and
elevation of runs.

7.8.4 Installation

Cable trays shall be installed as a complete system. Trays shall be supported

properly from the building structure. The entire cable tray system shall be rigid.

Each run of the cable tray shall be completed before the installation of cables.

In portions where additional protection is required, non combustible

covers/enclosures shall be used.

Cable trays shall be exposed and accessible.

Where cables of different system are installed on the same cable tray, non
combustible, solid barriers shall be used for segregating the cables.

Cable trays shall be grounded by two nos, earth continuity wires. Cable trays shall
not be used as equipment grounding conductors.

At no place the cable tray / rack / ladder running horizontally should rest on any
building partition like Brick wall, RCC beams etc. but instead proper MS supports/
hangers to be provided at minimum of 1500 mm intervals and at every Turning
Angles.

7.8.5 Jointing and termination‟s

Cable jointing shall be done as per the recommendations of the cable manufacturer.
All jointing work shall be done only by qualified/licensed cable jointer.

All jointing pits shall be of sufficient dimensions as to allow easy and comfortable
working.

Jointing materials and accessories like conductor, ferrules, solder, flex, insulating and
protective tapes, filling compound, jointing box etc. of right quality and correct sizes,
confirming to relevant Indian Standards.

Each termination‟s shall be carried out using brass compression glands and cable
sockets. Hydraulic crimping tool hall be used for making the end termination‟s.
Cable gland shall be bonded to the earth by using suitable size copper wire/tape.

7.8.6 Specific Requirements - Power Cables

The cables shall be 1100V grade, single / multicore, stranded XLPE insulated
aluminium/copper conductor and FRLS PVC sheathed. The cables for emergency
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 services shall be with additional FRLS properties. The cables shall conform to IS-
1554 - Part - I (1988). For multicore cables, fillers used to fill in the space between
the phases shall be non-hygroscopic, chemically inert and non-putrescent.

Cables laid outside the building, either buried or in trench shall be of armoured type.

7.8.7 Specific Requirements - Control Cables

1100V grade multicore, 1.5 / 2.5 sq.mm stranded copper conductor, PVC insulated
and extruded PVC inner sheathed and extruded FRLS PVC outer sheathed of PVC.
FRLS cables, which have outer sheath of specially formulated FRLS PVC cable,
shall be used for cables connected to Emergency services. The cables shall conform
to IS 1554 Part- I (1985) / IEC 502 (1983) in all other respects.

Cables laid outside the building, either buried or in trench shall be of armoured type.

7.8.8 Design Criteria For Cable Sizing

Power cables shall be selected on the following basis:

a) Power cable shall carry the full load current of the circuit continuously
under site conditions considering the various derating factors like ambient air
temperature (50 deg C), grouping, laying methods etc.

b) Power cables shall be sized to restrict the voltage drop to 5% and a voltage
dip of 10% for motors.

c) Power cable shall withstand the fault current of the circuit for the duration
not less than the maximum time taken by the primary protective system to
isolate the fault.

7.8.9 Testing of Cables

Cables shall be tested at works for all routine tests as per IS including the following
tests before being dispatched to site by the project team.

Insulation Resistance Test.

Continuity resistance test.

Sheathing continuity test.

Earth test.(in armoured cables)

Hi Pot Test.

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 Test shall also be conducted at site for insulation between phases and between phase
and earth for each length of cable, before and after jointing. On completion of cable
laying work, the following tests shall be conducted in the presence of the
Employer‟s site representative.

Insulation Resistance Test (Sectional and overall)

Continuity resistance test.

Sheathing continuity test.

Earth test.

All tests shall be carried out in accordance with relevant Standard Code of
Practice and Electricity Rules. The Contractor shall provide necessary
instruments, equipment and labour for conducting the above tests and shall bear
all expenses in connection with such tests. All tests shall be carried out in the
presence of the Engineer In charge/ his representative, results will be noted and
signed by all present and record be maintained. All the test certificate shall be
submitted by contractor.

7.9 CABLE TRAYS

7.9.1 Cable Trays shall be Hot dip Galvanized and factory fabricated out of G.I. channels,
angle iron, tee, bends, sections, flats and perforated sheet for different loads and
number and size of cables as given below :
Cable trays shall be galvanized as per Specification given elsewhere.
1000 mm wide
Runners 25 x 100 x 25 x 3 mm
Rungs 2# 20 x 40 x 20 x 3 mm 250 mm C/C
Suspenders 2 Nos. 40 x 40 x 5 mm GI angle 1500 mm C/C with base support of 40x
40 x 5mm GI angle.
750 mm wide
Runners 20 x 75 x 20 x 2.5 mm
Rungs 20 x 30 x 20 x 2.5 mm 250 mm C/C
Suspenders 2 Nos. 32 x 32 x 5 mm GI angle 1800 mm C/C with base support of 40x
40 x 5mm GI angle.
600 mm wide
Runners 20 x 75 x 20 x 2.5 mm
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 Rungs 20 x 30 x 20 x 2.5 mm 250 mm C/C
Suspenders 2 Nos. 32 x 32 x 5 mm GI angle 1800 mm C/C with base Support of 40x
40 x 5mm GI angle.
450 mm wide
Runners 20 x 75 x 20 x 2.5 mm
Rungs 20 x 30 x 20 x 2.5 mm 250 mm C/C
Suspenders 2 Nos. 25 x 25 x 4 mm GI angle 1800 mm C/C with base support of 40x
40 x 5mm GI angle.
7.9.2 Supply and fixing of perforated type cable trays of the following sizes of pre-
galvanized iron.
a) 1000 mm width x 75 mm depth x 2 mm thick
b) 900 mm width x 75 mm depth x 2 mm thick
c) 750 mm width x 75 mm depth x 2 mm thick
d) 600 mm width x 75 mm depth x 2 mm thick
e) 450 mm width x 50 mm depth x 2 mm thick
f) 350 mm width x 50 mm depth x 2 mm thick
g) 300 mm width x 50 mm depth x 1.6 mm thick
h) 250 mm width x 50 mm depth x 1.6 mm thick
i) 150 mm width x 50 mm depth x 1.6 mm thick
Note: Suitable length of 10 mm dia GI rod suspenders at 1800 mm interval shall be
included in the item for perforated type cable tray.
Specification for Hot Dip Galvanizing Process for Mild Steel Used For Earthing,
Cable Trays Or Junction Boxes For Electrical Installation.
7.9.3 General Requirements
7.9.3.1 Quality of Zinc
Zinc to be used shall conform to minimum Zn 98 grade as per requirement of IS:209-
1992.
7.9.3.2 Coating Requirement
Minimum weight of zinc coating for mild steel flats with thickness upto 6 mm in
accordance with IS:6745-1972 shall be 400 g/sqm.
The weight of coating expressed in grams per square metre shall be calculated by
dividing the total weight of Zinc by total area (both sides) of the coated surface.
The Zinc coating shall be uniform, smooth and free from imperfections as flux, ash
and dross inclusions, bare patches black spots, pimples, lumpiness, runs, rust stains
bulky white deposits, blisters.
Mild steel flats / wires shall undergo a process of degreasing pickling in acid, cold
rinsing and then galvanizing.
The thickness of galvanizing shall be 610 gm / Sq. mtr. (87 Microns) in line with IS:
4759
All finished cable trays and accessories shall be free from sharp tees, corners, burrs
and unevenness.
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7.9.3.3 Cable Trays - Installation Notes
Cable trays shall be installed generally at the elevations shown in respective cable
tray layout drawings. If any major modifications in the drawings are envisaged in the
field, these should be carried out after getting approval from design office.
Before laying the trays, contractor shall submit the shop drawing & take the approval
from client/Project Manager.
It shall be the responsibility of the electrical contractor to mark up all the field
modifications on the latest issues of the drawings and return two copies of all such “
as constructed ” drawings to client/Project Manager‟s design office.
The type and size of tray to be used shall be as mentioned in the individual
layout drawings.
Cable trays shall be welded to the mounting/carrier structures. Trays shall be
supported with suitable angle/hitech rod supports.
Each continuous laid out length of cable tray shall be earthed at minimum two
places by GI flats of minimum size 25x6 mm (unless otherwise noted) to the
Employer‟s earthing system. The distance between earthing points shall not exceed
10 meters.
The following shall be checked before laying the cables on trays.
a) Check for proper identification nos. of the trays.
b) Check for continuity of cable trays over the entire route.
c) Check that all sharp corners, burrs and waste materials have been removed
from the tray.
d) Obtain clearances from piping contractor / engineer that no piping will be
taken in the way of cable trays.
e) Check for earth continuity & earth connection of cable trays.
f) Cable tray installation work shall comply with all currently applicable statutes,
regulations and safety codes in the locality/country where the installation is to
be carried out.

7.10 LIGHTING SYSTEM

7.10.1 Scope
This specification covers the design, material specification, manufacture, testing,
inspection and delivery to site installation, testing and commissioning of lighting
system equipment such as lighting fixtures, light control switches, receptacle units,
lighting wires, lighting poles, conduits and other similar items necessary for lighting
system. Customer / Architect shall have final authority to select light fittings.
7.10.2 STANDARDS
The items of supply and installation shall comply with the latest applicable standards
as specified in specification, Notes and Details and lighting layout drawings. Where
no standards are available, the supply items shall be backed by test results shall be of

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 good quality and workmanship and any supply items which are bought out by the
CONTRACTOR shall be procured from approved manufacturers acceptable to the
EMPLOYER.
7.10.3 LIGHTING FIXTURES AND ACCESSORIES
7.13.3.1Lighting Fixtures / Luminaries – General Requirements:
a) Luminaries shall be designed for continuous trouble-free operation under
atmospheric conditions without reduction in lamp life or without deterioration
of materials and internal wiring. Outdoor fittings shall be weatherproof and
waterproof.
b) All Luminaries shall be supplied complete with lamps suitable for operation
on a normal supply voltage and the variation in supply voltage and frequency
indicated in data sheet.
c) Fluorescent T5 type, sodium vapour and metal halide type Luminaries shall
be complete with accessories like lamps, ballasts, power factor improvement
capacitors, starters etc. These shall be mounted as far as possible in the
Luminaries housing only. If these cannot be accommodated integral with the
Luminaries then a separate metal enclosed control gear box shall be
included to accommodate the control accessories together with a terminal
block suitable for loop-in, loop-out connections. Outdoor type fixtures
shall be provided with outdoor type weatherproof box with IP 55 or
better.
d) Fluorescent type Luminaries with more than one lamp shall be provided with
capacitors connected in lead-lag circuit for correction of stroboscopic effect.
e) Each Luminary shall have a terminal block suitable for loop-in, loop-out and
T-off connection. Terminals shall be of stud or clamp type. Terminal blocks
shall be mounted with minimum two fixing screws.
f) Mounting facility and conduit knockouts for the Luminaries shall be
provided.
g) All hardware used in the Luminaries shall be suitably plated or anodised and
passivated for use in chemical, industrial and power plants.
h) Earthing
Each Luminaries and control gearbox shall be provided with an earthing
terminal suitable for connection earthing conductor as indicated.
i) Painting / Finish
All surfaces of the luminaries / control gearbox housing accessories shall be
thoroughly cleaned and degreased. It shall be free from scale, rust, sharp
edges and burrs.
The finish of the luminaries shall be such that no bright spots are produced
either by direct light source or by reflection.
j) External control gear box provided for housing accessories shall be
galvanized.

7.13.3.2LED (Light Emitting Diode) FITTED LUMINAIRE

a) The LEDs shall be of reputed make such as OSRAM / Philips / Lumileds /
Cree/ Nichia.
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b) LED fixtures to be utilized for Utility area and Street lighting.
c) LED module/ array shall deliver at least 85 % of initial lumens, when installed
for a minimum of 50,000 hours.
d) To enhance the secondary optics of the fixture, suitable Acrylic Optical
Lenses shall be used.
e) The Correlated Color Temperature (CCT) of the LED fixture shall be in the
range of 5500-6000°K.
f) The luminaries shall ensure a CRI of minimum 70.
g) The Uniformity Ratio (Emin /Eavg) shall be mimimum of 60%.
h) The LED luminaries shall produce constant lux level in the voltage range of
140V to 280V. Voltage variations/ fluctuations in the specified voltage range
shall not impinge upon the lux level it produces.
i) The life span of the LED source including its Driver shall be minimum or
greater than 50000 hours.
j) The P/N junction temperature of individual LED must not exceed 100ºC.
High Thermal conduction must be achieved by use of silicon heat conductive
greases an adhesive.
k) LED Light must be constructed to achieve the average illumination of 35
LUX and at the ground level/ working level for the all the Utility Plants roads
with the Uniformity Ratio (Emin /Eavg) of mimimum of 60% and tranverse
ratio (Emin/Emax) of 0.4 as per relevant to the employers requirement.
l) All fasteners must be of stainless steel and rustfree.
m) LED must be mounted on heat sinking conductive bars if any with suitable
large area surface by means of fins to dissipate the conducted heat. The fins
must be exposed to ambient flowing air.
n) Heat sink used should be aluminium extrusion / high pressure die cast
aluminium having high conductivity. Heat sink should be integrated within
luminaire and efforts shall be made to keep the overall outer dimensions
optimum such that it permits sufficient heat dissipation through the body itself
so as to prevent abnormal temperature inside the luminaire and consequential
damage to cover, gasket material, LEDs, lenses and drivers.
o) The electrical component of the LED and LED driver must be suitably
enclosed in hermetically sealed unit.
p) In addition, LEDs should be voltage control dimmable with provision for
power line communication modem or other standard communication system
which shall be able to communicate with electronic drivers or similar type of
lighting controllers and operate without generating excessive heat. All the
LEDs should be “on” while dimming
q) The luminary should be provided with in-built power unit & electronic driver.
The luminary should be so constructed to ensure that the drivers are
replaceable, if required.
r) The luminaries shall conform to IEC 60598 or equivalent standard. The driver
should comply with IEC 61347-2-13, IEC 61547, CISPR-15; and 61000-3-2.
The supplier should submit luminary test report conforming to the specified
standards.
s) Light Distribution shall be of Cut Off/ Semi Cut Off type.
t) Each lighting fixture shall be provided with an earthing terminal suitable for
connecting 2.5 sq. mm (1 core of the 3Cx2.5 sq. mm copper-PVC cable to be
used) copper stranded conductor.
u) Applicable standards
v) The standards and code of practices referred to below shall be the latest
editions Including all official amendments and revisions.

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 w) General safety requirements: IS 1913 - for luminaries
x) Luminaries for street lighting: IS 10322 - electric cables
y) Current waveform for the LED drivers should meet relevant national and
international standard.
z) Electronic components IC (Integrated circuit) shall be of industrial grade or
above.
aa) Metallic film/ Paper/ Polyester Capacitor shall be rated for a sustained
operating temperature of 105° C.
bb) The construction of PCBs and the assembly for components for PCBs should
be as per IS standards.

7.10.4 Construction
a) The casing of the lighting luminaries shall be made of pressure die cast
aluminum coated with epoxy polyester powder coat single. The driver unit
must be accessible and if need be replaceable easily and with minimum use of
tools.
b) The casing made of non-corrosive aluminum having high conductivity shall
have external surface designed in a manner so as to act as an efficient heat
sink to extract heat generated at PN-junction of a LED. Efforts shall be made
to install the fittings on the required street light pole without compromising on
the performance of the LEDs or luminary.
c) The assembly and manufacturing process for the LED source assembly in
modules/arrays shall be designed to assure all internal components are
adequately supported to withstand sudden impacts and mechanical shock and
vibration from high winds and other sources.
d) No part shall be constructed of polycarbonate unless it is UV stabilized.
e) Material used for the lens of LED source shall be of toughened glass, heat
resistant and shall not undergo discoloration during lifetime of the LED
source. It shall conform to ASTM specifications for the materials. Any
discoloration observed in the lens shall be considered a failure under warranty
clause.
f) All luminaries shall be provided with acrylic / polycarbonate / glass diffusers
and/or aluminized reflectors and/or lenses to provide proper road lighting
distribution.
g) Toughened and/or tempered glass of sufficient strength may be provided
under the LED chamber to protect the LEDs and luminaries.
h) The LED lens shall be UV stabilized and shall be capable of withstanding
ultraviolet (direct sunlight) exposure for a minimum period of 60 months
without exhibiting evidence of deterioration.
i) The finish of the fixture shall be powder coated and of grey colour.
j) The luminaries shall be capable of operating normally in ambient
temperatures from -20°C to 50°C maintaining junction temperature below
100°C and heat sink temperature below 60°C, ensuring efficient thermal
management of the luminaire.
k) The fixture shall be designed in such a manner that it is easy to handle and
install, is not too large and unwieldy, is of robust construction, light weight
and conforms to minimum IP66 class of protection for outdoor use.

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 Luminary‟s manufacturer should submit IP test report from Govt. Accredited
Test Lab / R&D Labs.
l) The luminary shall be provided with a built-in external heat sink as well as an
aluminum MCPCB printed circuit board, designed in such a way that the heat
generated within the LED source is efficiently dissipated to the surrounding
atmosphere without abnormal rise in temperature. Any debris build up shall
not degrade heat dissipation performance of the luminaries. A lighting
luminaire fitted with an assisted cooling system is not acceptable.
m) The Entire LED lamps should be driven by minimum 2 or more numbers of
the driver circuits. The entire power supply to the LED Lamps should be
divided among the drivers, thus each driver controlling a group of LED
lamps.
7.10.5 Thermal Management
a) The manufacturers shall ensure that the fixture is designed in such a manner
that it conducts the heat away from the LEDs as efficiently as possible. The
design shall ensure that the junction temperature is kept as low as possible
during operation. Thermal management shall be in such a way that Luminare
shall have trouble free operations from -20 ºC to +50ºC. The following tests
shall be done to determine efficient thermal Management.
b) The Fixture manufacturer shall perform solder point temperature (Tsp)
measurement and compute junction temperature (Tj). The manufacturer shall
show the proof that the junction temperature shall not go beyond the LED
manufacturer‟s maximum junction temperature for long term lumen
maintenance (i.e., 85% of the original value of lumen output after 50000
hours of operation).
c) The fixture manufacturer shall furnish proof that the LEDs that have been
offered and used in the fixture have White Point stability data (6000 Hours) as
per IESNA‟s LM80-08, done at high ambient temperature 85°C and solder
point temperature of 85°C.
d) The fixture manufacturer shall furnish proof that the LEDs that have been
offered and used in the fixture have been tested to IEC 62471 for safety
requirements.
7.10.6 Electrical
a) The LED fitted lighting fittings shall operate at 50 Hz +/- 3 % Hz AC over a
voltage Ranging from 140V to 280V with a power factor > 0.95 in a 3-wire
distribution system. The total power consumption in the LED lighting fixture
shall not exceed the total guaranteed power consumption including power
consumption in the electronic circuit of the driver for that particular
application over the entire voltage range given in clause.
b) The fluctuations in line voltage shall have no visible effect on luminous
intensity of the LED luminaries. The operating voltage of the luminaries shall
be 230V. All parameters measured at this voltage shall stand valid for the
entire operating voltage range of 140- 280V.
c) Total harmonic distortion (THD) of current and voltage induced into the AC
power supply by an LED lighting source shall not exceed 15% for current and
5% for voltage. Harmonic Generation shall be as per EN61000-3-2 and
EN61000-3-3 / IEEE 519.

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 d) The driver module on board circuitry shall include voltage surge protection to
withstand High-repetition noise transients as stated in Section 2.1.6 of NEMA
Standard TS-2/ 1992.
e) The LED circuitry shall function at an operating frequency that must be
greater than 120Hz to prevent perceptible flicker to the unaided eye over the
entire voltage range Specified above.
f) The lighting luminaries shall withstand the following tests.
a. HV test of 4.5 KV
b. IR test of 500V
g) The output circuit shall have short circuit and open circuit protection inbuilt to
the driver unit.
h) The material used in the construction of driver printed boards; driver
enclosure etc. shall be non-flammable and heat resistant. Also, all the PCBs in
the system shall be coated to prevent any corrosion.
7.10.7 Testing
a) Design Qualification Testing shall be performed by the manufacturer or an
independent testing lab hired by the manufacturer on new LED module/ array
designs and when a major change has been implemented on an existing
design.
b) The bidder shall submit manufacturer‟s test certificates complete with
verification of Design Qualification Testing details by an independent testing
authority.
c) The Luminaire manufacturer must show proof that the LEDs they use have
been tested and approved to IESNA‟s LM80-09. The manufacturer must be
able to provide the test data set to establish the authenticity and genuineness
of the LEDs.
d) Tests conducted on LED luminaries are classified as: 1) Type test, 2)
Acceptance test, 3) Routine test and 4) Mock-up test.
i. Type Test shall be carried out to prove confirmation with the
requirements of specification and general quality/ design features of the
unit. In case of any change in Bill of Material or design of unit,
complete type test shall be repeated. If any sample fails in any of the
type tests, fresh samples shall be taken and tested. If any sample again
fails in that test, the whole lot shall be rejected.
ii. Acceptance Tests are carried out by an inspecting authority at the
supplier‟s premises on sample taken from a lot for the purpose of
acceptance of a lot. Acceptance tests shall not be carried out from
particular size or lot on which type tests have already been conducted,
iii. Routine Tests shall be performed by the manufacturer on each complete
unit of the same type and the results shall be submitted to the inspecting
agency, prior to offering the lot for acceptance test. The firm shall
maintain the records with traceability.
iv. Mock up Test.
The successful bidder shall provide proposed LED lamp and luminaries
on three consecutive poles as demonstration to prove the suitability of
the fittings matching with the requirement in regards to lux level,
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 quality of illumination for professional, objective & impartial review
jointly by the bidders team along with team of MSME Engineers. This
shall be carried out within two weeks from the date of issue of work
order and prior to submission of detail design package for approval.
Sample size and criteria for conformity

The luminaries shall be selected from the lot at random. In order to

ensure randomness of selection, procedures given in IS 4905-1968
(Reaffirmed 2001) may be followed.
Test Scheme:

Sr. Description of Test Type Accepta Routine

No Test nce Tests
Tests

1 Visual and Dimensional Y Y Y

check

2 Checking of documents Y Y Y
of purchase of LED

3 Resistance to humidity Y - -

4 Insulation resistance test Y Y Y

5 HV test Y Y Y

6 Over voltage protection Y - -

7 Surge protection Y - -

8 Reverse polarity Y Y Y

9 Temperature rise Y Y -

10 Lux measurement Y Y -

11 Fire retardant Y - -

12 Test for IP66 protection Y - -

7.10.8 Marking
i. The following information shall be distinctly and indelibly engraved on
the housing:
 Year of manufacture
 Batch Number
 Serial Number
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  Name of Manufacturer
 Rated Wattage and Voltage (Input)
 Markings like CE, CB
ii. ISO Certification: The agency shall preferably possess the ISO
certification for design, Manufacturing and supply of the complete Lighting
Unit.
7.10.9 Guarantee Terms and Condition
a) Warranty
b) In addition to meeting the performance requirements for the minimum period of
60 months, the manufacturer shall provide a written warranty against defects in
materials and workmanship for the modules/ arrays for a period of 60 months
after acceptance of the modules/ arrays. Replacement modules shall be
provided promptly after receipt of modules that have failed at no cost to the
Employer.
c) The bidder shall stand guarantee for full replacement of the luminary due to any
failure in 5 years, from the date of purchase. Failures shall include failure/
deterioration of LEDs in terms of performance like guaranteed luminous
efficiency, high junction temperature, and abnormal lamp lumen depreciation,
deterioration in LED including its lens, driver unit and quality of light. The
vendor shall replace the entire LED module/ array of the defective luminaire
with new module /array free of cost immediately.
d) In the event of single LED source getting defective, the entire array/ module
shall be replaced by the bidder by the new fittings.
e) The bidder shall stand guarantee against lumen depreciation beyond 15%.
Vendor shall ensure that LED module/ array shall deliver at least 85% of initial
lumens, when installed for a minimum of 50,000 hours, failing which bidder
shall carry out necessary rectification free of cost to the entire satisfaction of
MSME.
f) The bidder shall maintain appropriate level of inventory in India for immediate
replacement of a defective/ malfunctioning luminary/ LED module/ array/
driver etc.
7.10.10 Compliance to Standards
a) The luminaries shall comply with IS 10322 for functional, photometric and
safety requirements. The fixture shall conform to safety standard EN60598.
b) The luminaries shall conform to norms on transient voltages, voltage dips and
fluctuations as per EN 61547.
c) The luminaries fitted with LED source shall be CE and ISO certified to ensure
quality of the LED source.
d) The other relevant standards applicable to LED based lighting solutions to
which lighting luminary must conform are as under:

ANSIC78.377.2008 Specifications for the Chromaticity of Solid State

Lighting Products

IESNA LM- 79-08 IESNA Approved Method for the Electrical and
Photometric
Measurements of Solid State Lighting Products.

IESNA LM-80-08 IESNA Approved Method for Measuring Lumen

Maintenance of LED Lighting Sources.
(Recommended)

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 UL Standards  8750 Light Emitting Diode (LED) Light
(Latest Approved) Sources for use in Lighting Products.
 1598 Luminaries
 1012 Power Units other than Class-2
 1310 Class-2 Power Units
 2108 Low Voltage Lighting Systems.

IEC 62471 Photo-biological safety of lamps and lamp

systems.

7.10.11 Street lighting Design

Details and considerations as follows:

a. Configuration of the Road : 6.0 Mtrs

b. Mounting height : 6/8 Mtrs
c. Span : 20 Mtrs
d. Required Lux Level (Eavg) : 15
e. Emin/Eavg : 0.5
f. Emin/Emax : 0.3
g. Maintenance Factor : 0.7
7.10.12 Decorative Luminaries
a) Fluorescent Luminaries
 These luminaries shall be generally indoor type provided with cold rolled cold
annealed (CRCA) sheet steel channel / rail cum reflector housing complete
with all electrical control accessories mounted onit. The finish shall be
stove enameled.
 Decorative fluorescent type luminaries shall be either open type, provided
with translucent white opal acrylic diffusers, polystyrene lens prismatic or
square polystyrene louvres.
 Luminaries shall be suitable for the number of lamps of specified wattage,
direct mounting on ceiling / wall/ column pendant mounting or for recess
mounting in false ceiling.
 Decorative luminaries with mirror optic reflectors shall be made with
reflectors with a high specular reflectivity (of more than 90%) and wide-
angle dispersion type. Where these luminaries are mounted in control
rooms and computer rooms, special type of anti-glare mirror (CAT-2)
system shall be provided to direct the light output in the desired direction.
This is mainly to reduce reflection of the light source from computer
screens.
 Luminaries mounted recessed in false ceiling shall be with reflector housing
and spring loaded fixing arrangement for the diffuser / louvre frame. It shall
be possible to have access to the lamp and other accessories from below.

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  Low loss electronic ballasts shall be provided for all fluorescent & CFL lamp
lumunaries.
b) Incandescent / Mercury Vapour / Sodium Vapour / Metal Halide
Luminaries
 Decorative luminaries with sodium vapour lamp / metal halide shall be
generally outdoor weather proof type with degree of protection IP 55
suitable for conduit mounting.
 The luminaries may be provided with integral mounted control accessories or
with external mounted control gear box.
 Decorative lantern luminaries shall be outdoor weather proof type with degree
of protection IP 55, cast aluminums, stove enameled housing, prismatic
heat resistant, toughened glass cover complete with neoprene gaskets, top
or side conduit entry and integral mounted control gear box.
c) Bulk Head Luminaries
The luminaries shall be robust construction, cast aluminum / vitreous
enameled housing, heat and shock resistant prismatic or clear glass cover
fixed with neoprene gaskets for sealing. For mechanical protection to the glass
cover, round steel wire guard with vitreous enameled finish shall be provided.
The luminaries shall be suitable for incandescent lamp unto 150 watts, for
direct mounting to ceiling / wall /column and is used for general purpose
indoor lighting.
7.10.13 OUTDOORS LUMINAIRES
a) Street Lighting Luminaries
 Street lighting luminaries shall be outdoor weather proof LED and it will be
fed from Solar panel.
 The luminaries shall be constructed of die-cast aluminium clear printed
single panel, tempered safety glass cover adjust to tilt angles of 0º/5º Light
distribution : Asymmetrical, ME-Optic (Characteristic : For street
illumination) Elec. equip LED approx. 120W (5600k) with electronic
ballast, IP-66, Protection rating-I, can be mounted on standard poles with
fitter diameters - 60mm side mounted and 76.1 mm (Pole top mounted).
b) Post Top Lantern
 Post top lantern luminaries shall be generally outdoor weather proof type for
illumination of walkways, gate posts, gardens etc.
 The luminary shall have cast aluminium spigot finished with corrosion proof
paint for mounting, opal acrylic or high density polyethylene (HDP)
diffuser bowl, complete with integral mounted control gear, neoprene
gaskets, earthing terminal etc.
 The luminaries shall be suitable upto 100 W incandescent lamp, 40 W LED
c) Aviation warning system luminaries
 Medium Intensity type luminaries
 Medium intensity luminaries shall be outdoor, weather-proof type, suitable
for mounting on structures / buildings up to 200 metres height

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  This luminaries shall be with cast aluminum base with LED lamp, red
prismatic glass/acrylic cover, neoprene gaskets and bottom conduit / pipe
entry.
 The means for attaching the luminaries shall be designed to suit the weight of
the luminaries and strength to withstand wind speeds as applicable to
particular area as per relevant IS specification.
 Environmental Lighting Luminaries
d) Bollard Luminaries
 Bollard Luminaries shall be outdoor, weatherproof type for illumination of
lawns, gardens, pathways etc.
 The Luminaries shall be of FRP housing, clear acrylic cover, louvres for
directing light downward and bottom cable entry.
 The Luminaries shall be suitable for 40 LED or 9 / 11 W CFL.
7.10.14 Accessories For Luminaries
a) Reflectors
 The reflectors shall be made of CRCA sheet steel / aluminium / silvered
glass/ chromium plated sheet copper as indicated for above mentioned
Luminariess.
 Thickness of steel / aluminium shall comply with relevant standards specified
in Data Sheet. Reflectors made of steel shall have stove enamelled /
vitreous enamelled / epoxy coating finish. Aluminium used for reflectors
shall be anodized / epoxy stove enamelled / mirror polished. The finish for
the reflector shall be as indicated for above-mentioned fittings and or in
Data Sheet.
 Reflectors shall be readily removable from the housing for cleaning and
maintenance without disturbing the lamps and without the use of tools.
They shall be securely fixed to the housing by means of positive fastening
device of captive type.
b) Lamp / Starter Holders
Lamp holders shall comply with relevant standards specified in
Data Sheet. They shall have low contact resistance, shall be resistant to
wear and shall be suitable for operation at the specified temperature
without deterioration in insulation value. They shall hold the lamps in
position under normal condition of shock and vibration met with under
normal installation and use.
c) Ballasts
 Ballasts shall be designed manufactured and supplied in accordance with the
relevant standards specified in Data Sheet. The ballasts shall be designed to
have a long service life and low power loss.
 Ballasts shall be of the inductive, heavy-duty type copper wire wound, filled
with thermosetting, insulating, moisture repellent polyester compound
filled under pressure or vacuum. Ballasts shall be provided with taps to set
the voltage within the range specified in enclosed Data Sheet. End
connections and taps shall be brought out to a suitable terminal block
rigidly fixed to the ballast enclosure. Ballasts shall be free from hum and
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 such of those which produce hum shall be replaced by VENDOR with free
of cost.
 Separate ballast for each lamp shall be provided in case of multi lamp
Luminaries, except in the case of 2 x 20 watts Luminaries.
d) Electronic Ballast
Electronic ballast shall be suitable for 1x18W, 1x24W, 1x28W and 2x18W
fluorescent lamp and shall be energy saving, warm start type having a power
factor better than 0.96, having an optimum wattage delivery to the lamp. The
choke shall be suitable for 180 – 270 V AC for operation at ambient
temperature range of -15ºC to +50ºC. The choke shall have low radiated
and conducted EMI / RFI. Refer BOQ
e) Digital Ballast
Digital ballasts shall be designed and manufactured with latest techniques
using specially designed high-grade electronic components housed in pre
coated galvanized sheet. Shall be suitable for operation with luminaries
incorporating fluorescent and compact fluorescent lamps with dimming. The
ballast shall be suitable for 200 – 320 V AC for operation at ambient
temperature range of -15ºC to +50ºC. The ballast shall have low radiated
and conducted EMI / RFI. Refer BOQ
f) HIGH FREQUENCY ELECTRONIC BALLAST
High frequency electronic ballast shall be used with fluorescent / Compact
Fluorescent Lamps wherever specified in the schedule of quantities. High
frequency electronic ballast shall comply to the following:
 IEC 927, IEC 928 for ≤10% total harmonic distortion.
 EMI / RFI – Confirming to FCC / VDE Class A/B.
 Line Transient as per IEEE C62.41.
 Ballast Crest Factor C1.7%.
 No Stroboscopic Effect
 Constant Wattage / Light output between 240 V ± 10%.
 Circuit protection for surge current and inrush current.
 Short circuits, open lamp protection
 PF > 0.99 for fluorescent / T5 lamp and 0.95 for CFL.
 Deactivated lamp protection
 Suitable for use with single and twin lamps
 RFI < 30 MHz EN 55015
 Total Harmonic Distortion (THD) ≤10%
 Immunity to interference EN 61547
 Safety EN 60928 / IS 13021 (Part I)
 Performance EN 60929 / IS 13021 (Part II)
 Vibrations & Bump tests IEC 68-2-6 FC
 IEC 9001

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  Quality Standard ISO 9001
 Environmental Standard ISO 14001
 DC Operation EN 60924
 Emergency Lighting Operation VDE 0108
g) Starters
Starters, if required shall have bimetal electrodes and high mechanical
strength. Starters shall be replaceable without disturbing the reflector or
lamps and without the use of any tool. Starters shall have brass contacts and
radio interference capacitors.
The starters shall generally conform to the relevant standards specified in
Data Sheet.
h) Capacitors
Capacitors shall have a constant value of capacitance and shall be connected
across the supply of individual lamp circuits.
Capacitors shall be suitable for operation at supply voltage and shall
have a value of capacitance so as to correct the power factor of its
corresponding lamp circuit to the extent of 0.95 lag or better.
Capacitors shall be hermetically sealed preferably in a metal enclosure to
prevent seepage of impregnant and ingress of moisture.
i) Lamps 5 Star Rating
Lamps shall be capable of withstanding small vibrations and the connections
at lead in wires and filaments / electrodes shall not break under such
circumstances.
Lamps / tubes shall conform to relevant standards specified in Data Sheet.
j) Incandescent lamps
General lighting service (GLS) lamps shall be tungsten filament incandescent
type. The filament shall be coiled coil type rated for 230 / 250 volts, single
phase AC.
k) Halogen Lamps
Halogen lamps shall be tungsten halogen type suitable for fitment in flood
light Luminaries.
Lamps shall be rated 250 volts single-phase AC upto 1000 watts.
l) Fluorescent Lamps T5
Fluorescent T5 lamp lumaniaries shall be with TRULITE lamps, low wattage
consumption, high efficiency and longer burning life (about 10000 hours).
T5 Lamps shall be of warm white or cool day light type with triband
phosphor coated type, suitable for operation on 240V, single phase AC, in
standard lengths of 2 and 4 feet.
T5 Lamp colour shall be colour-82 for lift lobby and colour 86 for all other
areas.
m) Compact Fluorescent Lamps

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 These compact fluorescent lamps shall be of low pressure, low wattage type
with integral glow switch starter with separate/inbuilt ballast. Suitable for
operation on 240 V, single phase AC with burning life (about 10000 hours).
Lamps shall be rated 9 W, 11 W, 18W, for compact fluorescent (PL) type.
Lamp colour shall be colour-82 for lift lobby and colour 86 for all other
areas.
n) High Intensity Discharge Lamps
These lamps include the high-pressure sodium vapour lamp, metal halide
lamps.
High pressure sodium vapour lamps shall be with polycrystalline translucent,
coated discharge tube, coated shell, quick restrike time (of within 5 minutes)
and with burning life (about 10,000 hours) in standard ratings upto 400
watts.
Metal halide lamps shall be single ended or double ended as required. The
lamps shall be with quartz discharge tube and transparent / internal coated
shell, quick restrike time (of within 5 minutes) with burning life (upto 5000
hours) in standard ratings upto 2000 W. The colour rendering index of these
lamps shall be very high. These lamps shall be used only in enclosed
Luminariess (lamps without protective coating) and can be used only in open
Luminariess in lamps with Teflon or other coating to hold the shell in case of
non-passive end of lamp life.
7.10.15 Lighting System Equipment
Light Control Switches
a) Light control switches of ratings and types, i.e. decorative/industrial, shall be
supplied as indicated in project layout drawings/price schedule. The
switches shall be suitable for use on 240 V, 1 phase, 50 Hz supply.
b) Switches shall be of flush type for mounting behind an insulated plate or
incorporated with a switch or switch box/suitable enclosure. The switch
box/ enclosure may be recessed into or mounted on wall as per the
requirements of project layouts.
c) Size of enclosure boxes shall be chosen to accommodate the number
of switches to be installed at the particular location. The enclosures
shall be made of 1.2 mm thick CRCA sheet steel, stove
enameled/galvanized. The enclosure box shall be covered with
perspex/insulating cover. An enclosure intended for surface mounting
shall not have holes or gaps in its sides other than those expressly
provided for cable entry.
d) Switches shall conform to the relevant standards.
7.10.16 Receptacle Units
a) Receptacle units shall consist of socket outlet with associated switch, neon
indicating lamp and plug. The socket outlet and switch shall be flush mounted
within a stove enameled/ galvanized 1.2 mm thick CRCA sheet steel
enclosure with perspex/insulating cover. The box may be recessed into or
mounted on a wall as per requirements of project layouts.
b) Outdoor type receptacles shall be housed in a 2 mm thick CRCA sheet steel
epoxy painted enclosure with gasket, hinged door having locking

468
 arrangement. The enclosure shall be with rain canopy and removable gland
plate entry from bottom. Composite receptacle with switch modules housed in
a box shall be with degree of protection IP 66.
c) The receptacle units shall be suitable for 240 V, phase, 50Hz/415V,3 phase,
50 Hz supply as indicated in project layout drawings/price schedule.
d) Single-phase receptacles shall be associated with a switch/MCB of same
current rating and the receptacle shall become live only when the associated
switch/MCB is in “ON” position.
e) Three phase receptacles shall be associated with a TPN switch housed in the
same enclosure. The receptacle shall become live only when the associated
switch is in “ON” position and it shall not be possible to withdraw the plug
with the switch in “ON” position.
f) Plugs shall be provided with cord grips to prevent strain and damage to
conductors/wires at connection and entry points.
g) Types and current ratings of receptacle units shall be as indicated in the layout
drawing/price schedule and they shall conform to the applicable standards.
h) Whenever stated in layout drawing/price schedule, receptacle units may be
provided with MCBs instead of switch.

7.10.17 Lighting Wires

a) The wires for wiring in lighting system shall be 1100 V, 2Runs x 2.5 Sqmm
multi starnd PVC insulated copper wires with 1Runs x 1.5 Sqmm multi starnd
PVC insulated copper wire, The wires shall conform to the applicable
standards.
b) The minimum area of conductor for lighting fixtures shall be 2.5 sq.mm for
phase, neutral and earth, for 13A and 16A receptacles conductor size shall be
1100 V, 2Runs x 2.5 Sqmm multi starnd PVC insulated copper wires with
1Runs x 1.5 Sqmm multi starnd PVC insulated copper wire.
7.10.18 Lighting System Installation Work
Lighting Fixtures
a) The installation of lighting fixtures shall be based on the mounting
arrangement shown in the drawings enclosed with this specification. The unit
rates quoted for installation shall include all materials required to mount the
fixtures in the manner as shown in the drawings. Unit rate for installation of
lighting fixtures shall include cost of installation of control gearbox wherever
applicable.
b) Installation of receptacles and switches shall be carried out suitably as per the
lighting layout drawings. Switch shall be mounted in flush with the front
cover plate. Cost of supply and installation of necessary hardware shall be
included in the unit rates quoted for installation of receptacles/switches.
c) Lighting distribution boards shall be installed in the location indicated in the
layout drawings. Installation rates quoted for installation of lighting
distribution boards shall include supply and installation of wall brackets, etc.
7.10.19 External / Street Lighting Poles
a) Swaged Type Welded M.S. Tubular Poles

469
 4.5/6 Meter High Pole:
4.5 meter high (3.5 meter above and 1 meter below ground) shall be 60 mm
dia, 3.25 mm wall thickness MS tubular straight pole with a cast aluminium
adaptor for post top mounting. Pole shall be provided with 300 mm x 300
mm x 6 mm thick MS base plate. Foundation for the pole shall be of cement
concrete in 1:2:4 rates (1 part cement, 2 parts coarse sand and 4 parts stone
aggregate) IP-65 weather proof junction box shall also be provided to
accommodate 1 No. 3 phase and neutral terminal block and 1 No. 6 amps SP
MCB including 2.5 sq.mm PVC insulated copper conductor wires from the
terminal block to the fixture and 2 Nos. 32 mm dia GI sleeves of suitable
length shall be provided to the junction box.
b) Description of top bracket / arms
Single double decorative arm shall be provided on the pole (as asked for in
B.O.Q.), secured with the help of two nos. bolts outreach not less than 400
mm.
c) Service window
A service window of the size 150 mm x 100 mm shall be provided in the base
of the pole to allow access to electrical connections and terminations. It
shall be covered with MS plate and proper rubber gaskets shall be provided to
prevent any ingress of water etc.
d) Electrical connections
Four way connectors shall be provided along with Slide lock and 1 no. 6
amps Sp MCB including 2.5 sq mm PVC insulated copper conductor wires
from the terminal block to the fixture and 2 nos. 32 mm dia GI sleeves of
suitable length shall be provided up to the service window. An earth boss is
provided on the control plate along with connectors and interrupters.

7.11 EARTHING SYSTEM

7.11.1 A complete earthing system comprising earthing conductors, earth electrodes and
earth connections necessary for effective and permanent bonding to earth, all non-
current carrying metal work and for termination of the earthing conductors of all
electrical 415V switchboards, sub boards, distribution boards, etc., installed for the
Electricity Distribution System for this project shall be supplied, erected and
connected under this section of the specification and the associated drawings.
Earthing conductor shall be as follows
Conductors above ground level :Galvanised
and in cable trenches
Conductor buried in earth : GI
Electrodes : Galvanised Steel Pipe/GI plate /Cu plate
The earthing conductor sizes shall be as follows
Main earthing conductor: Refer Earthing layout
Equipment earthing lead

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 (a) 415 V Switchgear, Motor control centre and DG set : Refer
Earthing
layout

(b) Sub board, distribution boards, control panels, cable : Refer

trays, 3/1 phase receptacles Earthing
layout

(c) Lighting fixtures, single phase receptacles, power :

and lighting conduits, junction boxes, hand rails and Refer BOQ
exhaust fans

(d) Metallic non-current carrying structures : Refer

Earthing
layout

Earthing main conductor shall be provided around the buildings and interconnected
as shown in the drawings. The Main Conductor and tap off Conductors length buried
in soil shall be wrapped with bitumen tape for protection against corrosion.
Layout of earthing conductor inside the building shall be planned to provide earthing
connection to all equipment and structures by short and direct earth leads. Grid riser
in electrical shafts with tap-offs at each floor shall be provided.
The joints in the run of the earthing conductors shall be welded type. Connections
with equipment/ structure shall be of bolted type.
Cable trays, steel pipes / conduits, steel columns, etc., shall not be used as earth
continuity conductors.
Earth connections for all sections of installation shall be electrically and
mechanically sound.
All electrical equipment rated 240 Volts and above shall be earthed at two points
except the 3-phase / 1 phase receptacles, cable trays, lighting fixtures, conduits, hand
rails, metallic non-current carrying structures, which shall be earthed at one point.
All works performed under this section shall also comply with the requirements of
the local authority, IS 3043, 1987 and Earthing and Lightning Protection System-
Notes and Details.
All three phase equipment shall be double earthed.
7.11.2 Earthing Systems – Installation Notes
General
a) These notes shall be read and considered in conjunction with earthing drawings
and specification. In case of any conflict between these notes and drawings/
specification, the later shall prevail.
b) Earthing system layouts are diagrammatic only. Exact location of earthing
conductors, earth electrodes and test pits and connection may be changed to suit
the site conditions. Major modification should be referred to EMPLOYER for
clearance.

471
 c) Neutral point of the system of the different voltages, metallic enclosures and
frameworks associated with all current carrying equipment and extraneous
metal works associated with electric system shall be connected to a single
earthing system unless stipulated otherwise.
d) Earthing system installation shall be in strict accordance with the latest editions
of Indian Electricity Rules, Relevant Indian Standards and codes of practice
and Regulations existing in the locality where the system is installed.
7.11.3 Earthing Conductor Layout
a) Earthing conductor in outdoor area shall be buried at least 600mm below
finished floor level unless stated otherwise.
b) The spacing between adjacent rod / pipe electrode shall be twice the length of
the electrode, unless otherwise stated elsewhere. The spacing between adjacent
plate electrodes shall be 5000 mm minimum, unless otherwise stipulated
otherwise.
c) Earthing conductor around the building shall be buried in earth minimum
distance of 1500mm fro the outer boundary of the building.
d) Earthing conductors embedded in the concrete floor of the building shall have
at least 50mm concrete cover.
e) Earthing conductor along their run on the columns, walls, etc., shall be fixed by
suitable welding or cleating at intervals of 1000mm and 750mm respectively.
f) Tap connections from the floor earthing grid to the equipment / structure to be
earthed shall be terminated on the earthing terminals of the equipment, if the
equipment is available at the time of laying the grid. Otherwise “earth raiser “
or “earthing pads” shall be provided near the equipment foundation / pedestal
for future connection to the equipment earthing terminals.
g) In outdoor areas, buried conductors shall be brought 500mm above the ground
level for making tap connections to the equipment (above ground level)
h) Earthing conductors crossing the road shall be either installed in Hume pipes
are laid at greater depths to suit the site conditions.
i) Wherever earthing conductor cross underground service ducts, pipes, trenches,
tunnels, railway tracks etc., it shall be laid in Hume pipes and minimum
300mm below them. The earthing conductor shall be re-routed in case it fouls
with equipment foundation.
j) Wherever earthing conductor passes through walls, floors etc., galvanized
conduit / HDPE pipe sleeves shall be provided for the passage of the conductor.
Both ends of the sleeve shall be sealed to prevent the passage of water through
the sleeves. The seals in addition shall be fire proof if the specification / project
drawings call for the same.
k) Water stops shall be provided wherever earthing conductors enters the building
from outside, below the ground level.
l) Separate / isolated earthing system, if required, shall be provided for
instrumentation and control and control systems in the plant, including
dedicated earth pits.
7.11.4 Equipment And Structure Earthing

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 a) Earthing pads / terminals will be provided by the manufacturer of the
apparatus/ equipment at accessible positions. The connection between the
earthing pads/ terminals and earthing grids shall be made by short and direct
earthing leads free from kinks and splices.
b) Whether specifically shown in drawing or not, Steel / RCC columns, metallic
stairs, Hand rails etc., of the building housing electrical equipment shall be
connected to the nearest earthing grid conductor by at least one earthing lead.
Electrical continuity shall be assured by bonding the different sections of the
handrails and metallic stairs.
c) Electrical conduits, pipes and cable tray sections shall be bonded to ensure
electrical continuity and connected to earthing conductors at regular intervals.
Apart from intermediate connections end and beginning points shall also be
connected to earthing system. These details are covered separately under
cabling installation notes and details which shall apply.
d) Steel / RCC columns, metallic stairs, Hand rails, Cable trays, metallic conduits,
and pipes etc. shall not be used as earth continuity conductor.
e) A separate earthing conductor shall be provided for earthing lighting fixtures,
receptacles, switches, junction boxes, lighting conduits, poles etc. This
conductor in turn shall be connected to the main earth. These details are
covered separately under lighting installation notes and details, which shall
apply.
f) Whenever earthing conductor crosses or runs at less than 300mm distance
along metallic structures such as gas, water, steam pipes, conduits etc., and
steel reinforcement in concrete, it shall be bonded to the same. In case earthing
connection to pipe and conduit etc. at a distance higher than 300mm is required,
the same shall be marked on the drawing.
g) Miscellaneous items such as junction boxes, field switches, cable end boxes/
glands, fitting and fixture shall be earthed whether specifically show or not.
h) In general minimum two earth leads shall be used for earthing each equipment /
structure enclosing the power conductor operating at more than 250V and one
earth lead if the voltage level is 250V or less.
7.11.5 Jointing
a) Earthing connections to equipment earthing pads / terminals shall be bolted
type with GI bolts and nuts. Contact surfaces shall be free from scale, paint,
enamel, grease, rust or dirt. Two bolts (min.) shall be provided for making each
connection. Equipment bolted connections, after being checked and tested,
shall be painted with anti corrosive paint/ compound.
b) Connection between equipment earthing lead and main earthing conductors and
between main earthing conductors shall be welded / brazed type. For rust
protection the welds shall be treated with red lead and afterwards thickly coated
with bitumen compound to prevent corrosion.
c) Steel to copper, copper to copper connections should be brazed type. Welding
shall be adopted in case of steel. Welding to be done as per IS: 816.
d) The jointing whether welded, brazed of bolted shall be such that the resistance
of the joint is not more than the resistance of the equivalent length of the
conductor.

473
 e) Welding / brazing surfaces shall be cleaned and made free of all oxide films,
grease, oil or any foreign material. However, the joining surfaces should not be
made too smooth / highly polished, to prevent the joining material from flowing
away.
f) All brazing should be done by oxy- acetylene torch flame.
g) All welded connections shall be made by electric arc welding. All welded joints
shall be allowed to cool down gradually to atmospheric temperature before
putting any load on it. Artificial cooling shall not be allowed.
h) Bending of large diameter rod / thick conductors shall be done preferably by
gas heating.
i) All arc welding with large diameter conductor shall be done with low hydrogen
content electrodes.
j) For brazing alloys of silicon bronze/ phosphor or copper/ phosphor-silver-
copper shall be used.
7.11.6 Cable Earthing
Metallic sheaths, screens and armour of all multicore power/ control cables shall be
earthed at both equipment and source / switchgear end. Sheath and armour of single
core power cables shall be earthed at source /switchgear end only, unless otherwise
stated elsewhere.
7.11.7 Testing & Commissioning
After completion of erection works before equipment is charged, the following
minimum test shall be carried out. All test shall be recorded in the format as approved
by Architect/Project Manager besides the test mentioned below any other tests
specified by the local authority shall also be carried out. All tools and celebrated
instruments for testing, labour, materials and incidentals necessary, to conduct the
tests mentioned below shall be provided by the contractor at his own cost.
 Insulation resistance test of all the feeders by 500 V megger.
 Insulation resistance test of all LT cables with 500 V megger.
 Continuity test of all the cores and the armour cables.
 Sheathing continuity test.
 Testing of Wiring:
 All wiring systems shall be tested for continuity of circuits, short circuits,
and earthing after wiring is completed and before installation is energized.
 Testing of Earth Continuity Path:
 Insulation resistance Test
 Polarity test of switches
The above test reports shall be submitted by contractor to Engineer incharge.

474
7.12 LIGHTNING PROTECTION SYSTEM

7.12.1 The lightning protection air termination rods and/or horizontal air termination
conductors shall be fixed in such a way that they remain in their installed position
even during severe weather conditions. The necessary accessories such as cleats,
clamps, welding materials, bolts, nuts, shall be supplied by CONTRACTOR.
7.12.2 Air termination system shall be connected to earthing system below ground by down
conductors as shown in various project drawings. For this purpose separate treated
earth pit to be constructed. The down conductors shall follow a direct path to earth.
There shall not be any sharp bends, turns and kinks in the down conductors.
7.12.3 All joints in the down conductors shall be of welded/brazed type. All metallic
structures within 2 meters from down conductors shall be bonded to lightning
protection system.
7.12.4 The lightning protection system shall not be in direct contact with underground
metallic service ducts, cables, cable conduits and metal enclosures of electrical
equipment. However all metal projections, railings, vents, tanks etc. above the roof
shall be bonded together to form a part of roof grid.

7.13 DIESEL GENERATORS

7.13.1 Scope
The scope of this section consists of but not necessarily limited to the following in
accordance to Technical specification prescribed in tender:
a) The contractor shall supply, deliver to site, hoisting into position, install, test
and commission the Prime rated power generating set together with the
necessary controls and switchboards as specified and indicated in the Drawings.
Protection circuits, control wiring and interlock circuits not specified or
indicated in the Drawings, but deemed necessary for the safe operation of the
generating system shall be provided without any additional cost to complete the
system.
b) Provide manufacturer‟s factory representative‟s services, including
coordination, and start-up and testing supervision.
c) Testing (factory and field), start-up supervision, training and providing
necessary documentation and tools for operation.
d) Carry out performance test run at site with Load bank & Lube oil etc. arranged
by contractor.
7.13.2 Engine
Engine shall be multiple cylinder vertical, 4 stroke cycle, Prime rated, multi-
cylinder direct injection, compression ignition type operating at a speed of 1500 rpm
and shall be silent, vibration free while in operation and comply Center / State
Pollution Control Board , turbo charged after cooled as BS 5514/ISO 3046, 1500
RPM. Engine shall deliver not less than 400kW at site at 0.8 lagging power factor
and shall be suitable for sustaining of 10% overload for 1 hour in every 12 hours of
continuous operation at full load without damage. Engine shall be with the following
accessories:
a) Flywheel to suit flexible coupling.
475
b) Dry type air cleaner. Replaceable air cleaner elements with mechanical air
restriction gauge mounted on air cleaner. The filter shall be suitable for
operation under dusty conditions.
c) Exhaust Residential Type silencer with flexible connections and thermal
lagging.
d) Electronic Instrument panel comprising of:
 Power Command Control Module or equivalent ( for AMF System )
 Sensors
 Fuel control actuators
 Fuel shut-off valves
 Starting switch with key.
 Lube Pressure Gauge.
 Water temperature gauge.
 Battery charging ammeter & voltmeter.
e) Hour meter with RPM indicator.
f) Safety control for low lube, oil pressure, high water temperature and over
speed.
g) Lube oil cooler with all standard accessories.
h) Lube oil filter with replaceable type filter element as required.
i) Fuel oil system comprising.
 5 mm thick epoxy coated from inside MS Steel sheet daily service fuel
tank of 990 liters capacity including with glass type level indicator and
level controllers with potential free contacts.
 Fuel transfer pump including piping, fitting valves, strainers, filters
between day tank and engine.
 All instrumentation and control for day tank.
j) 2 No. 12 volt 25 plate lead acid batteries in series and parallel connection to
make 24 volts, 4 x 180 Ah batteries duly charged along with connecting leads
mounted on acid resistant frame work.
k) Anti vibration mounts as per manufacturer recommendation.
l) Electronic Governor with governing class „A‟ direct.
m) All moving parts to be mechanically guarded to minimize hazard to people
around.

Air intake and exhaust systems with filters, residential type silencers, ducts,
pipes, dampers, fittings, supports and other necessary accessories.
The exhaust gas expulsion system shall be in accordance with the drawings.
The exhaust piping shall be fitted with hospital type silencer in order to limit
the sound level. Expansion joints shall take care of thermal deformations. The
pressure drop in exhaust piping including silencer, bends, expansion joints etc.,
shall be compatible with exhaust gas leaving the engine. The exhaust piping
shall be duly covered throughout the length from engine outlet upto the outlet
point with mineral wool insulation and aluminium sheet cladding. The exhaust
piping shall be independent for each engine and shall be with minimum bends.
The bending radius of bends shall be not less than 3-internal diameters of

476
 chosen piping. A drain plug shall be fitted at the lowest point of piping for
condensate extraction. The exhaust pipe shall meet the following regulations of
pollution board as mentioned. Suitable supports shall be provided for proper
installation of exhaust pipes.
7.13.3 Limits Of Noise For Power Generating Sets Manufactured On Or After The 1st
January, 2005

7.13.3.3Applicability
These rules apply to Generator sets of rated output, installed on or after 1st January,
2005.

7.13.3.4Requirement of Certification

Every manufacturer or importer of Power Generating set must have valid certificates
of Type Approval and also valid certificates of conformity of production for each
year, for all the product models being manufactured or imported after 1st January,
2005 with the specified noise limit.

All Power Generator shall have a valid Type Approval certificate and conformity of
production certificate.

All Power Generator shall have conformance label meeting the requirements.

The conformance label shall contain the following information:

a) Name and address of the supplier (if the address is described in the Client‟s
manual, it may not be included in the label).
b) Statement “This product conforms to the Environment (Protection) Rules,
1986”
c) Noise limit viz. 75 dB(A) at 1 m.
d) Type approval certificate number.
e) Date of manufacturer of the product.
7.13.3.5Authorized agencies for certification
The following agencies are authorized to carry out such tests as they deem necessary
for giving certificates for Type Approval and Conformity of production testing of
Generator and to give such certificates :

a) Automotive Research Association of India, Pune.

b) National Physical Laboratory, New Delhi.
c) Naval Science & Technology Laboratory, Palghat
d) National Acrospace Laboratory, Bangalore
477
7.13.3.6Alternator

The alternator shall be brushless synchronous and suitable for 3 phase, 415 volts, 50
Hz., 0.8 p.f. and 1500 RPM.
The alternator shall be suitable for coupling directly to the engine described in clause
no. 1.3 It shall be drip proof screen protected as per IP23.
The alternator shall be continuously rated and shall have class “H” insulation
designed and built to withstand tropical conditions. It shall be confirming to IS:4722-
1992. The output of the alternator shall be 400 KW rated output at site conditions at
0.8 lagging power factor and shall be suitable for sustaining of 10% overload for 1
hour in any 12 hours period without damage.
Six nos. embedded Resistant Temperature Detector (RTDs) of plantinum, 100 ohms
resistance at 0 degree to measure the winding temperature and 2 Nos. BTDS to
measure bearing temperature shall be provided.
The leads of embedded RTDs shall be wired upto the terminal block in a separate
terminal box. Manufacturer shall indicate the setting values for each RTD/ BTD for
alarm and trip.
Greasing facility with grease nipples and grease relief device shall be provided.
All external nuts and bolts shall be of high tensile steel only.
Alternator shall be provided with anti-condensation space heater of adequate rating
suitable for 240 V, 50 Hz, 1 Phase AC supply and shall be wired upto a separate
terminal box.
The independent earth terminals on the frame complete with nuts, spring washer and
plain washer shall be provided.
Alternator shall be provided with suitable adaptor box for termination of cables.
Suitable arrangement shall be provided in the terminal box for formation of star point
for Alternator neutral earthing.
QDCT for synchronizing relay i.e. DG Set shall be capable of working in
synchronizing with other DG sets. The supply of any relays, contactors, CT‟s etc
required for this purpose shall be included.
Alternator shall be suitable for bearing the starting current of Transformer after
changeover.
7.13.3.7Excitation System
The alternator shall be provided with a complete rotating diode type brushless
excitation system, capable of supplying the excitation current of the generator under
all conditions of output from no load to full load and capable of maintaining voltage
of the generator constant at one particular value.
The exciter shall have class „H‟ insulation.
The excitation system shall comprise a shaft driven AC exciter with rotating
rectifiers. The rectifiers shall have in-built protection for over voltage.
The exciter shall be fast response type and shall be designed to have a low time
constant to minimize voltage transients under severe load changes. The excitation
voltage response ratio shall be at least 0.8.
The rated current of the main exciter shall be at least 10% more than the alternator
rated exciter current and it shall have 40% overload capability for 10 seconds.
478
 No external supply shall be required during starting and normal running of the
alternator.
7.13.3.8Automatic Voltage Regulator
An automatic high speed, dead band type voltage regulator shall be provided,
complete with all accessories. The regulation system shall be provided with
equipment for automatic and manual control.
The regulator shall regulate the output voltage from generator current and potential
signals. Series compounding transformer shall be provided to enable maintaining
adequate terminal voltage in the event of terminal faults. Alternatively excitation
system shall be provided with arrangement for field forcing. Contractor shall
coordinate suitability of protection relays for generator with the operational
characteristics of automatic voltage regulator, specially under short circuit conditions.
Voltage regulation and steady state modulation shall be within +/- 0.5% of the line
voltage.
Necessary equipment for field suppression and surge protection shall be provided as
integral part of alternator.
The response time of exciter and the generator shall be properly matched to avoid
hunting.
AVR system shall be provided with equipment for automatic and remote operation /
control.
AVR shall be suitable for 24 V supply.
Necessary equipment shall be furnished for the following.
 To prevent automatic rise of field voltage in case of failure of potential
supply.
7.13.3.9Acoustic Enclosure For Diesel Generator
Acoustic Enclosure for DG Set shall be as given below:
a) DG Set Capacity : 500kVA
b) Structure :
c) Panels :
d) Thickness of panels :
a. Outer sheet :
b. Inner Sheet :
c. Frame & Strainer :
e) Insulation : Mineral wool as per IS 8183 –
1993
f) Thickness : 100 mm thick (50 mm x 2 slabs)
g) Density : 64 Kg / m3
h) Air Circulation System
 Air Intake System : Axial flow fans of suitable
capacity for 500 KVA DG
Set offered.

479
  Air Exhaust System :
DG set offered
i) Finishing : Weather proof polyurethane
paint
(Shade approved by Project Manager / EMPLOYER.
Paint coating to be done after each
component goes through 7 tank process.)
j) Noise Level : 75 dBA at a distance of one
meter (as per CPCB)
k) Insertion Loss : 25 dBA
l) ΔT inside enclosure : should not exceed from 7 degree
C above
i. ambient temperature. 1 No. dial gauge temperature monitor shall also be
provided.
m) Location : Outdoor type
n) Lighting / Switch / : Proper arrangement shall be
provided inside
i. Wiring / Fans the acoustic enclosure
7.13.3.10 Microprocessor Based Auto Starting & Auto Mains Failure.
General
The auto synchronizing shall be provided as mentioned below and as per Schedule
of Quantity.
Protection Through Relays (For DG Set)
Following protection shall be provided through Numerical relay both for the stator
side and the rotor side if not provided in the controller:
a) Voltage restrained over current protection (50/51)
Relay shall not work when a over current fault occurs, due to higher current
levels. There shall be drop in terminal voltage for the same fault impedance,
the fault current shall reduce (with respect to terminal voltage) to a level below
the pick-up setting. Consequently, relay shall not pick-up. It shall be necessary
to have a relay whose pick-up setting shall be automatically reduce in
proportion to terminal voltage. Hence, the over current protection shall be
voltage restrained. Two levels over current protection shall be provided i.e.
low set and high set (for short circuit protection)
b) Thermal overload (49)
It monitors the thermal status of machine for current between 105% to the low
set O/C level (normally 150%).
c) Under / Over Voltage (27 / 59)
This will protect the machine from abnormal voltage levels, particularly during
synchronization and load throw off conditions.
d) Under / Over Frequency (81)

480
 This will protect the machine from abnormal frequency levels, particularly
during synchronization and load throw of conditions. This will also help in
load shedding scheme for the generator.
e) Breaker Failure Protection (52 BF)
This protection detects the failure of breaker to open after receipt of trip signal.
Another trip contact is generated under breaker fail conditions, with which
more drastic measures (like engine stoppage, etc.) can be taken.
7.13.3.11 Metering For Each DG
As mentioned in the Schedule of Quantities.
7.13.3.12 Annunciation
Annunciators with Hooter, Test, Accept and Reset P.B. and Annunciator.
16 Window Solid State Annunciator for each DG sets.

Channel Inscription
No.

01 Set fails to start (only alarm)

02 Over current (breaker trip)

03 Earth Fault (Breaker trip)

04 Excitation Failure (Engine should be stop with breaker trip)

05 Reverse Power (Breaker trip)

06 Over speed (Breaker will trip with engine stop command)

07 Low Lube Oil pressure (Breaker will trip with engine stop
command)

08 High Water Temperature (Breaker will trip with engine stop

command

09 Over / Under Voltage (Breaker trip)

7.13.3.13 PRE-COMMISSIONING CHECKS

All standards checks including the ones elaborated in the specifications to ensure
that the installation of the DG sets and associated systems has been carried out
satisfactorily shall be done on completion of installation. These shall include.
DG sets
a) Checking of piping interconnections
b) Checking electrical interconnections
c) Checking of insulation resistance
d) Checking of earthing
e) Checking of instruments and controls.
f) Checking of alignment
g) Checking of vibration transmission to building a structure.
481
 h) Checking of expansion joints.
Exhaust system
a) Checking of silencer operation
b) Checking of surface temperature of exhaust piping
Fuel system
a) Checking of automatic operation of fuel transfer pumps.
Upon completion of work the performance test shall demonstrate the
following among other things:
a) Equipment installed complies with specification in all respects and is of the
correct rating for the duty and site conditions.
b) All items operate efficiently and quietly to meet the specified requirements.
c) All circuits are correctly protected and protective devices are properly
coordinated.
d) All non current carrying metal parts are properly and safely grounded in
accordance with the specifications and appropriate codes of practice.
7.13.3.14 DG Sets – Test Procedure
The Tenderer shall enclose copies of type test certificates, wherever applicable, for
all the equipments and materials, quoted by him, along with the bid for Employer‟s
reference as per the relevant standards specified.
All the type tests, if not conducted earlier on similar type of equipments, covered
under the relevant standards, shall be conducted, wherever required, by the
suppliers for all the equipment and materials at manufacturer‟s works in the
presence of the Employer‟s representative. The test certificates of all the
equipments / materials shall be approved by the Employer‟s representative before
dispatch / acceptance of the equipment and materials. Routine tests for all
equipment will be witnessed by Engineer‟s Representative.
The following tests shall be done at works before dispatch,
Tests on alternator:

1 DC Resistance Measurement

1.1 Stator

1.2 Rotor

2 Insulation Resistance Measurement, before and after High Voltage

Test

2.1 Stator

2.2 Rotor

3 High Voltage Test

3.1 Stator

3.2 Rotor

482
 Functioning Tests on RTDs

DC Resistance Measurement

Characteristics

No Load Saturation Tests

1 Open Circuit Magnetization Characteristics

Voltage Measurement

Symmetry of generated voltage

Phase Sequence (Phase Rotation) check

Direction of Shaft Rotation check

Vibration Measurement

During No Load Mechanical Run

During No Load Open Circuit Magnetization Test

During Sustained 3Phase Short Circuit Magnetization Test

Over speed test (120% of rated speed for 2 minutes).

Regulation Tests

Voltage & current

Temperature Rise Test

No Load losses

Determination of efficiency

The following tests shall be carried out on Generator and Excitation system:

a) Insulation Resistance Tests

b) Winding Resistance Test

c) Phase sequence Test

d) Open and Short Circuit Characteristic Test

e) AVR response / Regulation Test.

f) Load test on Generator at both unity and 0.8 PF.

g) Excitation at full load and under specified variation of voltage and speed
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h) Measurement of voltage dips at the generator terminals while feeding the base
load 75% and on simultaneous starting of the largest motor.

i) EMPLOYER reserves the right to reject the equipment if the guaranteed

performance is not met with.

j) All instruments required for performance testing of the equipment covered in

this specification shall be provided by the TENDERER at no extra cost to the
Employer for entire duration of the performance test.

k) The TENDERER shall ensure that instruments and gauges to be used for
testing and inspection of critical parameters as identified in the specification
shall have valid calibration and the accuracy can be traceable to National
Standards.

l) In addition to the above guarantees, TENDERER shall also guarantee the

period for completing supply, erection, testing and commissioning as six (6)
months for DG set and accessories from the date of Letter of Award.

Load / Run Test at Site :

DG sets shall be tested at different loads at site after dispatch and installation at site.

In case at any point of the test a trip should occur the test shall be conducted again.
The necessary fuel oil, lube oil & consumables required for the test shall be
provided by contractor. No extra payment shall be made in this regard.

Copies of manufacturer‟s type test for the engine and the alternator of all ratings
shall be enclosed along with the dispatch of the DG sets as per relevant standard/
codes.

The contractor shall provide all necessary instruments and labour for testing. He
shall make adequate records of test procedures and readings and shall repeat any
tests requested by the Engineer Incharge. Test certificate duly signed by an
authorized person shall be submitted for scrutiny.

If it is proved that the installation or part thereof is not satisfactorily carried out then
the contractor shall be liable for the rectification and retesting of the same as called
for by the Engineer Incharge. All tests shall be carried out in the presence of Client
inspection team.

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These tests shall form part of this contract. Above tests shall be conducted for all
DG sets. The test results shall match with the technical requirements specified in the
technical data sheet.

The Engineer Incharge shall have the right to accept or reject the modules if it does
not meet the technical requirements.

The load test shall be conducted through resistive load bank at unity power factor.

Before conducting test, following shall be recorded on test report :

a) Engine serial No.

b) Engine model & make No.

c) Alternator serial No.

d) Engine & alternator rating

e) Date of testing

f) Rated speed, voltage & kW

Loads & duration: Engine shall be given a test run for atleast six hours with
alternator supplying full rated load at site and overload test to the extent of 10%
over the rated load shall be conducted immediately after the full load run test

No load : 5 mins

25% load – 30 mins

50% load – 30mins

75% Load – 30 mins

100% Load- 4.5 hrs

110% Load – 1 hr

The following parameters shall be noted on the test report

Description Time ( After start of Load test)

1 hr 2hrs 3hrs 4hrs 5hrs 6hrs 7hrs

a) Load in kW

b) Power factor

c) Voltage

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d) Current

e) Frequency

f) Alternator winding temperature

g) Alternator bearing temperature

h) Lube oil pressure

i) Lube oil temperature

j) Fuel consumption though flow meter

k) Cylinder head temperature

Impact test:

A block load of at least 50% shall be put on the DG from no load condition &
similarly when DG is 100% loaded, the load is removed & the parameters like
voltage, frequency & RPM is noted. The readings should be with in acceptable
limits.

Performance Tests

a) The following items of performance shall be guaranteed during site

performance tests in respect of the DG and the auxiliaries for the specified site
conditions:

b) Net electrical output (continuous)

c) Freedom from vibration and noise

d) Governor response, over-speed trip and speeder gear capability

e) Voltage regulator response

f) Excitation at full load and under specified variation of voltage and speed.

Start-up & testing at site

A equipment manufacturer's representative approved by the Project Manager /

Client shall be engaged to perform start-up and load test upon completion of
installation with the Project Manager / Client in attendance. A certified test record
shall be provided.

Tests shall include, but are not be limited to, the following:

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 a) Check fuel, lubricating oil, and antifreeze in liquid cooled models for
conformity to the manufacturer's recommendations under environmental
conditions present.

b) Test, prior to cranking of engine, for proper operation of accessories that

normally function while the set is in a standby mode.

c) Check, during start-up test mode, for exhaust gas leaks outside the building,
cooling air flow, movement during starting and stopping, vibration during
running, line-to-line voltage and phase rotation.

d) Test by means of simulated power outage, automatic start-up by remote-

automatic starting, transfer of load, and automatic shutdown. Engine generator
sets are to be synchronized and paralleled during tests. Monitor throughout the
test, engine temperature, oil pressure, battery charge level, generator voltage,
amperes, and frequency.

e) Tests shall demonstrate capability and compliance of system with operating

requirements. Where possible, correct malfunctioning units at site then retest
to demonstrate compliance; otherwise remove and replace with new units, and
proceed with retesting. Retesting to be at no cost to the Project Manager /
Client.

f) This section includes a very basic outline of the start-up sequence. The actual
sequence will be determined after the final design is completed. The
commissioning of the new generators will occur on weekends and after-hours
depending upon the scheduling requirements of the business.

7.13.3.15 Rejection

The Employer may reject any DG Sets during tests or service any of the following
conditions arise and the provision under the relevant clause of the general
conditions of contract shall immediately become applicable:

If it is not adhere to:-

a) GUARANTEED TECHNICAL PARTICULARS- Diesel Engine.

b) GUARANTEED TECHNICAL PARTICULARS- Generator

c) DG Sets fails on performance guarantee test at works.

d) DG Sets fails on performance guarantee test at site.

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 e) Proven performance in number of running hours for the type / Model of the
DG set

f) DG Sets is proved to have been manufactured not in accordance with the

agreed specification.

g) The Employer reserves the right to retain the rejected DG Sets and take it into
service until the tenderer replaces the defective DG Sets by a new acceptable
DG Sets at no extra cost. The tenderer shall repair or replace the DG Sets
within a reasonable period mutually agreed time to the satisfaction of the
Employer at no extra cost.

7.14 UPS SYSTEM

7.14.1 General Requirements

a) This specification covers the design, manufacture, testing, inspection at
Manufacturer‟s works, packing, forwarding and transport to site, unloading,
storing, installation, testing and commissioning of the UPS System as described
herein and shown on the drawings.
b) The UPS system shall consist of rectifier / battery charger, batteries, inverter,
static bypass transfer switch, synchronizing devices, protective devices, bypass
switch, filter circuits, and accessories as specified herein that will
automatically maintain the continuity of electrical power within specified
tolerance, without interruption, upon failure of the normal power supply.
c) The UPS system shall be manufactured in a modular way so as to enable the
power of the UPS system installed to be easily increased on the site by
paralleling more than one module to meet the new operating requirements and
the desired reliability. In this connection, transformation of unitary module into
a multi-module configuration shall be able to be carried out directly on site
without returning the equipment to the factory for modification and with a
minimum installation down time.
7.14.2 Quality Assurance
a) UPS ratings shall be the final effective values after the application of all
appropriate derating factors. These ratings shall be adjusted to suit local
conditions, viz. maximum ambient temperature, etc.. Derating factor due to the
non-linearity of the load to be connected to the UPS shall be taken into account.
b) The UPS shall be manufactured for continuous reliable operating such that the
“Mean-Time-Between-Failures” (MTBF) for individual modules of the UPS
viz. Rectifier / charger unit, inverter unit and static switch, etc.. shall be more
than 8760 hours.
c) To ensure minimum down time, the “Mean-Time-To-Repair (MTTR) of the
UPS shall not exceed one (1) hour. The MTTR shall be the time required to
diagnose the fault and restore the UPS to normal working condition, say by
means of module replacement at site, but excluding the traveling time.
d) All battery use shall be heavy duty type of life span of minimum 5 years.
e) The factory acceptance test shall include the following as a minimum:

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 Full load and half load efficiency test.
Frequency and voltage limits over the whole range of load;
Overload voltage and short circuit protection;
Voltage and frequency regulation during sudden load application.
Overload performance
Instrument calibration
Output tests while being supplied for batteries only; and
Battery charging and discharging test.
7.14.3 Submission
7.14.4 All technical submissions shall be approved by the Engineer in charge / Architect.
7.14.5 As a minimum requirement, the submission shall include the following:
Shop drawings showing the co-ordinated installation detail diagram
Client‟s works requirement;
Battery arrangement and manufacturer confirmation on „zero‟ gas emission by
battery to meet
Civil Defence requirement without separate room ventilation requirement.
7.14.6 System Operation
7.14.7 The UPS system shall generally include its basic and supporting equipment for the
monitoring, control and protection of the system, including input the output AC
filters, electronic AC line conditioner, AC and DC input and output circuit breakers,
converter, invertor, shielded isolation transformer, static by-pass switch and
mechanical bypass switch. The battery bank may be in a separate matching battery
enclosure (s).
7.14.8 Under normal conditions, power from the mains shall be supplied to the rectifier /
charger unit. The rectifier / charger unit shall convert the incoming AC power to DC
power which is fed into the inverter unit and battery unit. The inverter unit shall
convert the DC power to AC power, which is then supplied to the load through the
static transfer switch. As long as the operable inverter unit is supplied with DC, it
shall supply AC to the load.
7.14.9 Upon failure of the mains, the battery shall maintain the flow of DC to the inverter
unit and the inverter unit shall continue to supply the load without interruption. Upon
restoration of mains supply or when the generator supply is available, input power for
the inverter unit and for the recharging of the batteries shall automatically be supplied
from the rectifier / charger output without interruption. If the battery is exhausted
before the availability of the mains or generator supply, the UPS system shall shut
down automatically.
7.14.10 The static transfer switch shall normally connect the inverter output power to the
load. Should the inverter malfunction, the static switch shall automatically transfer
the load to the bypass source without interruption of the power supply to the load.
7.14.11 During periods when the UPS system is being serviced, the transfer switch shall be
operated to transfer the load to the bypass source.
7.14.12 In the case of the parallel redundant system, the total system load shall be
automatically distributed equally between the two UPS modules under normal
conditions. Malfunction in one of the UPS modules shall cause instantaneous
isolation of the faulty module from the system and the remaining healthy UPS
module shall take over the full critical load without interruption. If both UPS
modules fail, the critical load shall be transferred to the bypass source.
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7.14.13 Functional Requirements
a) Contractor shall furnish On-Line Uninterruptible Power Supply (UPS) system
of continuous duty of the ratings mentioned in Bill of Quantities. Each UPS
shall give regulated filtered & uninterruptible power supply as described in the
specifications.
b) Contractor shall note that the KVA ratings of the UPS systems shall be
guaranteed at 50 deg.C ambient temperature. In case contractor‟s standard
UPS KVA rating are based at a lower temperature, the contractor must
consider a derating factor of atleast 1.5% per deg.C for arriving at the
specified UPS capacity at 40 deg.C ambient temperature.
c) In case the calculated /specified UPS capacity is not the same as one of the
standard KVA ratings of the UPS manufacturer, the next higher standard
KVA rating shall be selected. UPS of non standard rating shall not be
acceptable.
d) UPS system supplied by the contractor shall be the latest state of the art
technology system fully digitalized using microprocessor controlled full wave
rectification and IGBT inverter.
e) Batteries shall be valve regulated lead acid specially meant for UPS
application.
f) Monitoring and control system shall also be state of the art technology LCD
touch panel type providing all relevant data described in this document.
g) The monitoring and control system shall be capable of RS232 input software
for connecting to customer‟s computer system for data display and monitoring.
h) All necessary components required for protecting UPS equipment and
connected inputs and outputs shall be furnished by the Contractor as an
integral part of the UPS system.
i) The control logic power supply shall have redundant power supply AC input
and the system battery as power sources.
j) The UPS systems shall include but not be limited to the following equipment
:
 UPS system including 100% capacity float-cum-boost charger with 100%
sealed valve regulated lead acid batteries with guaranteed battery life of 5
years.
 Suitable factory built battery cabinet for housing the batteries, including
terminal isolator / breaker and power disconnect device. The enclosure
shall conform to IP 20 as minimum.
 All cables, connectors, accessories like turning, cable trays, conduits etc.
required for connection between battery and the UPS unit.
7.14.14 Static Converter
General
The static converter (rectifier) shall be a multi-functional converter providing
functions of power conversion, battery charging and shall have the additional
functions of input power factor improvement and current harmonics reduction by
PWM / IGBT filter. The converter equipment shall include all necessary control
circuitry and device to conform requirements like voltage regulation, current limiting,
wave shaping, transient recovery, automatic synchronization etc. as given below.
The converter shall be a solid state static PWM converter utilizing Intelligent Power
Module (IPM) and shall include intelligent features like the drive circuitry, over

490
 current protection, over temperature protection, control power failure protection and
short circuit protection.
The IPM transistors shall enable high speed switching at 6 KHz thus reducing the
heat dissipation in the UPS and thereby providing high efficiency.
The PWM converter shall utilize the above and achieve unity power factor and
reduce input current harmonics as given earlier and thus improve the overall power
factor of the converter achieving input KVA savings.
During any step inverter load change (0-100%) the converter shall only supply 100%
current to the inverter. The battery shall not be cycled at any time during this step
load changes.
a) Input Current Limit
The converter logic shall provide input current limiting by limiting the DC output
current. Two (2) line-side current transformers shall be employed as a means of
sensing the current amplitude. The converter logic shall also be capable of providing
auxiliary current limited when the logic is signaled to do so via an external dry
contact closure (e.g. UPS fed from generator). The converter shall be capable of
supplying overload current in excess to the full load rating. It shall also have
sufficient capacity to provide power to a fully loaded inverter while simultaneously
recharging the system battery to 95% of full capacity within 10 times the discharge
time. The DC output current limit values shall be as follows:
Rectifier output current (maximum) 100% Note : 100% current shall be under the
battery recharging mode.
Battery Charge Current Limited
The converter logic shall provide current limiting function of battery charging to
prevent the battery from damage. The following battery current limit and protection
shall be provided.
 Battery charge current limit 10% of battery Ah rate.
 Over-current protection at 120% of above item.
b) Voltage Regulation
The rectifier / charger output voltage does not deviate by more than +/- 1% of the
nominal output voltage, due to the following conditions:
 From 0 to 100% loading.
 Rectifier input variations of voltage and frequency within the limitations set.
 Environmental condition variations within the limitations set.
7.14.15 Automatic Input Current Walk-in
The converter logic shall employ circuitry to allow a delayed and timed ramping of
input current. Subsequent to energizing the converter input, the ramping of current
shall be delayed by a maximum of 3 seconds. Upon starting the walk-in process, the
ramping of current is timed to assume the load gradually within 1 through 60 seconds
(every 1 second selectable).
7.14.16 Input Overload Protection
The A/C input fuses shall be provided at the converter input as a means of overload
protection.The AC maximum current shall be controlled by the Converter.
7.14.17 Equalizing Charge Timer
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 The UPS logic shall provide an electronic automatic equalize charge timer which
shall be selectable 24 hours for Lead Acid type or 8 hour for Alkaline type batteries.
The timer circuit, once activated shall provide a high rate equalizing charge voltage
to the system battery for the selected time. The circuit shall also be capable of
manual activation via the LCD touch panel mounted on the front door. The level of
equalizing voltage shall be equal to that stated by the battery manufacturer. Upon
completion of the timer count, the converter output voltage shall automatically return
to the specified float voltage.
7.14.18 Step Load Change
During any step inverter load change (0-100%), only the converter shall supply 100%
current to the inverter. The batteries SHALL NOT be cycled at any time during
these step load changes.
7.14.19 Input Voltage
The converter shall be fed from the Normal Power Supply source.
7.14.20 The converter shall meet the above specifications in addition to other requirements
stated in Data Sheet.
Static Inverter
General
The static inverter shall be of solid state type using proven Pulse Width Modulation
(PWM) technique. The inverter equipment shall include all necessary control
circuitry and devices to conform requirements like voltage regulation, current
limiting, wave shaping, transient recovery, automatic synchronization etc. as given
below.
The inverter shall utilize Insulated Gate Bipolar Transistors (IGBT) or Intelligent
Power Module (IPM) Transistors which shall provide intelligent features like the
drive circuitry, over-current protection, over temperature protection, control power
failure protection and short circuit protection.
The IGBT / IPM transistors shall enable high speed switching of 6 Khz thus reducing
the heat dissipation in the UPS and thereby providing high efficiency.
The UPS shall utilize both Voltage and Current feedback control circuits so that the
inverter shall act not only as a constant voltage source but also as a load required
current source. This shall enable the inverter to quickly adapt to the changing load
current value and wave shape.
7.14.21 Voltage Regulation
The inverter output voltage shall not deviate by more than +/- 1% RMS due to the
following steady state conditions:
a) From 0 to 100% loading
b) Inverter DC input voltage varies from maximum to minimum.
c) Environmental conditions variations within the limitations.
7.14.22 Frequency Control
The inverter output frequency shall be controlled by an oscillator internal to the UPS
module logic. It shall be capable of synchronizing to an external reference (e.g. the
bypass source or another UPS module) or operating asynchronously. The oscillator
shall maintain synchronization with the external reference within the limitations set
hereunder. The inverter shall operate on self run mode without synchronism if the
bypass frequency exceeds the set value. The oscillator, while running
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 asynchronously, shall maintain the frequency as 50 Hz + 0.01% (or + 0.005 Hz).
Automatic adjustment of phase relationship between inverter output and standby
bypass source shall be gradual at a controlled slew rate which shall be adjustable at
the rate of 0.5, 1.0, 2.0, 3.0 Hz / second. (default 2.0 Hz / second).
The inverter output frequency shall not vary during steady state or transient operation
due to the following conditions:
a) From 0 to 100% loading.
b) Inverter DC input varies from maximum to minimum.
c) Environmental condition variations within the limitations.
7.14.23 Output Voltage Harmonic Distortion
The inverter output shall limit the amount of harmonic content to the values as
indicated in data sheets. The use of excessive or additional filtering shall not be
required to limit the harmonic content thus maintaining a high level of efficiency,
reliability and original equipment footprint.
7.14.24 Output Overload Capability
The inverter output shall be capable of providing an overload current while
maintaining rated output voltage to the values as indicated in data sheets. An LED
indicator shall be located on the control panel to identify this condition. If the time
limit associated with the overload condition expires or the overload is in excess of the
set current amplitude, the load shall be transferred to the bypass source without
interruption.
7.14.25 Inverter Current Limit
The inverter output shall be limited to 150% of rated load current. The two sensing
locations shall operate separately and independently thus providing redundancy and,
in the event of a failure, preventing unnecessary damage to power transistor
components / fuses. Load current above 150% shall cause an immediate transfer of
the load to the bypass source for fault clearing.
7.14.26 Inverter Overload Protection
The AC output from the inverter shall utilize fuses for overload protection. The
inverter shall utilize a contactor to isolate the inverter output from the critical bus.
The inverter fuses shall be the fast acting semiconductor type.
The inverter output isolation contactor shall be located in the UPS module and shall
be controlled by the internal UPS module system logic.
The inverter shall meet the following specifications in addition to other requirements
stated in Data Sheet.
7.14.27 Built-in Isolation Transformer
This shall provide neutral separation which shall mean that output neutral will be
independent of incoming neutral, hence critical load shall be isolated from the
problems like incoming neutral open or, short or, variations in neutral to earth voltage
due to sudden loading in neighboring installation.
7.14.28 Reverse Phase Sequence Protection
In the event of Phase sequence reversal at the input, UPS system shall continue to
work on the main power supply, or UPS systems shall go into battery mode, and shall
not trip the UPS system.

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7.14.29 The overall efficiency of complete UPS system shall not be less than or equal to
94%
7.14.30 Bypass And Static Transfer Switch
A bypass circuit shall be provided as an alternate source of power other than the
inverter. A high speed switch and wrap-around contactor shall be used for the critical
load during automatic transfers to the bypass circuit. The static switch and wrap-
around contactor shall drive power from an upstream bypass feed circuit breaker
internal to the UPS module provided for overload protection. The wrap-around
contactor shall be electrically connected in parallel to the static switch and shall at the
same time as the static switch, energize and upon closure, maintain the bypass source.
The static switch shall only be utilized for the time needed to energize the wrap-
around contactor thus increasing reliability. The bypass circuit shall be capable of
supplying the UPS rated load current and also provide fault clearing current. The
UPS system logic shall employ sensing which shall cause the static switch to
energize within 150 microseconds thus providing an uninterrupted transfer to the
bypass source when any of the following limitations shall exceed:
a) Inverter output under voltage or over voltage.
b) Overload beyond the capability of the inverter
c) DC circuit under voltage or over voltage
d) Final end voltage of system battery is reached.
e) Bypass source present and available
f) System failure (eg. Logic fail, fuse blown, etc.)
7.14.31 Keeping the above requirements in view, the static switch shall have the following
minimum rating. Capacity continuous equal to 100% of continuous rating of
the inverter. Capacity overload equivalent to overload characteristics specified
for UPS.
Technical parameter are given in Technical Data sheet shall be followed.
7.14.32 Automatic Re-Transfer
In the event that the critical load must be transferred to the bypass source due to an
overload, the UPS system logic monitors the overload condition and, upon the
overload being cleared, perform an automatic re-transfer back to the inverter output.
The UPS system logic shall only allow a re-transfer to occur three times within a ten
minute period. Re-transfer shall be inhibited on the fourth transfer due to the
likelihood of a recurring problem at the UPS load distribution. The re-transfer a load
to the inverter shall also be inhibited due to the limitations set.
7.14.33 Manual Transfer
The UPS shall be capable of transferring the critical load to / from the bypass source
via LCD touch panel. When performing manual transfer to inverter or automatic re-
transfers, the UPS system logic shall force the inverter output voltage to match the
bypass input voltage and then parallel the inverter and bypass source providing a
make-before-break transition allowing a controlled walk-in of load current to the
inverter.
7.14.34 Maintenance Bypass Switch (MBS)
The UPS shall include as standard equipment, a zero energy maintenance bypass
switch. Full UPS wrap-around enables personnel to do work inside the UPS module
or maintenance bypass switchboard without danger from high voltage conditions.

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7.14.35 UPS Battery System
a) The UPS system shall, as an integral part, provide battery system for 15
minutes (Full Load) standby capacity.
b) The latest state of the art Valve Regulated Sealed Maintenance Free Lead Acid
Batteries shall be used with a 20 hours discharge rating.
c) The battery system shall be sized to provide 15 minutes back up time when the
UPS is supplying 100% rated load at 0.8 load power factor.
d) An ageing factor of 15% shall be applied to the capacity arrived at, to allow for
compensation against capacity loss during float operation.
e) The battery system design shall be provided with necessary devices to prevent
deep discharge beyond recommended limits to prevent the batteries discharging
beyond end cell voltage specified by the battery maker. The connections from
battery to battery shall be by using copper bus bar strips and the entire battery
system shall be used in IP20 steel cabinet enclosure and shall be similar to the
UPS enclosure.
f) All batteries shall be clearly identified and identification numbers marked on
the batteries and a schematic diagram along with the complete calculations,
including manufacturers supporting curves, shall be submitted with the tender.
7.14.36 Operation
a) Under normal operation, the UPS load will be fed from the Inverter with the
bypass switch inhibited. The Converter, apart from providing DC power to the
Inverter, also charges the battery under the float charge mode. The battery
charge system shall have float charge, equalizing charge and recovery charge
modes, to replenish the batteries self-discharging part while the battery
is fully charged, equalizing the battery cell voltage to a constant value forcibly
and recharging the battery system to the required values when the batteries
have been used, respectively.
b) The Inverter shall constantly monitor the AC source frequency and shall be in
synchronization with the AC input source till the frequency of the AC input
source is within synchronizing limit and if the frequency of the standby source
exceeds the synchronizing limit the Inverter will work on its own internal
oscillator maintaining an output frequency of 50 Hz +/- 0.01% under all
conditions of load. When the Inverter operates on its internal oscillator, it shall
continuously monitor the frequency of the input source and when the input
source frequency returns to within synchronization limit, the Inverter shall
automatically synchronize itself with the input A/C source frequency and use it
as a signal for Inverter output frequency control.
c) Battery Operation:
 When the A/C input voltage drops below specified limits or in case of a
power failure the Inverter continues to supply AC power of constant
voltage and constant frequency utilizing the battery system as a power
source until the input voltage returns to normal requirement. When the
power supply is resumed or the input voltage returns to limits, the
Converter shall automatically start and the load fed for normal operation
status.
 If the power failure continues beyond battery back up time or the battery
voltage drops to the final discharge voltage, the Inverter should
automatically stop and at the same time transferring the load to the bypass
circuit. On resumption of power supply, the Converter shall
automatically re-start the operations and charge the batteries whereas the
Inverter should inhibit automatic start and should be started manually.

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7.14.37 Bypass Operation:
When power is supplied from the Inverter in synchronization with the bypass, it shall
accomplish the following:
a) When the UPS output current reaches overload status it shall automatically
transfer the load to bypass circuit with no interruption and when the overload
status is cleared it automatically re-transfers the load to Inverter.
b) When the battery final discharge condition is reached, the load shall
automatically be transferred to the bypass circuit without interruption.
c) In case of failure of the UPS, the load shall be automatically transferred to the
bypass circuit with no interruption and when the failure is cleared, re-transfer
the load to the Inverter shall be done manually.
d) There should be provision made in the system to prevent, when necessary,
asynchronous transfer.
e) When the UPS goes on bypass mode in any of the conditions described above
and if at that time there is no bypass power supply available due to power
failure, the UPS shall remain in standby mode and as soon as the bypass power
supply is available will transfer the load to bypass.
f) A maintenance bypass transfer switch shall be provided with lock and key
arrangement and should be manually done by authorized personnel only.

7.14.38 Cabinet And Enclosures

a) The entire UPS system, including all components like inverter, static switch,
maintenance bypass, shall be housed in free-standing steel type factory-finished
enclosures complying with the protection standards of IP20. The enclosure
shall be open able using a special tool for internal access. The colour shall be
light grey.
b) Ventilation
Forced air-cooling shall be provided to allow components to operate within their
rated temperature specified. The cooling fans shall have thermal relays protection
using a latched cut fire re-setting, as a protection for the cooling fans.
Similarly, the backup battery system shall also be housed as described earlier in an
IP20 cabinet.
7.14.39 Control And Monitoring
a) The UPS shall utilize state of the art full DDC control software driven Control
and Monitoring System. For UPS less than 40kVA software of lower version
may be given.
b) It shall be provided with LED displays. The display system shall have, as a
minimum individual LEDs with different colours for the following:
 Load on Inverter
 Battery operation
 Load on Bypass
 UPS failure
 LCD failure
 Overload

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 c) The UPS logic should provide one set of normally open dry contact / relay
output to allow interfacing of UPS operating status to an external system and
should be capable of providing, as a minimum, 10 numbers status and, should
the UPS manufacturer‟s standard product does not provide such software, the
bidder must add additional equipment and cost for the same.
d) The UPS shall also have an RS232 port for interfacing to BAS system or
client's centralized computer network.
7.14.40 LCD touch panel
a) The UPS shall be provided with a operator friendly large scale LCD touch
panel.
b) The LCD touch panel shall also include graphic measurement display,
operational procedures of each activity, fault status display and also have
capability to record at least 50 faults.
c) The touch screen panel shall clearly define specified areas for operational
function, execution and message display.
d) It should be possible to operate the entire UPS system and its components and
obtain all measurements and data through the touch screen operation. The
measurement software should provide capability to measure phase voltage,
current in each phase, frequency, power factor, available battery time etc.
e) Under all operating conditions, the system software should have capability for
displaying fault alarm automatically. The tenderer should describe in detail the
faults that would be displayed under this mode.
7.14.41 UPS Testing
a) The Contractor shall perform the following tests, as a minimum, at site prior to
handing over, to confirm the functional and the performance specification of
the UPS as specified. All required test equipment like Digital Oscilloscope,
Voltage Regulator, Measurement Meters, required artificial load etc. shall be
the responsibility of the Contractor without any additional cost.
b) The Contractor shall demonstrate as a minimum the following features on site
by providing all required test equipment, such as power factor improvement,
input current THD, output voltage THD, output frequency and all other
performance monitoring requirements detailed before as required by the
Employer. Warrantee/ guarantee certification shall be submitted by Contractor.
c) Testing procedure is to be given by vendor and approved by Engineer incharge.

497
7.15 LIST OF ACT / BYE LAWS

The installations shall also be governed by the following Acts/Bye-laws/Codes as

amended upto date in addition to the codes specified in the tender:

a) ANSI/ASME/CENEN 81 CODE

b) National Building Code of India - 2005

c) Energy Conservation Builsding Codes 2007

d) Relevant Codes of Bureau of Indian Standards

e) NEC - NFPA 70, National Electric Code.

f) Relevant Codes of National Fire Codes 2008

NOTE:

 Equipment, accessories, component parts, raw materials and tests shall in

general conform to IS AND IEC.
 Latest edition of above mentioned codes / Bye Laws / Act shall be referred

498
7.16 SPARES AND MAINTENANCE TOOLS AND TACKLES

7.16.1 GENERAL
a) All spares and maintenance tools and tackles shall be designed to enable
maintenance to be carried out in the least time and at the least cost and support
resources without affecting the performance and safety aspects.

b) For all major equipment including pumps, fans, drives, heat exchangers
and large valves etc., appropriate structural steel members shall be provided for
mounting various handling devices which are necessary for the dismantling and
re-assembly of the equipment components during maintenance.

c) All the spares and maintenance tools and tackles supplied shall be new and
unused.

d) The VENDOR/CONTRACTOR shall guarantee that before going out

of production of spares and maintenance tools and tackles for the
equipment furnished, he shall give at least 12 months advance notice to the
EMPLOYER, so that the latter may order his requirement in one lot, if so
desired.

7.16.2 SPARES

The BIDDER shall include the following three (3) categories of spares in his scope of
supply.

a) START-UP AND COMMISSIONING SPARES

Spares required for start-up and commissioning of the equipment, plant

or system shall be indicated by the BIDDER in „Schedule of Start-up and
Commissioning Spares‟. Total value of such spares shall be included in the
quoted price for supply or erection of the equipment, plant or system. No
additional amount is payable to the CONTRACTOR for equipment, plant and
system for which erection and commissioning is in the CONTRACTOR‟s
scope..

b) All spares supplied shall be strictly inter-changeable with the parts for
which these are intended to be replacements. The spares shall be treated and
packed for long term storage under the climatic conditions prevailing at the site
e.g., small items shall be packed in sealed transparent plastic bags with
desiccator packs as necessary.

c) Each spare shall be clearly marked or labelled on the outside of its packing
with its description and purpose. When more than one spare is packed in a
single case, a general description of the contents shall be shown on the
outside of such case and a detailed list enclosed. All cases, containers
and other packages shall be suitably marked and numbered for the purposes of
identification.

499
7.17 Approved Make of Electrical Component/Equipment :
NOTE:
- All materials and products shall conform to the relevant standards and shall be of
approved make and design. A list of manufacturers/ vendors is given separately
herein below for guidance. The Engineer shall give the approval of a manufacturer/
vendor/ only after review of the sample/ specimen. In case the same is not available in
the market or in case of change in trade name, equivalent makes/ re-designated
manufacturer then an equivalent approved make shall be used with the approval of
Employer/ Engineer. The complete system and installation shall also be in conformity
with applicable Codes & Standards and Tender specifications.
- Only “First” class quality materials shall be used.
- Employer reserves the right to choose any of the approved make / vendors as per this
list.
- In case of products not indicated in this list, bis marked products shall be preferred.
- Specification of manufacturer‟s item shall be checked against tender item /
specifications before selecting any product or brand name. In case of any discrepancy,
tender item/ specifications shall prevail, and any such brand of item shall not be used
which is not conforming to tender specifications even if it is listed in this list.
- For use of material from a bis listed/ certified manufacturer, the contractor shall
furnish a copy of the BIS certificate to Employer before procuring the material.
- In case non-availability of any item/ material among approved manufacturers/ brands
at a particular site/ region, alternate manufacturers/ brands conforming to BIS/ BS etc.
shall be used subject to approval by Employer.
- In case of non-availability of any manufacturer among approved manufacturers at a
particular site/ region, alternate manufacturer‟s name shall be proposed along-with
required credentials for Employer‟s approval.
- In case of any item/ product neither covered in this list nor having A BIS
specifications, the contractor shall submit the proposed item/ product along-with
technical details/ specifications (as per bid), test certificates etc. And other credentials
of the manufacturer for Employers approval.

LIST OF APPROVED MAKES FOR PRODUCTS AND MATERIALS FOR

ELECTRICAL WORKS ARE INDICATED IN THE TABLE BELOW. HOWEVER,
ANY OTHER MAKE WHICH IS EQUIVALENT AND MEETING THE TENDER
SPECIFICATIONS ARE ALSO ACCEPTABLEWITH PRIOR APPROVAL OF
THE ENGINEER

Sl. No. Item Sub-Vendor’s Name

M/s Kirloskar Electric Co.Ltd.
M/s Crompton Greaves Ltd
1 DG Sets M/s Sudhir
M/s Bharat Bijlee
M/s Jyoti Limited

2 Control & Relay Panels M/s Areva

500
Sl. No. Item Sub-Vendor’s Name

M/s Siemens,
M/s ABB,
M/s Easun Reyrolle
M/s Schneider,
M/s Siemens,
3 HT switchgear M/s ABB,
M/s Areva
M/s L&T
M/s ABB
M/s Schneider
4 33/0.415kV Transformer
M/s Siemens
M/s Areva
M/s L&T
5 LT Sandwich Bus Duct M/s Godrej
M/s Schneider
M/s ABB
M/s Schneider Electric
M/s L&T
6 Protective Relays M/s GE
M/s Siemens
M/s Areva T&D
M/s Easun Reyrolle
M/s Pragati
M/s Jyoti
7 Current Transformers M/s Kappa
M/s Ind Coil

M/s Pragati
M/s Jyoti
8 Voltage Transformers
M/s Kappa
M/s Ind Coil
M/s Schneider Electric
M/s ABB
LT panels / LV Switchgears &
9 M/s. Siemens
Control gears
M/s GE
M/s L&T
M/s Philips
10 Lighting Fixtures and Accessories M/s Havells
M/s Crompton Greaves Limited

501
Sl. No. Item Sub-Vendor’s Name
M/s Wipro
M/s Bajaj Electricals

11 Emergency Lighting Fixtures Prolite or equivalent.

M/s Indo Kopp

M/s Legrand
LDB‟s, UPSDB‟s, MCB‟s,
12 M/s L&T
RCCB‟s
M/s Siemens
M/s Schneider
M/s Legrand
M/s Havells
13 Switches , Plugs, Sockets M/s Anchor
M/s Schneider
M/s ABB
M/s RPG
M/s KEI
M/s Gloster
M/s Universal
14 33kV Cables
M/s Nicco
M/s Polycab
M/s Finolex
M/s Havells
M/s Raychem
M/s Mahindra
15 33 / 11kV Cable termination
M/s REPL Engineering Ltd.
M/s 3M
M/s Kaycee
16 Selector switches
M/s Siemens
M/s Teknic
M/s Vaishno
17 LED Indicating Lamps
M/s Siemens
M/s Mathura Switchgears Pvt.Ltd
M/s Elmex
18 Terminal Block
M/s Connectwell
M/s Siemens
19 Control fuses
M/s GE
M/s Siemens
M/s L&T
20 Push Button
M/s Teknic,
M/s Mathura Switchgears Pvt.Ltd

502
Sl. No. Item Sub-Vendor’s Name
M/s Schneider
M/s AE
M/s Rishabh
21 Meters ( Ammeter, Voltmeter) M/s Meco
M/s Enercon
M/s IMP
M/s Indiana
M/s Patni
22 Cable Trays
M/s Reliance
M/s Sadhana
M/s Secure
Digital Multifunction Meters / M/s AE
23
Load Manager M/s Conzerv
M/s Enercon
M/s Universal Cables
M/s Polycab
24 LT Power Cables and Wires
M/s Havell‟s
M/s Finolex
M/s Dowells
25 LT Cable Lugs M/s Jainson
M/s Comet
M/s Braco
M/s Dowells
26 LT Cable Glands
M/s Hex
M/s Comet
M/s Jayshree
27 Lightning Arrestors M/s Elpro
M/s Oblum
M/s Amara Raja Batteries Ltd
M/s Exide Ltd
28 Batteries M/s Standard Batteries Ltd
M/s Sherene Electro Controls
M/s Amco Power Systems Ltd.
M/s HBL Nife
M/s Exide
29 Battery Charger M/s Automatic Electric Ltd.
M/s Mass.Tech Controls (P) Ltd.
M/s Chabbi Electricals Pvt Ltd
M/s Emerson
30 UPS
M/s DB Power Electronics

503
Sl. No. Item Sub-Vendor’s Name
M/s Hi Rel Electronics Pvt.Ltd
M/s Enercon Systems Pvt Ltd.
M/s C&S Protection & Control Ltd
M/s M.K. Engineers
M/s Godrej
31 Sandwich Busduct
M/s Schneider
M/s Legrand
M/s Power Gear Pvt. Ltd
M/s Legrand
Receptacles, switches & M/s MK
32
switch boxes M/s Crabtree
M/s Anchor Roma

33 M/s Bajaj
Lighting poles & High-Mast
M/s India Electric Poles Manucturing co.
M/s L& T
34 Contactors M/s Siemens
M/s Schneider-Telemecanique
M/s Bajaj
M/s Crompton
35 Ceiling fans M/s Usha
M/s Havells
M/s Orient
M/s Precision
36 PVC Conduits M/s VIP
M/s Avon
M/s Bajaj
37 Geysers M/s Ketco
M/s Recold
M/s Jainson
38 Exhaust fan M/s Crompton
M/s Havells
M/s OSRAM
M/s Philips
39 M/s Lumileds
LED
M/s Cree
M/s Nichia
M/s High Beam

504
TECHNICAL SPECIFICATION

IBMS AND IT WORKS

505
 IBMS & IT WORKS

8.1. BUILDING MANAGEMENT SYSTEM

8.1.1 Scope of work

8.1.1.1. This specification covers the requirement for design, engineering, manufacturing,
testing at Vendor‟s/Sub-Vendor‟s works, supply, packaging, forwarding, delivery at
site, unloading from carriers, storage at site, transport to site, loading, unloading,
installation, commissioning, carrying out performance guarantee / acceptance tests at
site of field instruments and Integrated Building Management System (IBMS). Scope
shall also include laying of cabling, necessary for installation of the system as
indicated in the specification and Bill of Quantities. Any openings/chasing in the
wall/ceiling required for the installation shall be made good in appropriate manner.
8.1.1.2. The BIDDER shall be a recognised leader in integration of IBMS system and capable
of supplying all necessary support services including hardware & software support,
configuration services, system installation, commissioning & maintenance support.
At least One- (1) no. of similar installations of the IBMS offered by the BIDDER
should be in continuous operation for a minimum period of one year.
8.1.1.3. Microprocessor based Integrated Building Management System (IBMS) with
functions distributed both geographically and functionally over the field controllers
shall be provided. IBMS shall comprise of Direct Digital Controllers (DDC), IBMS
server and IBMS operator station. The field instruments for HVAC system shall be
supplied, installed, monitored and controlled by the vendor.
8.1.1.4. HVAC system, the Fire Detection & Alarm System (FDAS), Access Control System
(ACS), Public Address System (PAS), CCTV system, DG sets, UPS, Energy meters
and all other utilities and systems as Fire Fighting System, Waste Water Treatment
plant shall be integrated with the IBMS system, monitored and controlled from Fire
Command Centre room located at Ground floor in the Administration block.
8.1.1.5. It is not the intent to specify completely herein all details of design and construction
of equipment or materials to be supplied or of services to be rendered. However, the
equipment, materials and services shall confirm in all respects to high standards of
engineering design, workmanship and be capable of performing in continuous
commercial operation in a manner acceptable to EMPLOYER who shall interpret the
meaning of drawings and specifications and shall have the power to reject any work
or material which in his judgement are not in full accordance therewith.
8.1.2 Codes and Standards
8.1.2.1. All equipment, systems and works covered under this specification shall comply with
all currently applicable statutes, regulations, standards and safety codes in the locality
where the equipment shall be installed.
8.1.2.2. In particular, the following standards are applicable

BIS : Bureau of Indian Standards

IEC : International Electrotechnical Commission
NEC : National Electric Code

506
 NEMA : National Electrical Manufacturer‟s Association
NBC: National Building Code
GRIHA : Green Rating for Integrated Habitat Assessment

8.1.2.3. Other national standards established to be equivalent or superior to the codes and
standards specified are also acceptable. The BIDDER shall furnish English translation
of all standards specified in this specification.
8.1.2.4. In the event of any conflict between the codes and standards referred to in the
specification and the requirements of this specification, the more stringent of these
requirements shall govern.
8.1.2.5. Unless indicated otherwise, all codes and standards referred to in this enquiry
specification shall be understood to be the latest version on the date of offer made by
the Bidder.
8.1.3 System Description
8.1.3.1. Integrated Building Management System (IBMS) shall be a microprocessor based
system with functions distributed both geographically and functionally over the field
controllers. IBMS shall be PC based system allowing full seamless integration of
following:
a) Energy Management.
b) Utility Services such as Water Treatment Plant, fire fighting system etc,
c) DDC/Converters for Software Integration
d) DDC‟s for Ventilation system
e) Fire Detection & Alarm System
f) Public Address System (PAS)
g) Access Control System (ACS)
h) DG set
i) CCTV system
j) Uninterruptible Power Supplies (UPSs)
All the above systems shall be integrated and monitored from the IBMS supervisory
workstations.
8.1.3.2. IBMS server will be placed in the server room located at Second floor in the
Administration block whereas workstations will be placed in the server room located
at Fire command centre, Ground floor in the Administration block.
8.1.3.3. Building Management System DDCs shall have facility to connect any standard
analog and digital Input / Outputs. Such as 4 to 20 mA, 0 to 10V, RTD and potential
free contacts. 20% of used channels installed / wired spares shall be provided while
sizing / selecting the DDCs. Energy Management functions such as duty cycling and
optimisation for controlling AC&V equipment shall be done in optimum manner.
8.1.3.4. The supply & installation of the DDCs is in the BIDDER‟s scope.
8.1.3.5. These DDCs shall be interfaced with the IBMS system over
MODBUS/LON/BACNET protocol and necessary hardware & software required in
IBMS for interface shall be provided by the bidder.

507
8.1.3.6. Also the communication cables for interfacing the DDCs to IBMS system shall be
provided by the bidder.
8.1.3.7. DDC shall have the following software features as minimum:
8.1.3.8. Energy management and Control Programs and Associated Data files shall be in non-
volatile EEPROM or power-backed RAM memory.
8.1.3.9. Each DDC shall contain up to 10 unique User modifiable time programs (TP). Each
TP shall consist of daily, weekly and annual programs plus a “TODAY” temporary
function.
DAILY Programs shall be definable for day types such as working day, half day,
holiday, weekend etc. Each daily program shall allow a list of time based Analog and
Digital commands to be used to user selected plant elements and points.
WEEKLY programs shall allow a user selected set of daily programs to be defined
for each day of the week (MONDAY through SUNDAY).
The ANNUAL program shall initially be an Automatic Compilation of 52 weekly
programs. Selecting a date of the ANNUAL Program shall allow modification of the
daily selection entered into the weekly program (such as changing JAN 26 from
working day to a Holiday).
8.1.3.10. Control Application Software for DDC shall be customised strictly to meet the
detailed requirements of the „Sequence of Operation” specified.
8.1.3.11. Initial Software shall be fully modifiable, and not restricted by Vendor‟s
Specific Configuration guidelines.
8.1.3.12. All DDC control software shall be designed via a graphic programming
facility.
8.1.3.13. IBMS Software shall include the following as minimum features:
a) Microsoft Windows-based operating system.
b) User Friendly Graphical interface providing a complete overview of all the
systems connected to the IBMS system. The graphics should be universally
understood.
c) Seamless Integration of the various systems provided in the plant
d) Measured values, operating status of drives displayed in real time
e) Facility to be provided to the operator to adjust Set point from screen.
f) Alarms displayed in real time, can be acknowledged & reset by operator from
screen
g) Time Scheduling – Time programmes shall ensure that HVAC & lighting are
switched off automatically at the end of the day & during holidays. Apart from a
7-day programme, exception programmes shall also be made as required
h) Historical Trending
i) Report Generation – Provides a snapshot of the systems at any specific time or
when specific events occurred.
j) Access of viewing to only authorised users by provision of password at various
levels.
k) Separate screens shall be developed for operation and monitoring of each system.
IBMS shall have capability to develop minimum 250 nos. of screens.
l) Facility shall be provided to monitor and control all the systems from any IBMS
operator station.

508
 m) Facility shall be provided to configure the software for any addition / deletion of
data from any IBMS operator station.
n) General arrangement drawings and architectural drawings for each building will
be made available to the CONTRACTOR by client. CONTRACTOR shall
develop complete 3D view of the buildings displaying location of each equipment
such as VRF‟s, cameras, access controlled doors, DG sets, stores, receptions etc.

8.1.4 System Specification

8.1.4.1. Air Conditioning

a) Variable Refrigerant Flow System (VRF)
Variable Refrigerant Flow System is monitored and controlled through soft
integration using RS 485/MODBUS communication. There shall be total five nos. of
VRF controllers for Training & Production Block, Admin Block and Dining Block.
 Time scheduled based operation
 Remote start/stop of each VRF unit through BMS.
 Monitor the status of each VRF unit through BMS and keep a log of the number
of hours run.
 Monitor the space temperature through BMS & give an alarm for a high/low
space temperature.
b) Scrubbers
There shall be total two nos. of scrubbers for Dining Block.
 Time scheduled based operation
 Start/stop of each fan through BMS.
 Monitor the status of each fan through BMS and keep a log of the number of
hours run.
8.1.4.2. Electrical System
a) Monitor one no. of Incoming medium voltage breaker (HT) status
b) Monitor two no. of outgoing low voltage breakers (LT) status. Keep provision for
monitoring of one no. of outgoing low voltage breakers (LT) status for future.
c) Tentatively 14 nos. of energy meters will be provided. However exact quantity
and location will be finalised during detail engineering.
The Supply and installation of above system is not in the bidder‟s scope.
These energy meters shall be interfaced with the IBMS system over
MODBUS/LON/BACNET protocol and necessary hardware & software required
in IBMS for interface shall be provided by the bidder.
Also the communication cables for interfacing the energy meters to IBMS system
shall be provided by the bidder.
This shall mainly focus on the integrated system as a whole for energy
conservation at gross level whereas network operation monitors each utility.
Electrical management shall be taken care i.e. the following parameters shall be
monitored that contributes to the cost of electrical energy.
 Power (KW)

509
  Power factor
 Energy (KW H)
 Demand
 Voltage
 Current
 Frequency
d) UPS will be provided at various locations depending upon the load requirement
for reliable backup supply. Two nos. of UPS shall be provided in Utility building
and two nos. of UPS shall be provided in Admin Building. The supply &
installation of UPSs is not in the BIDDER‟s scope. However these UPSs shall be
interfaced with the IBMS system over MODBUS/LON/BACNET protocol and
necessary hardware & software required in IBMS for interface shall be provided
by the bidder. Also the communication cables for interfacing the UPSs to IBMS
system shall be provided by the bidder.

8.1.4.3. Plumbing System

a) Monitor Hi/Lo level at One no. of Underground Domestic water tank
b) Monitor Hi/Lo level at One no. of Underground Flushing water tank
c) Monitor Hi/Lo level at 11 nos. of Overhead Domestic water tank
d) Monitor Hi/Lo level at 11 nos. of Overhead Flushing water tank
e) Monitor and control 11 nos. of solenoid valve based on Overhead Domestic water
tank level. If water is at high level setpoint, then valve shall closed, whereas if
water is at low level setpoint, then valve shall open.
f) Monitor and control 11 nos. of solenoid valve based on Overhead Flushing water
tank level. If water is at high level setpoint, then valve shall closed, whereas if
water is at low level setpoint, then valve shall open.
g) Monitor and control 2 Duty +1 Standby Domestic water pump based on Overhead
Domestic water tank level and solenoid valve command.
If all Domestic water tank level is at High setpoint and all solenoid valves are
command to close, then duty pumps shall command to stop.
If any of Domestic water tank level is at Low setpoint and any of solenoid valve is
command to open position, then duty pumps shall command to start.
h) Monitor and control 2 Duty +1 Standby Domestic water pump based on Overhead
Flushing water tank level and solenoid valve command.
If all Domestic water tank level is at High setpoint and all solenoid valves are
command to close, then duty pumps shall command to stop.
If any of Domestic water tank level is at Low setpoint and any of solenoid valve is
command to open position, then duty pumps shall command to start.

8.1.4.4. Fire Fighting System

a) Monitor one no. of Jockey pump status
b) Monitor one no. of Fire pump status
c) Monitor one no. of Diesel pump status

510
8.1.5 Direct Digital Control (DDC) Specification

Sr. Description Requirement

No.

A. GENERAL

1. Make Bidder to Specify

2. Model No Bidder to Specify

B. FEATURES

1. Type Microprocessor based fully programmable

with onboard real time clock

2. Local display with DDC Required

Not Required

3. Communication port Required

Not Required

4. Memory Non volatile memory

5. Network capability Required

Not Required

6. Management function as alarm Required

management, trending functions, Not Required
remote management, access protection
levels, time scheduling, data
processing etc

7. Communication between DDC to Peer to Peer communication

DDC

8. Network interface TCP/ IP

9. Inputs to DDC Digital inputs, Analog inputs

10. Outputs to DDC Digital outputs, Analog outputs and PFC to

drive auxiliary contactor

11. Numbers of I/O module Refer I/O table sheet

12. Facility to expand I/O channels in each Required

DDC Not Required

13. LED status for each I/O channel Required

Not Required

511
Sr. Description Requirement
No.

14. Power supply 230VAC from UPS

15. Data back-up in case of power failure Required

Not Required

16. Location of the DDC Please refer floor layout

17. Final paint colour (Exterior) RAL-7032

18. Final paint colour (Interior) Glossy white

19. Heat dissipation Bidder to Specify

20. Rating of relay contact Bidder to Specify

21. Analog input/ output Refer I/O table sheet

22. Digital input/ output Refer I/O table sheet

C. CONSTRUCTIONAL FEATURES

1. Sheet material CRCA-cold rolled prefabricated

2. Sheet material thickness 2mm

3. Gland plate thickness 3mm

4. Neoprene gaskets for doors / covers Required

Not Required

5. Cable entry Bottom

Top
Side

6. Lighting Fluorescent
(Fluorescent lamp of 40w shall be provided
from one end of the panel to the other end at
continuous length and shall be operated by
the door switches as well as by manual
switches.)

7. Name plates Required

Not Required

8. SS metal tags for all instruments (to be Required

tagged at all hardware inside panel) Not Required

512
Sr. Description Requirement
No.

9. Receptacle with fuse switch Bidder to Specify

(Note: Each section of the panels shall be
provided with one each 3 pin receptacles for
230V,1P,50C/S)

10. Adequate maintenance space Required

Not Required

11. Weight of the panel (total) Bidder to Specify

12. Panel shall be powder coated with Required

thickness of coating of min. 60 Not Required
microns

D. ENVIRONMENTAL CHARCTERISTICS

1. Ambient temperature range 0-50°C

2. Humidity range 95%

3. Weather protection class Min. IP52 for indoor panels

E. SPARE

1. Quantity Required

Input /Output table

EQUIPMENT QT AI AO DI DO
Y
SCRUBBER (DINING
BLOCK)
FAN ON/OFF STATUS 2 0 0 2 0 AT FAN MCC
PANEL
FAN START-STOP 2 0 0 0 2 AT FAN MCC
COMMAND PANEL
FAN TRIP ALARM 2 0 0 2 0 AT FAN MCC
PANEL
MANUAL/OFF/AUTO 2 0 0 2 0 MANUAL/OFF/AUT
SWITCH O SWITCH

PLUMBING SYSTEM
DOMESTIC WATER
WATER TANK HIGH 11 0 0 11 0 LEVEL SWITCH
LEVEL (OVERHEAD
TANK)
WATER TANK LOW 11 0 0 11 0 LEVEL SWITCH
LEVEL
513
(OVERHEAD TANK)
WATER TANK HIGH 1 0 0 1 0 LEVEL SWITCH
LEVEL (UNDERGROUND
TANK)
WATER TANK LOW 1 0 0 1 0 LEVEL SWITCH
LEVEL (UNDERGROUND
TANK)
VALVE ON/OFF 11 0 0 0 11 SOLENOID VALVE
COMMAND
VALVE ON/OFF STATUS 11 0 0 11 0 SOLENOID VALVE
PUMP ON/OFF STATUS 3 0 0 3 0 AT PUMP MCC
PANEL
PUMP START-STOP 3 0 0 0 3 AT PUMP MCC
COMMAND PANEL
PUMP TRIP ALARM 3 0 0 3 0 AT PUMP MCC
PANEL
MANUAL/OFF/AUTO 3 0 0 3 0 MANUAL/OFF/AUT
SWITCH O SWITCH

FLUSHING WATER
WATER TANK HIGH 11 0 0 11 0 LEVEL SWITCH
LEVEL (OVERHEAD
TANK)
WATER TANK LOW 11 0 0 11 0 LEVEL SWITCH
LEVEL (OVERHEAD
TANK)
WATER TANK HIGH 1 0 0 1 0 LEVEL SWITCH
LEVEL (UNDERGROUND
TANK)
WATER TANK LOW 1 0 0 1 0 LEVEL SWITCH
LEVEL (UNDERGROUND
TANK)
VALVE ON/OFF 11 0 0 0 11 SOLENOID VALVE
COMMAND
VALVE ON/OFF STATUS 11 0 0 11 0 SOLENOID VALVE
PUMP ON/OFF STATUS 3 0 0 3 0 AT PUMP MCC
PANEL
PUMP START-STOP 3 0 0 0 3 AT PUMP MCC
COMMAND PANEL
PUMP TRIP ALARM 3 0 0 3 0 AT PUMP MCC
PANEL
MANUAL/OFF/AUTO 3 0 0 3 0 MANUAL/OFF/AUT
SWITCH O SWITCH

SEWAGE TREATMENT 1 SOFT

PLANT (PLC) INTEGRATION

FIRE FIGHTING SYSTEM

JOCKEY PUMP STATUS 1 0 0 1 0 AT PUMP MCC
PANEL

514
MAIN FIRE PUMP STATUS 1 0 0 1 0 AT PUMP MCC
PANEL
DIESEL PUMP STATUS 1 0 0 1 0 AT PUMP MCC
PANEL

ELECTRICAL SYSTEM
INCOMING BREAKERS 1 0 0 2 0
STATUS (HT)
OUTGOING BREAKERS 3 0 0 6 0 2 + 1 (FUTURE)
STATUS (LT)
SMART METERS 14 0 0 0 0 SOFT
INTEGRATION
UPS 4 0 0 0 0 SOFT
INTEGRATION

VARIABLE 5 0 0 0 0 SOFT
REFRIGERANT FLOW INTEGRATION
(VRF) CONTROLLER

TOTAL 8 0 105 30

8.1.6 EQUIPMENT & SERVICES PROVIDED BY OTHERS

8.1.6.1. The following are the equipment and services that shall be provided to the
CONTRACTOR by others:
a) 240V AC, Feeder (UPS supply), for IBMS system at one location will be
provided by Employer. CONTRACTOR shall lay the Power cables from the
power supply distribution board to all the equipment supplied by
CONTRACTOR.
b) Uninterruptible Power supply (UPS).
c) Energy meters
d) DG set system
e) Utility Systems as Fire fighting systems, Waste water Plant
f) The cabling between utility systems & DDCs.
g) HVAC system (excluding field instruments and controls). Tapping for mounting
of instruments on HVAC equipment and ducts.
h) Electrical & Instrument earth Pits

8.1.7 Cables and Conduits:-

8.1.7.1. Cabling
a) Contractor shall supply & lay the following cables along with cable trays,
conduits and all other installation hardware and accessories

515
 b) Field instruments / modulating valves to IBMS Server/operator station through
DDC
c) VRF controllers to IBMS Server/operator station through DDC
d) AHU panels to IBMS Server/operator station through DDC
e) Ventilation panels to the IBMS Server/operator station through DDC
f) Power supply cabling from UPS system to the IBMS server/ operator station
g) Power supply cabling from UPS to DDCs.
8.1.7.2. Cabling (standard communication link) from IBMS to other control systems viz., Fire
detection and Alarm system, UPS(s), DG set panel, energy meters for
communication.
8.1.7.3. Cable specification for Instrument signals
a) For Digital signals 2 core x 1.5 sq.mm stranded annealed tinned copper
conductor, PVC insulated, overall shielding with aluminium tape, FRLS sheathed,
armoured cable. For Analog Signals 1P X 1.0 sq.mm, stranded annealed tinned
copper conductor, twisted pair, PVC insulated, overall shielding with aluminium
tape, FRLS sheathed, armoured cable.
b) All these cables shall be from field instruments to DDC Controllers and should be
laid in conduits.
c) The cables standards shall be conforming to IS 1554, BS:5308.
8.1.7.4. Conduits shall be UPVC as per IS: 9537 Part III and accessories i.e. junction boxes,
tees etc. as per IS: 3419. Flexible conduits shall be used at relevant places. The size of
the conduits shall be discussed during detailed engineering.
8.1.7.5. CONTRACTOR shall use UPVC conduits upto 2 runs of cables, above two runs
Galvanised Iron covered cable trays shall be used for laying of cables.

8.1.8 Installation Works

8.1.8.1. Bidder has to supply and lay the conduits with the structural steel supports and
required accessories. Supply and laying of all the cables of IBMS in the conduits shall
be done by the bidder.
8.1.8.2. Bidder shall be responsible for the following:
a) Exposed conduiting is planned overall, above false ceiling and laying of the
exposed conduits along with accessories for the systems shall be by the
CONTRACTOR.
b) Cabling and conduiting for the modules located on walls shall be concealed and
laying of concealed conduits shall be by the bidder. CONTRACTOR should carry
out necessary chasing in the brick/block walls, laying, fixing, re-doing the
plastering and making the surface neat.
c) CONTRACTOR to estimate the quantity of cables and conduits as per the system
layout enclosed.
d) CONTRACTOR to confirm the BOM based on the system being supplied. Any
changes suggested by the CONTRACTOR in the system layouts enclosed with
this tender should be supported by valid explanation. On mutual agreement the
BOM shall then be revised.
516
 e) UPS power shall be provided and further distribution at all elevations wherever
required shall be by the CONTRACTOR.
f) CONTRACTOR to indicate the feeder requirements at all elevations.
g) CONTRACTOR shall use UPVC conduits upto 2 runs of cables, above two cable
runs Galvanised Iron covered cable trays shall be used for laying of cables

8.1.9 POWER SUPPLY

8.1.9.1. IBMS shall be operated on 230V AC, single Phase, 50 Hz Supply. The entire IBMS
shall be on UPS with battery backup for 30 minutes. The feeder or socket points shall
be provided by others at the required points and the further cabling shall be by the
bidder. Bidder to indicate total UPS power/feeder requirement at each location.

8.1.10 Instrument Grounding

8.1.10.1. Separate instrument earth pits as required will be provided for grounding the
instrument cable shield. Instrument casing will be connected to electrical safety earth.
The ground resistance shall be less than / equal to 10 ohms.
8.1.10.2. Earthing:
a) Earthing for the entire system to be provided, shall be in CONTRACTOR‟s
scope. Separate electrical & instrumentation earth pits shall be provided by others.
Both electrical and instrument earth pit will be interconnected. Contractor shall
connect the safety ground bus & instrument ground bus for the systems supplied
by him to the respective earth pits.
b) Single point earthing configuration shall be followed for the cable shields i.e. all
signal and control cables shields shall be grounded at one end only to avoid
ground loop.

8.1.11 SUMMARY OF DATA TO BE FURNISHED ALONG WITH BID AND

AFTER ACCEPTANCE OF PURCHASE ORDER

8.1.11.1. The CONTRACTOR shall ensure the following documentation are prepared
and submitted to EMPLOYER for his review / record.

Sr.no. Drawings/Docs. To be To be
furnished furnished
along after award of
with bid contract
1 Data sheet & write-up shall be *
signed/filled and stamped by the
CONTRACTOR indicating
compliance to the specifications.

2 Technical Catalogues of each *

module/card/instrument of each
type required for the complete
IBMS system with software
features
517
Sr.no. Drawings/Docs. To be To be
furnished furnished
along after award of
with bid contract

3 Overall system Configuration *

diagram with add on interfacing

4 Dimensional drawings of Panels *

along with estimated BOQ for
each of the systems.

5 Testing & evaluation plan for the *

systems offered

6 Operation & maintainance *

manuals

7 Quality assurance documentation *

specific for the project.

8 Final built documentation folder *

with all items for future reference.

9 Unpriced purchase order copy for *

various bought out / sub
contracted equipment / services.

10 Internal wiring diagrams *

indicating termination details of
each component.

11 Bill of material indicating tag no, *

quantity, make / model no. of
various cards / modules for
IBMS system with software,
DDCs, field instruments, any
other item required for
completion of system.

12 Datasheets & catalogues for *

power & Communication, I & C
cable.

13 Cable schedules & *

interconnection cable schedules

14 Copies of the graphics / screens to *

be developed for operation and
monitoring of entire system.

15 List of signals connected to each *

518
 Sr.no. Drawings/Docs. To be To be
furnished furnished
along after award of
with bid contract
DDCs.

16 Power supply distribution scheme *

17 Estimated Power consumption *

location wise

* CONTRACTOR shall furnish the data.

8.1.12 TRAINING

8.1.12.1. 1 No. Contractor‟s engineer shall be made available for 1 month for assistance in
operation, maintenance, tuning & training of Employer‟s personnel at Site after
commissioning of IBMS & PA system with all necessary integration with other
systems.
8.1.12.2. Training shall be required on both hardware & application software development.
8.1.13 SITE ACCEPTANCE TEST
Full integrated site acceptance test shall be performed before hand over of total
system to the EMPLOYER. The test shall demonstrate the entire system
functionality to the complete satisfaction of client / Project Manager. The supplier
shall provide all personnel, test facilities, equipment and tools etc. for the same.
8.1.14 MAINTENANCE REQUIREMENTS
In order to carry out preventive maintenance, it should be possible to readily
disassemble, repair, and reassemble the equipment in the shortest period and to
attend to any defect by a minimum disassembly.
All system must have convenient maintenance characteristics including easy access
to replacement part which can be installed by personnel with minimum skill.
8.1.15 ANNUAL MAINTAINANCE CONTRACT
All components, system software, parts and assemblies supplied by the BIDDER
shall be guaranteed against defects in materials and workmanship for one year from
acceptance date.
Bidder to quote for Annual maintenance & operations Contract of IBMS system
after defects liability period, for a period of three years.

8.1.16 TESTING, INSTALLATION, COMMISSIONING AND ACCEPTANCE

8.1.16.1. Testing Requirements
8.1.16.2. Tests on cables
 Check details are in accordance with the specification.
 Check for physical damage.
 Megger test between each core and armour/sheath

519
  Continuity check including screen continuity
 Terminations of the cables at both ends.
8.1.16.3. Tests on electrical installation
 Checking of closing, tripping, supervision and interlocking of control devices.
 Checking operation of all system circuits.
8.1.16.4. Test on complete IBMS system.
 On completion, the functioning of IBMS systems with all other utilities systems
interfaced with it shall be tested to demonstrate its correct operation in accordance
with the Specification.
 For testing, the Contractor may provide temporary means to simulate operating
conditions, but the system shall not be finally accepted until correct operation has
been demonstrated to the satisfaction of the Employer.

8.1.17 COMMISSIONING
8.1.17.1. Commissioning Procedure shall be carried out in a methodical sequence as follows
 Start-up,
 Initial running,
 Operability adjustment,
 Stable operation
 Final adjustment
8.1.17.2. The Contractor shall check the operating conditions by constantly monitoring
operating data.
8.1.17.3. The CONTRACTOR shall specify for each discrete part of the system for which the
operational data has to be recorded and the manner in which the data is to be taken.
All the operating data shall be recorded, evaluated and submitted to the
EMPLOYER.

8.1.18 SPARES AND MAINTENANCE TOOLS AND TACKLES

8.1.18.1. GENERAL
a) All spares and maintenance tools and tackles shall be designed to enable
maintenance to be carried out in the least time and at the least cost and support
resources without affecting the performance and safety aspects.
b) All the spares and maintenance tools and tackles supplied shall be new and
unused.
c) The VENDOR/CONTRACTOR shall guarantee that before going out of
production of spares and maintenance tools and tackles for the equipment
furnished, he shall give at least 12 months advance notice to the EMPLOYER,
so that the latter may order his requirement in one lot, if so desired.
8.1.18.2. SPARES
The BIDDER shall include the following three (3) categories of spares in his scope
of supply.
520
 a) All spares supplied shall be strictly inter-changeable with the parts for which
these are intended to be replacements. The spares shall be treated and packed for
long term storage under the climatic conditions prevailing at the site e.g., small
items shall be packed in sealed transparent plastic bags with desiccator packs as
necessary.
b) Each spare shall be clearly marked or labelled on the outside of its packing with
its description and purpose. When more than one spare is packed in a single case,
a general description of the contents shall be shown on the outside of such case
and a detailed list enclosed. All cases, containers and other packages shall be
suitably marked and numbered for the purposes of identification.

8.2. FIRE DETECTION AND ALARM SYSTEM

8.2.1 Scope of work

8.2.1.1. This specification covers specific requirements of design, preparation of detailed
drawings, manufacture, testing at manufacturer‟s works, supply, inspection at
Bidder‟s/Sub-Bidder‟s works, packing, forwarding, transportation, transit insurance,
delivery at site, installation, testing at site and commissioning of the Fire Detection
and Alarm System (FDAS). Scope shall also include laying of cabling, necessary for
installation of the system as indicated in the specification and Bill of Quantities. Any
openings/chasing in the wall/ceiling required for the installation shall be made good
in appropriate manner.
8.2.1.2. FDAS shall be proposed for Training and Production block, Administration block,
Dining Block and Utility block.
8.2.1.3. Main Fire Alarm Control Panel (FACP) shall be placed in the Fire command centre
room at Ground Floor in the Administration block. One no. of FACP is placed at
Reception area of Training and Production Block and one no. of FACP is placed at
Ground Floor of Dining Block. Additionally a repeater fire alarm panel shall be
provided at the Main security gate of entire complex.
8.2.1.4. The FDAS system shall form a network to monitor the status of entire system in the
Fire command centre room at Ground Floor in the Administration block. Graphical
presentation of FDAS system shall be viewed at IBMS monitor.
8.2.1.5. It is not the intent to specify completely herein all details of design and construction
of equipment or materials to be supplied or of services to be rendered. However, the
equipment, materials and services shall conform in all respects to high standards of
engineering design, workmanship and be capable of performing in continuous
commercial operation in a manner acceptable to EMPLOYER who will interpret the
meaning of drawings and specifications and shall have the power to reject any work
or material which in his judgement are not in full accordance therewith.
8.2.2 Codes and Standards
The equipment and installation shall comply with the current and latest edition
of the following codes and listing:
8.2.2.1. Codes
a. National Fire Protection Association (NFPA):
 NFPA 72 National Fire Alarm Code
 NFPA 76 Telecommunication Facilities
 NFPA 101 Life Safety Code

521
  NFPA 90A Air conditioning & ventilation system
8.2.2.2. Listings
a. Underwriters Laboratories Inc. (UL) - USA:
 UL 268 Smoke Detectors for Fire Protective Signalling Systems
 UL 864 Control Units for Fire Protective Signalling Systems 9th
Edition
 UL 268 A Smoke Detectors for Duct Applications
 UL 521 Heat Detectors for Fire Protective Signalling Systems
 UL 464 Audible Signalling Appliances
 UL 38 Manually Actuated Signalling Boxes
 UL 346 Water flow Indicators for Fire Protective Signalling
Systems
 UL 1971 Visual Notification Appliances
 UL 228 Door Holders
 UL 1481 Power Supply for fire protective signalling system.
 UL 1711 Amplifiers for Fire Protective Signalling Systems.
 UL 1635 Digital Alarm Communicator System Units

ADDENDUMS thereafter in UL Code for Fire Detection (2007).

 UL 9th Schedule Certification
 International Standards Organization (ISO)
 ISO-9000
 ISO-9001
 European Union (EU)
 EMC Directive 89/336/ EEC
 Electromagnetic Compatibility Requirements
 Factory Mutual (FM) Approval

b. Local Codes
 NATIONAL BUILDING CODES
 IS-2189

c. European Standards
 EN54

8.2.3 System Description

8.2.3.1. The Fire Detection and Alarm system comprises of the following.
a. Multi-Criteria Detector
b. Smoke Detector
c. Heat detectors
d. Sounders cum Strobe
e. Manual call points
f. Response Indicator
g. Fault Isolator Module
h. Control Module
i. Monitor Module
j. 3 Nos. FDAS panel
k. 1 No. Repeater panel to be located in Security gate.
l. Cabling for FDAS
522
8.2.3.2. Please refer FDAS layout drawings for location of fire detectors, manual call points
and sounders. However it is the contractor‟s responsibility to evaluate the quantity &
type of fire detectors, manual call points and sounders as per the specified Codes &
standard.
8.2.4 Specifications
8.2.4.1. Fire Alarm Control Panel Specification

Sr. Description Requirement

No.

A. GENERAL

1. Type Microprocessor Based

2. Panel Location 1. Fire Command Centre, Ground Floor, Administration

Building
2. Reception Area, Ground Floor, Training & Production
Building
3. Ground Floor, Canteen Building

B. DISPLAY ON PANEL

1. Type Backlit LCD

2. Lines X LCD, Alphanumeric, display of addresses, Minimum 80/160

Characters characters

3. Parameters to be 1. Addresses
displayed
2. Fire situation

3. Fire progression

4. Evacuation details

5. Fault Conditions

4. LED indication 1. Power ON

for:
2. Fire alarm

3. Maintenance

4. Fault conditions

5. Programming 1. Keypad
facility
2. Touch screen

6. Password and Required

selectable access
level

523
Sr. Description Requirement
No.

7. Switches / Push Acknowledge, Silence and System reset

buttons

C. PANEL CHARACTERISTICS

1. Audio indication Required

on alarm

2. Fault isolation Required

capability

3. Alarm Required
verification
capability

4. Sensitivity Required
adjustment

5. Sensor self test Required

capability

6. Zone wise Required

grouping

7. Response time 10 Seconds (Max) for full loaded panel.

Note: The maximum allowable response delay from activation of
an initiating device to receipt and display by the receiver/ fire
alarm control unit shall be 10 seconds.

8. Fault tolerant Required

wiring capability

9. No. of loops / 2 Nos. Loops (Working + Spares for future)

Panel Spare cards shall be mounted inside the panel along with working
cards

10. Expansion Required

capability

11. Minimum Each loop shall be loaded upto 80% of its capacity. However 20%
addressable spare shall be considered in each loop for future additional
points per loop detectors / devices.

12. SLC loop Style 6, class „A‟ as per NFPA 72

cabling type

13. Loop length Upto 1.5 Km

supported

524
Sr. Description Requirement
No.

14. Memory NON-Volatile, NON-Erasable and NON-Rewritable

15. Networking 1. Panel to Panel

2. Panel to Repeater Panel

3. Panel to Graphical User Interface (GUI)

4. PC to printer

16. Networking RS-485 or Ethernet

protocol

17. Degraded mode Required

operation

18. Redundancy for Not Required

controller

19. Event recorder Required

D. POWER

1. Supply voltage 230V - 10%, 50Hz, UPS mains supply

to panel

2. Operating Bidder to specify

current

3. Output voltage Bidder to specify

4. Wattage Bidder to specify

consumption

5. Types of Sealed Maintenance Free (SMF)

batteries Note:- Battery shall be supplied having manufacturing date nearer
to the supply date of battery.

6. Battery capacity As per NFPA 72

Note:- Battery shall have sufficient capacity to power the fire
alarm system under non alarm condition for a minimum of 24
hours and shall be capable of operating the system during
emergency condition for a period of 15 minutes at maximum
connected load, upon normal AC power failure. The full load shall
consist of simultaneous operation of all sounders, operation of
detectors at least 25% of zones (with minimum of two zones) and
the operation of fault indicators.

7. Terminal blocks Required

for mains supply
525
Sr. Description Requirement
No.

8. Isolated earth bar Required

for shield
grounding

E. MECHANICAL CHARACTERISTICS

1. Dimensions Bidder to specify

2. Weight Bidder to specify

3. Mounting Wall
Surface
Flush
Semi Flush

4. Sheet thickness 1.6mm

5. Colour shade Bidder to specify

6. Housing material CRCA

F. ENVIRONMENTAL CHARCTERISTICS

1. Ambient 0-50°C
temperature
range

2. Humidity range 95%

3. Weather Min. IP 20 for indoor panels located in air condition space

protection class

G. APPROVAL / CERTIFICATE

1. UL/ FM/ VDS/ Required

EN-54/ LPCB

2. Make Bidder to specify

3. Model No Bidder to specify

8.2.4.2. Fire Alarm Repeater Panel Specification

Sr. Description Requirement

No.

A. GENERAL

526
Sr. Description Requirement
No.

1. Make Bidder to specify

2. Model No Bidder to specify

B. DISPLAY ON PANEL

1. Type Backlit LCD

2. Lines X Alpha-numeric, LCD display with minimum 80 character, with

Characters LED indications

3. Parameters to be 1. Addresses
displayed
2. Fire situation

3. Fire progression

4. Evacuation details

5. Fault Conditions

4. LED indication 1. Power ON

for:
2. Fire alarm

3. Maintenance

4. Fault conditions

5. Programming 1. Keypad
facility
2. Touch screen

6. Password and Required

selectable access
level

7. Switches / Push Acknowledge, Silence and System reset

buttons

C. PANEL CHARACTERISTICS

1. Audio indication Required

on alarm

2. Alarm Required
verification
capability

3. Response time 10 Seconds (Max) for full loaded panel.

Note: The maximum allowable response delay from activation of
527
Sr. Description Requirement
No.
an initiating device to receipt and display by the receiver/ fire
alarm control unit shall be 10 seconds.

4. Memory NON-Volatile, NON-Erasable and NON-Rewritable

5. Networking Required

6. Networking RS-485 or Ethernet

protocol

D. POWER

1. Supply voltage to 230V - 10%, 50Hz, UPS mains supply

panel

2. Operating current Bidder to specify

3. Output voltage Bidder to specify

4. Wattage Bidder to specify

consumption

5. Types of Sealed Maintenance Free (SMF)

batteries Note:- Battery shall be supplied having manufacturing date nearer
to the supply date of battery.

6. Battery capacity As per NFPA 72

Note:- Battery shall have sufficient capacity to power the fire
alarm system under non alarm condition for a minimum of 24
hours and shall be capable of operating the system during
emergency condition for a period of 15 minutes at maximum
connected load, upon normal AC power failure. The full load shall
consist of simultaneous operation of all sounders, operation of
detectors at least 25% of zones (with minimum of two zones) and
the operation of fault indicators.

7. Terminal blocks Required

for mains supply

8. Isolated earth bar Required

for shield
grounding

E. MECHANICAL CHARACTERISTICS

1. Dimensions Bidder to specify

2. Weight Bidder to specify

528
Sr. Description Requirement
No.

3. Mounting Wall
Surface
Flush
Semi Flush

4. Sheet thickness 1.6mm

5. Colour shade Bidder to specify

6. Housing material CRCA

F. ENVIRONMENTAL CHARCTERISTICS

1. Ambient 0-50°C
temperature
range

2. Humidity range 95%

3. Weather Min. IP20 for indoor panels located in air condition space
protection class

G. APPROVAL / CERTIFICATE

1. UL/ FM/ VDS/ Required

EN-54/ LPCB

2. Make Bidder to specify

3. Model No Bidder to specify

8.2.4.3. Fire Alarm Control Relay Module Specification

Sr. Description Requirement

No.

A. GENERAL

1. Make Bidder to specify

2. Model No Bidder to specify

B. MODULE CHARACTERISTICS

1. Application Activating conventional Sounder cum

Strobe
To operate the dry contact for third party

529
Sr. Description Requirement
No.
application

2. Type Microprocessor Based

3. Addressable Required

4. Number of relay 1 No.

outputs in each 2 No.
module
4 No.
8 No.

5. Type of relay contact Bidder to specify

/ contact rating

6. Cabling Two wire signal line circuit style 6, class „A‟ as per NFPA-72

7. Built-in isolator Not Required

Note: In case of built-in isolator requirement the approval/

certification shall be VDS/ EN-54/ LPCB else UL/ FM
approval/ certification shall be applicable.

C. POWER

1. Operating voltage 24 VDC (Loop powered)

2. Operating current Bidder to specify

3. Wattage Bidder to specify

consumption

D. MECHANICAL CHARACTERISTICS

1. Dimensions Bidder to specify

2. Weight Bidder to specify

3. Material of Non Corrosive

Enclosure

E. ENVIRONMENTAL CHARCTERISTICS

1. Ambient temperature 0-50°C

range

2. Humidity range 95%

3. Enclosure weather For Indoor IP54

protection class For Outdoor IP65

530
Sr. Description Requirement
No.

4. Explosion proof
enclosure

5. Hazardous area
classification

F. APPROVAL / CERTIFICATE

1. UL/ FM/ VDS/ EN- Required

54/ LPCB

8.2.4.4. Fire Alarm Heat Detector Specification

Sr. Description Requirement

No.

A. GENERAL

1. Make Bidder to specify

2. Model No Bidder to specify

B. DETECTOR CHARACTERISTICS

1. Type Microprocessor Based-Combination of

Fixed Temperature and Rate of Rise of
Temperature
Microprocessor Based-Fixed Temperature
Microprocessor Based-Rate of Rise of
Temperature

2. Addressable Required

3. LED Status Multi colored, multi status LED

4. Response Time The maximum allowable response delay from activation of

an initiating device to receipt and display by the receiver/
fire alarm control unit shall be 10 seconds

5. Terminals for connecting Required

response indicator (Bidder to consider fault isolator module after every 10
Nos. detectors/ devices for UL/ FM offered panel or
inbuilt fault isolator base shall be provided for EN-54/
VDS/ LPCB offered panel. Bidder to provide necessary
provision to connect the response indicator for any type of
531
Sr. Description Requirement
No.
fire detectors.)

6. Sensor Coverage Bidder to specify

7. Alarm set point for Heat For fixed temperature type - 55OC
For rate of rise of temp. type 7OC / Minutes

8. Sensitivity Adjustment Required

9. Immune to false alarm Required

10. Cabling Two wire signal line circuit style 6, class „A‟ as per
NFPA-72

11. Built-in isolator Not Required

Note: In case of built-in isolator requirement the approval/

certification shall be VDS/ EN-54/ LPCB else UL/ FM
approval/ certification shall be applicable.

C. POWER

1. Operating voltage 24 VDC (Loop powered)

2. Operating current Bidder to specify

3. Wattage consumption Bidder to specify

D. MECHANICAL CHARACTERISTICS

1. Dimensions Bidder to specify

2. Weight Bidder to specify

3. Material of Enclosure Non Corrosive

4. Colour Bidder to specify

E. ENVIRONMENTAL
CHARCTERISTICS

1. Ambient temperature 0-50°C

range

2. Humidity range 95%

F. APPROVAL / CERTIFICATE

1. UL/ FM/ VDS/ EN-54/ Required

LPCB

532
8.2.4.5. Fire Alarm Multi-Sensor Detector Specification

Sr. Description Requirement

No.

A. GENERAL

1. Make Bidder to specify

2. Model No Bidder to specify

B. DETECTOR CHARACTERISTICS

1. Type Microprocessor based, combination of smoke and heat

detector (Fixed and Rate of Rise of Temperature type)

2. Addressable Required

3. LED Status Multi colored, multi status LED

4. Remote / Local Test Required

Capability

5. Response Time The maximum allowable response delay from activation

of an initiating device to receipt and display by the
receiver/ fire alarm control unit shall be 10 seconds

6. Terminals for connecting Required

response indicator (Bidder to consider fault isolator module after every 10
Nos. detectors/ devices for UL/ FM offered panel or
inbuilt fault isolator base shall be provided for EN-54/
VDS/ LPCB offered panel. Bidder to provide necessary
provision to connect the response indicator for any type of
fire detectors.)

7. Sensor Coverage Bidder to specify

8. Alarm set point for Heat For fixed temperature type - 55OC
For rate of rise of temp. type 7OC / Minutes

9. Sensitivity Adjustment Required

10. Immune to false alarm Required

11. Cabling Two wire signal line circuit style 6, class „A‟ as per
NFPA-72

12. Built-in isolator Not Required

Note: In case of built-in isolator requirement the approval/

certification shall be VDS/ EN-54/ LPCB else UL/ FM
approval/ certification shall be applicable.

533
Sr. Description Requirement
No.

C. POWER

1. Operating voltage 24 VDC (Loop powered)

2. Operating current Bidder to specify

3. Wattage consumption Bidder to specify

D. MECHANICAL CHARACTERISTICS

1. Dimensions Bidder to specify

2. Weight Bidder to specify

3. Material of Enclosure Non Corrosive

4. Colour Bidder to specify

E. ENVIRONMENTAL
CHARCTERISTICS

1. Ambient temperature 0-50°C

range

2. Humidity range 95%

F. APPROVAL / CERTIFICATE

1. UL/ FM/ VDS/ EN-54/ Required

LPCB

8.2.4.6. Fire Alarm Beam Type Smoke Detector Specification

Sr. Description Requirement

No.

A. GENERAL

1. Make Bidder to specify

2. Model No Bidder to specify

B. DETECTOR CHARACTERISTICS

1. Type Reflective beam type smoke detector

Projected beam type smoke detector

2. Addressable Required

534
Sr. Description Requirement
No.

Note: In case bidders offers conventional beam

detector, same shall be made addressable by providing
addressable monitor module.

3. LED Status Multi colored, multi status LED

4. Remote / Local Test Required

Capability

5. Response Time The maximum allowable response delay from

activation of an initiating device to receipt and display
by the receiver/ fire alarm control unit shall be 10
seconds

6. Sensor Coverage Bidder to specify

7. Alarm set point for Heat Bidder to specify

8. Sensitivity Adjustment Required

9. Immune to false alarm Required

10. Cabling Two wire signal line circuit style 6, class „A‟ as per
NFPA-72

C. POWER

1. Operating voltage 24 VDC

2. Operating current Bidder to specify

3. Wattage consumption Bidder to specify

D. MECHANICAL CHARACTERISTICS

1. Dimensions Bidder to specify

2. Weight Bidder to specify

3. Material of Enclosure Non Corrosive

4. Colour Bidder to specify

5. Spacing & mounting As per the norms of NFPA 72,2010 edition & as per
manufacturer‟s instructions

E. ENVIRONMENTAL
CHARCTERISTICS

1. Ambient temperature range 0-50°C

535
Sr. Description Requirement
No.

2. Humidity range 95%

3. Weather protection class For indoor application: IP 54

F. APPROVAL / CERTIFICATE

1. UL/ FM/ VDS/ EN-54/ Required

LPCB

8.2.4.7. Fire Alarm Smoke Detector Specification

Sr. Description Requirement

No.

A. GENERAL

1. Make Bidder to specify

2. Model No Bidder to specify

B. DETECTOR CHARACTERISTICS

1. Type Microprocessor Base- Photoelectric Type

2. Addressable Required

3. LED Status Multi colored, multi status LED

4. Remote / Local Test Required

Capability

5. Response Time 10 Seconds Max. For Full Loaded Panel. Detectors

Response Time Shall Be Suitable For The Same.
Note: The maximum allowable response delay from
activation of an initiating device to receipt and display
by the receiver/ fire alarm control unit shall be 10
seconds.

6. Terminals for Connecting Required

Response Indicator

7. Sensor Coverage Bidder to specify

8. Sensitivity Adjustment Required

9. Immune to false alarm Required

10. Cabling Two wire signal line circuit style 6, class „A‟ as per

536
Sr. Description Requirement
No.
NFPA-72

11. Detector Mounting Base With Isolator

Without Isolator

C. POWER

1. Operating voltage Bidder to specify

2. Operating current Bidder to specify

3. Wattage consumption Bidder to specify

4. Loop Powered Required

D. MECHANICAL CHARACTERISTICS

1. Dimensions Bidder to specify

2. Weight Bidder to specify

3. Material of Enclosure Non Corrosive

4. Colour Bidder to specify

5. Spacing & mounting As per the norms of NFPA 72,2010 edition & as per
manufacturer‟s instructions

E. ENVIRONMENTAL
CHARCTERISTICS

1. Ambient temperature range 0-50°C

2. Humidity range 95%

3. Weather protection class For indoor application: IP 65

F. APPROVAL / CERTIFICATE

1. UL/ FM/ VDS/ EN-54/ Required

LPCB

8.2.4.8. Fire Alarm Monitor Module Specification

Sr. Description Requirement

No.

A. GENERAL

537
Sr. Description Requirement
No.

1. Make Bidder to specify

2. Model No Bidder to specify

B. MODULE CHARACTERISTICS

1. Application To normally open dry-contact alarm activation devices

2. Type Microprocessor Based

3. Addressable Required

4. Number of relay 1 No.

outputs in each 2 No.
module
4 No.
8 No.

5. Response time The maximum allowable response delay from activation of an

initiating device to receipt and display by the receiver/ fire
alarm control unit shall be 10 seconds

6. Cabling Two wire signal line circuit style 6, class „A‟ as per NFPA-72

7. Built-in isolator Not Required

Note: In case of built-in isolator requirement the approval/

certification shall be VDS/ EN-54/ LPCB else UL/ FM
approval/ certification shall be applicable.

C. POWER

1. Operating voltage 24 VDC (Loop powered)

2. Operating current Bidder to specify

3. Wattage consumption Bidder to specify

D. MECHANICAL CHARACTERISTICS

1. Dimensions Bidder to specify

2. Weight Bidder to specify

3. Material of Enclosure Non Corrosive

E. ENVIRONMENTAL CHARCTERISTICS

1. Ambient temperature 0-50°C

range

538
Sr. Description Requirement
No.

2. Humidity range 95%

3. Enclosure weather For Indoor IP54

protection class For Outdoor IP65

4. Explosion proof Bidder to specify

enclosure

5. Hazardous area Bidder to specify

classification

F. APPROVAL / CERTIFICATE

1. UL/ FM/ VDS/ EN- Required

54/ LPCB

8.2.4.9. Manual Call Point (MCP) Specification

Sr. Description Requirement

No.

A. GENERAL

1. Make Bidder to specify

2. Model No Bidder to specify

B. MCP CHARACTERISTICS

1. Type Break glass type

Push and pull type
Lift and pull type

2. Clear and visible operating Required

instructions on the body

3. The word "FIRE" indication on Required

the front of MCP in raised letters,
1.75 inches (44 mm) or larger

4. Response Time The maximum allowable response delay from

activation of an initiating device to receipt and
display by the receiver/ fire alarm control unit
shall be 10 seconds

5. Cabling Two wire signal line circuit style 6, class „A‟ as

per NFPA-72

539
Sr. Description Requirement
No.

6. Built-in isolator Not Required

Note: In case of built-in isolator requirement the

approval/ certification shall be VDS/ EN-54/
LPCB else UL/ FM approval/ certification shall
be applicable.

C. POWER

1. Operating voltage 24 VDC (Loop powered)

2. Operating current Bidder to specify

3. Wattage consumption Bidder to specify

D. MECHANICAL CHARACTERISTICS

1. Dimensions Bidder to specify

2. Weight Bidder to specify

3. Material of Enclosure Non Corrosive

4. Colour Bidder to specify

E. ENVIRONMENTAL CHARCTERISTICS

1. Ambient temperature range 0-50°C

2. Humidity range 95%

3. Enclosure weather protection For Indoor IP54

class For Outdoor IP65

4. Explosion proof enclosure Bidder to specify

5. Hazardous area classification Bidder to specify

F. APPROVAL / CERTIFICATE

1. UL/ FM/ VDS/ EN-54/ LPCB Required

2. ATEX/ CCOE Not Required (For Explosion Proof type)

8.2.4.10. SOUNDER cum STROBE Specification

540
Sr. Description Requirement
No.

A. GENERAL

1. Make Bidder to specify

2. Model No Bidder to specify

B. SOUNDER/ STROBE CHARACTERISTICS

1. Type Loop Powered

Externally Powered

Note: Externally powered through FACP.

2. Addressable Required

3. Response time The maximum allowable response delay from activation of an

initiating device to receipt and display by the receiver/ fire alarm
control unit shall be 10 seconds

4. dB level 90 db at 10 Feet from device

5. Light intensity 15/30/75/110 cd

6. Number of Minimum 4
selectable tones

7. Cabling Two wire signal line circuit style 6, class „A‟ as per NFPA-72

8. Built-in isolator Not Required

Note: In case of built-in isolator requirement the approval/

certification shall be VDS/ EN-54/ LPCB else UL/ FM approval/
certification shall be applicable.

C. POWER

1. Operating voltage 24 VDC

2. Operating current Bidder to specify

3. Wattage Bidder to specify

consumption

4. Power Supply Bidder to specify

D. MECHANICAL CHARACTERISTICS

1. Dimensions Bidder to specify

2. Weight Bidder to specify

541
Sr. Description Requirement
No.

3. Material of Non Corrosive

Enclosure

4. Mounting Wall
Surface
Structure beam

Note: - All accessories shall be supplied and erected as

applicable

E. ENVIRONMENTAL CHARCTERISTICS

1. Ambient 0-50°C
temperature range

2. Humidity range 95%

3. Weather IP 65
protection class

F. APPROVAL / CERTIFICATE

1. UL/ FM/ VDS/ Required

EN-54/ LPCB

2. ATEX/ CCOE Not Required (For explosion proof type)

8.2.4.11. Fire Alarm Fault Isolator Module Specification

Sr. Description Requirement

No.

A. GENERAL

1. Make Bidder to specify

2. Model No Bidder to specify

B. MODULE CHARACTERISTICS

1. Type Microprocessor Based

2. Addressable Required

3. After every numbers of 10 nos.

detector/devices

4. Automatically resets on correction Required

542
 Sr. Description Requirement
No.
of short

5. Wide viewing angle of LED Required

6. Cabling Two wire signal line circuit style 6, class „A‟ as

per NFPA-72

C. POWER

1. Operating voltage 24 VDC (Loop powered)

2. Operating current Bidder to specify

3. Wattage consumption Bidder to specify

D. MECHANICAL CHARACTERISTICS

1. Dimensions Bidder to specify

2. Weight Bidder to specify

3. Material of Enclosure Non Corrosive

E. ENVIRONMENTAL CHARCTERISTICS

1. Ambient temperature range 0-50°C

2. Humidity range 95%

3. Enclosure Weather protection For Indoor IP54

class For Outdoor IP65

F. APPROVAL / CERTIFICATE

1. UL/ FM/ VDS Required

8.2.5 Interlocks for FDAS

8.2.5.1. Minimum 8 nos. of Potential free contacts shall be provided from the FDAS Panel
through relay module for following Interlocks in the event of fire:
a. Building Management System
b. Sprinkler / Pumps System
c. Access control system
8.2.6 Installation
8.2.6.1. Installation shall be in accordance with the IS 2189, NEC, NFPA 72, local and state
codes, as shown on the drawings, and as recommended by the major equipment
manufacturer.

543
8.2.6.2. The complete installation hardware and cabling for FDAS system is in scope of
Contractor.
8.2.6.3. All conduit, junction boxes, conduit supports and hangers shall be concealed in
finished areas and may be exposed in unfinished areas.
8.2.6.4. Detectors shall not be installed prior to the system programming and test period.
8.2.6.5. If construction is ongoing during this period, measures shall be taken to protect
smoke detectors from contamination and physical damage.
8.2.6.6. All fire detection and alarm system devices, control panels and remote annunciators
shall be flush mounted when located in finished areas and may be surface mounted
when located in unfinished areas.
8.2.6.7. Manual fire alarm boxes shall be suitable for surface mounting or semi-flush
mounting and shall be installed not less than 42 inches (1067 mm), nor more than 48
inches (122 mm) above the finished floor.
8.2.7 Power Supply
8.2.7.1. One feeder of 240 V AC, UPS power shall be made available in the UPS for the Fire
Alarm & Detection System. The Contractor shall lay cables from UPS to the FDAS
system. All the other necessary power supply required for the functioning of the
FDAS system shall be derived by the contractor from this power supply.
8.2.8 Power Cables
a. The specifications for power cables shall be as below:
b. Conductor material: Stranded Copper
c. Insulation Material: Cables shall be PVC insulated as per application.
d. Voltage grade: 1100 V
e. Armouring: All power cables shall be GI wire armoured.
f. Sheathing Material: Inner & Outer sheaths shall be FRLS PVC

8.2.9 I&C Cables

8.2.9.1. All multipair & multicore cables shall be provided with 20% (of used pairs/cores)
spare pairs & cores for future use. Cables for Ethernet connectivity shall be CAT 6
cables which shall be armoured. Cables for RS-485 connection shall be twisted pair
cables, shielded & armoured.
8.2.9.2. Cable Glands
All cable glands shall be of double compression type with high quality neoprene
gaskets. Cable glands shall be of brass with nickel plating.
8.2.9.3. Cable trays
Cable trays shall be perforated of hot dipped galvanized steel. Cable trays shall have
50 mm collar height. The cable trays shall be covered type.
The cables coming in the beam area shall be allowed to pass through conduits.
The cables laid between two different buildings shall be laid in conduits in cable
trenches.
I&C Cables and power cables shall be routed through different cable trays to avoid
Electromagnetic Interference.
544
 Minimum 300 mm distance shall be maintained between I&C cables / 24 V DC
power supply cables and 415 V AC/ 230 V AC power cables.
All cable trays shall be provided with 20% spare space for future use.
8.2.9.4. Fire proof Sealing for Cable penetration
Cables/ cable tray openings in walls and floors or through pipe sleeves from one area
to another or one elevation to another shall be sealed by a fireproof sealing
compound. The fire-proof sealing compound shall effectively prevent the spread of
fire from the flaming to non-flaming side, in the event of fire.
8.2.9.5. The specifications of cables shall be as mentioned below.

Description Power Control Signal Triad

Cable cable cable Cable
GENERAL Type 1. Armoured Screened, Twisted, screened,
armoured armoured
Voltage2.grade 1100 V 1100 V 660 V
Material3. Annealed Tinned Copper
Shape of4. Stranded circular
CONDUCT
conductor
OR
Size 5.
No. of strands
6. 7 nos.
Material7. Extruded Polyethylene (PE) as per BS-EN 50290-2
Thickness
8. of 0.8 mm
insulation
PRIMARY
(Nominal)
INSULATIO
Colour 9.
code Grey White +ve, Brown,
N
Black –ve Black and
(For each blue
pair)
Twist 10. NA NA Min. 10 nos. twist / meter
INDIVIDUA
for each pair
L PAIRS /
Identification
11. NA NA Numbers at not more than
TRIADS
250mm length
Material12. NA NA AL Mylar tape applied
helically with metallic
side down in contact with
drain wire
Tape thickness
13. NA NA Minimum 0.075 mm thick
for single pair cables
Minimum 0.05 mm thick
INDIVIDUA for multipair cables
L PAIR /
Overlap14.NA NA Min 100 Min. 100
TRIAD
.25 % 25% %
SCREENIN
%
G
Polyester
15.tape NA NA Polyester tape of 0.05 mm
thick each. two tapes with
min. 25% overlap &
100% coverage
Drain wire
16.
Material17. NA NA Annealed Tinned Copper
Size 18. NA NA 0.5mm2, with 7 strands,

545
 each of 0.3 mm dia.
Material19. NA AL Mylar tape applied helically with
metallic side down in contact with drain
wire
Tape thickness
20. NA Minimum 0.075 mm
Overlap21.Cover NA Min. 100 Min. 100 Min 100%
OVERALL
age 25% % 25% % .
SCREENIN
25
G
%
Drain wire
22. NA
Material23. NA Annealed Tinned Copper
Size 24. NA 0.5mm2, with 7 strands, each of 0.3 mm
dia.
Type 25. Non-Hygroscopic, two tapes with min. overlap of 25%
BINDER
& 100% coverage
TAPE
Tape Thickness
26. Each tape of min. 0.023 mm thick
Material27. Extruded flame retardant PVC type ST-2, 90oC as per
IS-5831 ,
oxygen index over 30% and temp. index over 250 deg
C.
Thickness
28. As per BS-EN 50288 part 7 (Note-2)
INNER (Nominal)
SHEATH Colour 29. Black
Diameter30.over Bidder to Specify
inner sheath Note:- Cable dimensions (OD under armour, OD over
armour, overall OD) shall be as per BS-EN-50288-7.
Maximum tolerance in dimensions shall be +/- 2 mm.
Rip Chord
31. Non-metallic required under inner sheath
Material32. Galvanised steel
Size 33. As per BS-EN 50288
ARMOURIN Diameter
34.over Bidder to Specify
G armour Note:- Cable dimensions (OD under armour, OD over
armour, overall OD) shall be as per BS-EN-50288-7.
Maximum tolerance in dimensions shall be +/- 2 mm.
Material35. Extruded flame retardant PVC IEC-332, Type ST-2,
90oC as per IS-5831
Thickness
36. As per BS-EN 50288 part 7 (Note-2)
(Nominal)
Colour 37. Black Black, for Intrinsic Black
OUTER safe light blue
SHEATH Overall38. Bidder to Specify
Diameter Note:- Cable dimensions (OD under armour, OD over
armour, overall OD) shall be as per BS-EN-50288-7.
Maximum tolerance in dimensions shall be +/- 2 mm.
Cable 39. Running length printed at min. every 1 metre interval
identification
Conductor
40. As per BS-EN 50288 part 7
ELECTRICA resistance
L Drain wire
41. NA < 30 ohms/km @ 20 deg c. Noise
PROPERTIES resistance rejection ratio > 76 db.
Insulation
42. 1 G Ω/KM as per BS EN 50288

546
 resistance
Mutual 43. NA < 110 nF/KM @ 1 KHz
capacitance
Capacitance
44. NA < 400 nF/KM @ 1 KHz
between core
and screen
Inductance
45. NA < 1 mH/KM @ 1 kHz
L/R Ratio
46. NA As per BS-EN 50288 part 7

8.2.10 Panels Accessories & Wiring

8.2.10.1. Wiring
All inter cubical and internal wiring for all panels shall be carried out with 1100V
grade, stranded tinned copper conductors with PVC insulation. The minimum size of
the stranded copper conductor used for the panel wiring shall be 0.5 mm2 for analog
signals and 1.0 mm2 for commands. For power supply, the conductor size shall be
provided as per the load rating (min. 2.5 sq. mm for 230 V AC). Control & Power
wiring shall be segregated and routed in PVC troughs. Different colour wires shall be
used for different voltages.
Engraved core identification plastic ferrules, marked to correspond with the panel-
wiring diagram shall be fitted at both ends of each wire. Cross ferruling shall be done.
This shall also be applicable for fibre optic cable & cores.
All spare contacts and spare terminals of the panel mounted equipment and devices
shall be wired to the terminal blocks.
8.2.10.2. Plug Points and Interior Lighting
A 5/15 Amp 230V, 1 phase, 50 Hz, AC 3 pin plug point shall be provided in the
interior of each panel with ON/OFF control switch and MCB.
For interior lighting 230V, 1 Phase, 50 Hz, 40W compact fluorescent lamp with
operating door switch and protective devices like MCBs shall also be provided.
Power supply for all exhaust fans shall be provided through MCBs.
8.2.10.3. Relays
All relays used for interposing shall have at least 2 nos. changeover contacts. The
relays shall have status indication and shall be provided with free wheeling diodes.
8.2.10.4. Labels
All front mounted equipment, as well as equipment mounted inside the panels/control
desks shall be provided with individual labels with equipment designation engraved.
These shall be phenolic overlays (1.6 mm thick) with black background and white
lettering and shall be fixed to the panel by stainless steel screws (counter sunk). The
panels shall also be provided at the top with a label engraved with the designation.
Lettering for panel designation shall be 6 mm.
The minimum lettering size for instrument/device labels shall be 3mm. The lettering
on the labels shall be subject to EMPLOYER'S approval. Labels of internally
mounted equipment shall be clearly visible.
8.2.10.5. Earthing
Each panel shall be provided with a safety ground bus & system ground bus made of
copper securely fixed along the inside base of the panels. These buses shall be
547
 typically of 25 mm wide and 6 mm thick of copper. The safety ground bus shall be
properly secured to the plant safety earthing. All metallic cases/frames of relays,
instruments, other panel mounted equipment shall be connected to the safety ground
bus and shields & drain wires of signal/control cables shall be connected to the
system ground bus by independent copper wires of not less than 2.5 sq. mm. The
system ground bus shall be electrically isolated from AC mains earthing bus. The
system ground bus shall be insulated from the panel body. The insulation colour code
for earthing wires shall be green with yellow bands.

8.2.11 SUMMARY OF DATA TO BE FURNISHED ALONG WITH BID AND

AFTER ACCEPTANCE OF PURCHASE ORDER
The BIDDER shall ensure the following documentation are prepared and submitted to
EMPLOYER for his review / record.
8.2.11.1. Technical Bid
The following drawings/ documents shall be submitted:
a. Data sheet an catalogs of instruments/ equipments
b. Dimensional Drawings of Panels along with estimated BOQ for each of the
systems.
c. Overall System Configuration Diagram
d. Engineering activity and manufacturing schedule giving activity wise breakup to
meet the delivery schedule.
e. Testing & Evaluation plan for the systems offered.
8.2.11.2. Final Documents
a. Operation and maintenance manuals.
b. Quality assurance documentation specific for the project.
c. Final as built documentation folder containing all items for future reference.

8.2.12 SCHEDULE FOR SUBMISSION OF DATA AND DRAWINGS BY

CONTRACTOR (DATA TO BE FURNISHED AFTER THE AWARD OF
CONTRACT)
The CONTRACTOR shall submit the following drawings / documents after award
of contract for review & approval. CONTRACTOR shall adhere to the
delivery schedule as submitted along with the BID. CONTRACTOR shall also refer
to data sheets for list of deliverables to be submitted for various instruments/ panels.

Sl. No. Details

(a) Bar chart for the design, manufacturing, erection, commissioning,

trial operation and performance testing of the system offered.

(b) Overall System Configuration Diagram indicating all components

including networking.

(c) Unpriced purchase order copy for various bought out /sub
contracted equipment / services.

548
 Sl. No. Details

(d) Following drawings for panels:

Front facia layout showing all instruments with cut-outs, bezel

dimensions, construction details, foundation details and interior
G.A. drawings showing interior layout of various modules,
instruments etc.

Internal wiring diagrams indicating termination details of each

component.

Bill of Material (B.O.M.) indicating tag no, quantity, service &

model no. of the various modules/instruments/items.

(e) FDAS Configuration and Layout drawings.

(f) Data Sheets & catalogues for I&C cables & power cables.

(g) Earthing diagrams

(h) Cable Schedules and Interconnection cable schedules.

(l) Load calculations for FDAS system

(j) QAPs for all instruments & panels for each system, I&C cables,
Power cables & fibre optic cables.

(k) Standard FAT & SAT for the specified systems

(l) „As Built‟ drawings

(m) Instruction manual for installation and start-up (for each system)

(n) System operation and maintenance manual

8.2.13 TRAINING
8.2.13.1. 1 No. Contractor‟s engineer shall be made available for 2 weeks for assistance in
operation, maintenance, tuning & training of Employer‟s personnel at Site after
commissioning of each system.
8.2.13.2. Training shall be required on both hardware & application software development.

8.2.14 TESTING, INSTALLATION, COMMISSIONING AND ACCEPTANCE

8.2.14.1. General
On the basis of guidelines specified in this specification Bidder shall submit their
own testing, installation, commissioning and acceptance procedure. The procedure
shall include purpose of test, test definition, results expected and acceptance criteria.

549
 For software it shall include details of the method, list of tests, sequence of
execution, results expected and acceptance criteria.
8.2.14.2. Site Acceptance Tests (SAT)
Full integrated site acceptance test shall be performed before hand over of total
system to the EMPLOYER. The test shall demonstrate functionality of the entire
system supplied & erected by the Contractor. The Contractor shall provide all
personnel, test facilities, equipment and tools etc. for the same. All test instruments
shall have calibration certificates from approved test house, valid for minimum 6
months. A test procedure is required for approval 2 weeks prior to the schedule start.
8.2.14.3. Testing Requirements
a. Tests on cables
 Check details are in accordance with the specification.
 Check for physical damage.
 Megger test between each core and armour/sheath (For electrical cables)
 Continuity check including screen continuity (For electrical cables)
 Terminations of the cables at both ends.
b. Fire Alarm System
 Before energizing the cables and wires, check for correct connections and
test for short circuits, ground faults, continuity, and insulation.
 Open initiating device circuits and verify that the trouble signal actuates.
 Open and short signalling line circuits and verify that the trouble signal
actuates.
 Open and short notification appliance circuits and verify that trouble
signal actuates.
 Ground all circuits and verify response of trouble signals.
 Check presence and audibility of tone at all alarm notification devices.
 Check installation, supervision, and operation of all intelligent smoke
detectors using the walk test.
 Each of the alarm conditions that the system is required to detect should
be introduced on the system. Verify the proper receipt and the proper
processing of the signal at the FDAS PANEL and the correct activation of
the control points.
 When the system is equipped with optional features, the manufacturer's
manual shall be consulted to determine the proper testing procedures. This
is intended to address such items as verifying controls performed by
individually addressed or grouped devices, sensitivity monitoring,
verification functionality and similar.
c. It shall be ensured that erection of all panels is as per approved layout drawings.
Checking for tagging/identifications of all the panels shall be done. Checks for
continuity and termination of all power, signal, control and fibre optic cables as
per approved drawings shall be carried out. All the panels supplied & erected by
the Contractor shall be checked at site by carrying out the following tests:
 Visual & Mechanical testing.

550
  Power up tests
 Checks on incoming voltage and power distribution
 Checking of incoming power supply to the panels supplied & erected by
the Contractor.
 Switching on the incoming supply to panels by switching on
MCCBs/MCBs one after the other.
 Power „ON‟ PCs for Fire Alarm System
 Demonstration of all system functions for Fire Alarm System
 Checking of 100% logic as per sequences
 Checking of all HMI screens, alarms etc.
 Checking of proper functioning of all Printers with printouts of alarm lists,
reports, important alarms etc.
d. Tests on electrical installation
 Checking of closing, tripping, supervision and interlocking of control
devices.
 Checking operation of all alarm circuits.
e. Test on complete control system.
 On completion, the functioning of all systems shall be tested to
demonstrate its correct operation in accordance with the Specification.
 For testing, the Contractor may provide temporary means to simulate
operating conditions, but the system shall not be finally accepted until
correct operation has been demonstrated to the satisfaction of the
Employer.

8.2.15 Commissioning
8.2.15.1. Commissioning Procedure shall be carried out in a methodical sequence as follows
 Start-up,
 Initial running,
 Operability adjustment,
 Stable operation
 Final adjustment
8.2.15.2. The Contractor shall check the operating conditions by constantly monitoring
operating data.
8.2.15.3. The Contractor shall specify for each discrete part of the system for which the
operational data has to be recorded and the manner in which the data is to be taken.
All the operating data shall be recorded, evaluated and submitted to the Employer

8.2.16 EQUIPMENT & SERVICES TO BE PROVIDED BY THE CONTRACTOR

8.2.16.1. This specification covers specific requirements of design, preparation of detailed
drawings, manufacture, testing at manufacturer‟s works, inspection at Vendor‟s/Sub-
Vendor‟s works, packing, forwarding, transportation, transit insurance, delivery at

551
 site, installation, testing at site, erection and commissioning of Fire Detection &
Alarm System (FDAS) as per specification and data sheets enclosed.
8.2.16.2. The following shall be in the scope of the CONTRACTOR
FDAS comprising of FDAS control panel, initiating devices such as smoke
Detectors, heat type Detectors, Manual Call Points (MCP), Sounders, isolators,
1 No. Repeater panel at security gate, software (to be installed in IBMS PC), A4 size
monochrome LASER jet Printer, all associated cabling and installation hardware for
the system as detailed in the specification and data sheets enclosed.
8.2.16.3. Cabling
a) Contractor shall supply & lay the following cables along with all the installation
hardware and accessories:
 UPS to FDAS panel
 FDAS system cabling
b) Cable Trays & Conduits
8.2.16.4. Earthing
a) Earthing for the entire system to be provided by the Contractor shall be in his
scope. Separate electrical & instrumentation earth pits shall be provided by
others. This earth pit shall be interconnected with electrical earth pit. Contractor
shall connect the safety ground bus & system ground bus for the systems
supplied by him to the respective earth pits.
b) Single point earthing configuration shall be followed for the cable shields i.e. all
signal and control cables shields shall to be grounded at one end only to avoid
ground loop.

8.2.17 SPARES AND MAINTENANCE TOOLS AND TACKLES

8.2.17.1. GENERAL
a) All spares and maintenance tools and tackles shall be designed to enable
maintenance to be carried out in the least time and at the least cost and support
resources without affecting the performance and safety aspects.
b) All the spares and maintenance tools and tackles supplied shall be new and
unused.
c) The VENDOR/CONTRACTOR shall guarantee that before going out of
production of spares and maintenance tools and tackles for the equipment
furnished, he shall give at least 12 months advance notice to the EMPLOYER,
so that the latter may order his requirement in one lot, if so desired.
8.2.17.2. SPARES
a) All spares supplied shall be strictly inter-changeable with the parts for which
these are intended to be replacements. The spares shall be treated and packed for
long term storage under the climatic conditions prevailing at the site e.g., small
items shall be packed in sealed transparent plastic bags with desiccator packs as
necessary.
b) Each spare shall be clearly marked or labelled on the outside of its packing with
its description and purpose. When more than one spare is packed in a single case,
a general description of the contents shall be shown on the outside of such case

552
 and a detailed list enclosed. All cases, containers and other packages shall be
suitably marked and numbered for the purposes of identification.

8.3. PUBLIC ADDRESS SYSTEM

8.3.1 Scope of Work

8.3.1.1. The intent of the specification is to define the functional & design requirements for
the PA system meant to broadcast announcements and alarm to people in the facility.
8.3.1.2. This specification covers specific requirements of design, preparation of detailed
drawings, manufacture, testing at manufacturer‟s works, inspection at
CONTRACTOR‟s/Sub- CONTRACTOR‟s works, packing, forwarding,
transportation, transit insurance, delivery at site, installation, loading, unloading,
testing at site, erection and commissioning of Public Address System (PA system) as
per specification and datasheet enclosed. Scope shall also include laying of cabling,
necessary for installation of the system as indicated in the specification and Bill of
Quantities. Any openings/chasing in the wall/ceiling required for the installation
shall be made good in appropriate manner.
8.3.1.3. Contractor shall supply PA system with paging amplifier/speaker, sound system, call
station etc. with necessary add on items required to complete the PA system.
8.3.1.4. This document is specifying the minimum criteria for the Design, Supply,
Installation and Commissioning & Maintenance of Public Address System. Bidder
shall be responsible for detailed engineering based on products proposed. The
contractor during detailed engineering shall carry out the acoustic coverage study
and the results of the same shall be submitted to Employer‟s approval. The sound
pressure level at ear level shall be 20 dB above ambient noise level. The design
calculations along with the loudspeaker model selected and quantities based on the
Acoustic Coverage area study for the facility shall be submitted for EMPLOYER‟s
approval.
8.3.1.5. Public Address (PA) system shall be provided at Production and Training Block,
Administration Building, Canteen Block and Utility block. Call stations shall be
located as follows:
a) Administration Building – Reception
b) Training Block – Reception
c) Production Block - Reception
8.3.1.6. It is not the intent to specify completely herein all details of design and construction
of equipment or materials to be supplied or of services to be rendered. However, the
equipment, materials and services shall confirm in all respects to high standards of
engineering design, workmanship and be capable of performing in continuous
commercial operation in a manner acceptable to EMPLOYER who shall interpret the
meaning of drawings and specifications and shall have the power to reject any work
or material which in his judgement are not in full accordance therewith.
8.3.2 System Description

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8.3.2.1. The public address system shall be a safety system, being critical with respect to
personnel safety and shall be fully operational during emergency situations.
8.3.2.2. This PA system shall consist of speaker loop and control equipment being located in
Server Room at Second floor, Administration Building.
8.3.2.3. The system shall be specifically & fundamentally designed as failsafe, with
extensive system & fault status monitoring for maximum availability at all times.
8.3.2.4. The system shall be used for one-way communication only.
8.3.3 Zoning
8.3.3.1. The various areas shall be divided into zones and the PA system shall be designed to
make zone wise announcements. The zoning shall be flexible and will be designed to
meet the geographical layout of the Production and Training Block, Administration
Building, Canteen Block and Utility block.
8.3.3.2. Intra Zone Communication
a. PA system shall have Paging mode which shall be open line, common talking
type. Paging mode shall be used for locating a person and for general
instructions.
b. Whenever the “Press to page” push button is pressed on any of the Call station,
a pleasant chime shall be broadcast over all the loudspeakers except the one
associated with that handset station to attract attention.
c. Unless requested to be routed through the central exchange, announcements /
communication within a zone shall not be audible in other zones.
d. The Emergency announcements shall be routed through all zones without any
selection.
8.3.3.3. The PA system shall have provision for broadcasting a wailing sound (for
emergency), steady tone (for testing), and a pleasant musical chime (for calling
attention prior to announcement).
8.3.3.4. The Public Address System shall be designed and configured to provide paging,
alarm and messaging facility in the various blocks.
8.3.3.5. The PA system shall comprise of:
a) Loud speakers, junction boxes and cabling.
b) PA system Network controller.
c) Call Station
d) CD player
8.3.4 Loud Speakers:
a) Indoor loudspeakers shall be located such that all blocks are provided with an
adequate level of coverage where alarm tones and emergency announcements
are audible.
b) Indoor loudspeakers shall be acoustic & aesthetic in design.
c) The Indoor loudspeakers shall also be provided for waiting reception areas,
reception areas, common areas and conference halls.
d) Physically, loudspeakers shall support zones where one or more circuits can be
partitioned into a zone. Each loudspeaker shall be connected to the central
exchange for amplification and control/monitor functions.

554
 e) The calls shall be transmitted through loudspeakers installed in the various units
and buildings throughout the facility.
f) Loudspeakers circuits shall be supervised using line monitoring equipment from
control room.
g) The loud speaker shall have 100V line transformer with multiple wattage taps.
8.3.5 Amplifiers:
The main function of the power amplifier is the amplification of audio signals for the
loudspeakers
a) Centralised amplifiers will be provided which eliminates the need for local
amplifier at multiple locations in the building and also the power cabling at each
location. The system will be also provided with standby amplifier with
changeover circuitry to ensure continuous operation at all times.
b) Amplifiers shall be solid state, class-D type, in built with the handset fully
conforming to equivalent international standard. It shall have selectable output
voltage.
c) Amplifiers shall have 0-100% volume control setting. with facility for coarse
and fine setting along with following controls which shall be located inside the
Handset Station:
 Input sensitivity control.
 Receiver volume control.
 Bass cut filter.
 Anti-side tone control feature.

8.3.6 Pre-recorded digital tones and messages

a) The PA system central control unit shall control the generation of individual
signalling and alarm tones, followed by pre-recorded speech messages. The
system shall be provided with alarm and test tones. Messages and alarm tones
shall be fully configurable, with virtually unlimited capacity of expansion.
b) The PA system central control unit shall have facility for playing background
music in the predefined area. Separate speakers with good sound quality shall be
provided for the same. The source port shall be provided for playing external
music.

8.3.7 Call Stations For PA System :

Call Station shall support facilities for an operator to execute routine or emergency
zone wise announcements, and initiate and terminate prioritized alarms. Panels shall
provide status information on panel and external operations, and system health.
Operator facilities shall be selected from a features list to meet a customer‟s specific
operational requirements.
Call station shall be provided as follows:

a) The Desktop call station shall be provided in Main Reception Area of

Administration Block and Training & Production Block with following features:

555
  Minimum 12 zone select push button/alarm push button, emergency
pushbutton
 System status LED‟s
 weatherproof enclosures
 Various speech buttons
 Gooseneck microphone/fist noise cancelling microphone.

Call Station shall have provision for :

a) Address a call to individual zones (individual calls)
b) Address a call to multiple zones, by activating the selected groups of zones
(group calls)
c) Transmit a general call activating all zones simultaneously

8.3.8 Microphone Specification

Sr. Description Requirement

No.

A. GENERAL

1. Make Bidder to specify

2. Model No Bidder to specify

3. Frequency range 100 Hz to 15 kHz

4. Sensitivity (mV) Bidder to specify

5. Impedance: ≤ 600 Ohm Bidder to specify

6. Dimensions Bidder to specify

7. Weight Bidder to specify

8. Colour Bidder to specify

9. On/off switch Required

10. Cable length 2 meter minimum

11. Connector Lockable

12. Voltage range & current Bidder to specify

consumption for
condenser type
microphone

13. Operating temperature 0° to 50° C

14. Relative humidity < 95%

556
Sr. Description Requirement
No.

15. Certificate CE

16. Accessories Bidder shall provide appropriate mounting accessories like

microphone holder, extension cable, mounting bracket,
table stand, floor stand to suit the site requirement and
same shall be submitted to Employer‟s approval

8.3.9 Loudspeaker Specification

Sr. No. Description Requirement

A. GENERAL

1. Make Bidder to specify

2. Model No Bidder to specify

3. Maximum power (W)

4. Rated power/ wattage tapping (W)

5. Power tapping/ Rated voltage 100V & 70V

6. Sound Pressure Level (SPL)

7. Frequency Response

8. Colour

9. Rated impedance Bidder to specify

10. Dimensions Bidder to specify

11. Weight Bidder to specify

12. Colour Bidder to specify

13. Material Aluminium/ ABS

14. Standards CE, EN60065

15. Operating Temperature 0° to 50° C

16. Related Humidity <95%

17. IP rating IP54

18. Ex-proof rating

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8.3.10 Desktop Call Station

Sr. No. Description Requirement

A. GENERAL

1. Make Bidder to specify

2. Model No Bidder to specify

3. Microphone

a) Frequency Response: 100 Hz to 15 kHz

b) Sensitivity (mV) Bidder to specify

c) Impedance: <600 Ohm

d) Type: Uni-directional Condenser Gooseneck

e) Signal to Noise Ratio: >60 dB

f) Load Bidder to specify

4. Loudspeaker

a) Rated power Bidder to specify

b) Signal to Noise Ratio: >60dB

c) Sound Pressure Level: 85 dB

d) Frequency Response: 100 Hz to 15 kHz

e) Rated impedance Bidder to specify

5. Material Bidder to specify

6. Standards: CE, EN60065

7. Operating Temperature : 0° to 50° C

8. Related Humidity: <95%

9. Input voltage Bidder to specify

10. Load (W) Bidder to specify

11. Multi colour multi status LED: Required (for

indication of active zones, emergency
massages, power ON, error signals)

12. Attachment for add-on keypads : Required

(No. of keypads shall be decided as per

558
 Sr. No. Description Requirement
requirement considering no. of zones and
multiprogramming key requirement)

13. Key station/ keypad: Required (keys shall be

used for assigning zones and for
multipurpose use)

14. Dimensions Bidder to specify

15. Weight Bidder to specify

16. Colour Bidder to specify

17. Mounting: Desk mountable type

18. Mute button: Required (for inbuilt

loudspeaker)

19. 3.5mm jack for headphone & microphone:

Required

8.3.11 EQUIPMENT & SERVICES TO BE PROVIDED BY THE CONTRACTOR

8.3.11.1. Cabling
a) The complete cabling for PA system shall be in the scope of CONTRACTOR.
b) Contractor shall supply & lay the following cables along with all the
installation hardware and accessories:
 PA system cabling(Cabling from loud speakers to central exchange
amplifiers)
c) The complete insulation hardware, cable trays & Conduits, structured steel for
erection work shall be in scope of CONTRACTOR.
8.3.11.2. Earthing
a) Separate electrical & instrumentation earth pits shall be provided by others.
Earthing for the entire system shall be provided by the Contractor. This earth pit
shall be interconnected with electrical earth pit. Contractor shall connect the
safety ground bus & system ground bus for the systems supplied by him to the
respective earth pits.
b) Single point earthing configuration shall be followed for the cable shields i.e. all
signal and control cables shields shall be grounded at one end only to avoid
ground loop.
8.3.11.3. Interfacing with third party devices
The PA system shall be interfaced with Fire alarm system:
Informing the occupants in case of any fire situation and giving directions for safe
evacuation. Pre recorded messages shall be automatically transmitted on
programmed events.

559
8.3.12 SPARES AND MAINTENANCE TOOLS AND TACKLES
8.3.12.1. GENERAL
a) All spares and maintenance tools and tackles shall be designed to enable
maintenance to be carried out in the least time and at the least cost and support
resources without affecting the performance and safety aspects.
b) All the spares and maintenance tools and tackles supplied shall be new and
unused.
c) The VENDOR/CONTRACTOR shall guarantee that before going out of
production of spares and maintenance tools and tackles for the equipment
furnished, he shall give at least 12 months advance notice to the EMPLOYER,
so that the latter may order his requirement in one lot, if so desired.
8.3.12.2. SPARES
a) All spares supplied shall be strictly inter-changeable with the parts for which
these are intended to be replacements. The spares shall be treated and packed for
long term storage under the climatic conditions prevailing at the site e.g., small
items shall be packed in sealed transparent plastic bags with desiccator packs as
necessary.
b) Each spare shall be clearly marked or labelled on the outside of its packing with
its description and purpose. When more than one spare is packed in a single case,
a general description of the contents shall be shown on the outside of such case
and a detailed list enclosed. All cases, containers and other packages shall be
suitably marked and numbered for the purposes of identification.

8.4. CLOSED CIRCUIT TELEVISION SYSTEMS

8.4.1 Scope of Work

8.4.1.1. This specification covers specific requirements of design, preparation of detailed
drawings, manufacture, testing at manufacturer‟s works, inspection at Vendor‟s/Sub-
Vendor‟s works, packing, forwarding, transportation, loading, unloading, transit
insurance, delivery at site, installation, testing at site and commissioning of CCTV
System. Scope shall also include laying of cabling, necessary for installation of the
system as indicated in the specification and Bill of Quantities. Any openings/chasing
in the wall/ceiling required for the installation shall be made good in appropriate
manner.
8.4.1.2. This Specification and its associated Data Sheets covers the minimum technical
requirements for the design, manufacture, supply, testing, installation and
commissioning of Close Circuit Television System (CCTV) Equipment, which shall
be supplied under this Contract.
8.4.1.3. Analog Type Close Circuit Television System (CCTV) is proposed for following
locations.
a) Productions and Training Block, Administration Building, Canteen Block,
Executive Hostel, Girls Hostel, Boys Hostel, Staff Accommodation Building

560
 and Utility Block entrance will be provided with Indoor type dome camera
varifocal lens weather proof
b) Interior area of Productions and Training Block, Administration Building,
Canteen Block, Executive Hostel, Girls Hostel, Boys Hostel, Staff
Accommodation Building and Utility Block (Indoor type camera varifocal lens )
c) Outdoor area (Outdoor type camera weather proof )
d) Server/IT room, Fire command centre room (Indoor type dome camera varifocal
lens)
8.4.1.4. It is not the intent to specify completely herein all details of design and construction
of equipment or materials to be supplied or of services to be rendered. However, the
equipment, materials and services shall conform in all respects to high standards of
engineering design, workmanship and be capable of performing in continuous
commercial operation in a manner acceptable to EMPLOYER who will interpret the
meaning of drawings and specifications and shall have the power to reject any work
or material which in his judgement are not in full accordance therewith.

8.4.2 SYSTEM DESCRIPTION

8.4.2.1. The provision of a CCTV system at the Technology centre, Pudi is required for
operation and security purposes.
8.4.2.2. Indoor cameras suitable for both day and night coverage shall be strategically
positioned to monitor activities within buildings.
8.4.2.3. CCTV Surveillance shall be made available from Fire command centre at Ground
Floor, Admin Building.
8.4.2.4. The communication between the CCTV equipment located at two different buildings
shall be done using coaxial cable between camera and DVR.
8.4.2.5. Analog cameras with mounting adapter, Ceiling / wall mount, enclosure and all other
accessories shall be provided at various locations of Productions and Training Block,
Administration Building, Canteen Block, Executive Hostel, Girls Hostel, Boys
Hostel, Staff Accommodation Building and Utility Block. Please refer CCTV
System Layout of each block and external services for location of CCTV.
8.4.2.6. The design of the CCTV system shall be modular, such that faults and damage
experienced in one module does not render the entire system non-functional.
8.4.2.7. Indoor equipment shall be with a degree of protection of IP 20, while outdoor
equipment shall be with a degree of protection of IP 65.
8.4.2.8. It shall be possible to place a camera almost anywhere. There shall be no limitations
tied to physical inputs or frame grabbers.
8.4.2.9. Memory to maintain a record of one month (30 Days) minimum, unless local laws
require a longer storage time. By storing the images on hard disks, it shall be
possible to erase any old unwanted images automatically.
8.4.2.10. The Contractor shall guarantee satisfactory performance of the equipment under
stipulated variations of voltage and frequency. The design and manufacture shall be
such that equipment/components of same type and rating shall be interchangeable.
8.4.2.11. The Contractor shall submit the following data / drawings after award of contract:
a) Detailed block schematic / configuration drawing.

561
 b) Power wiring diagram
c) Layout drawing indicating exact location of cameras
d) Cable routing drawings
8.4.2.12. All systems and designs must be flexible enough to accommodate changes in size,
operation, configuration, and technology updates that may become necessary due to
future expansions and requirements

8.4.3 SPECIFICATIONS

8.4.3.1. CCTV Camera Specification

Sr. No. Description Requirement

A. GENERAL

1. Make Bidder to specify

2. Model No Bidder to specify

3. Camera details Colour - Day/ Night camera

4. Image sensor 1/3” CCD

1/3” CMOS

5. Lens type Fixed lens

Varifocal lens
IR corrected lens
Motorized zoom lens

6. Lens format Minimum 1/3”, shall be compatible with image

sensor

7. IR cut filter Required

or
IR corrected lens

8. IRIS Automatic

9. F-STOP Range F/1.4 to F/16

10. Sensitivity for usable video Minimum 0.1 Lux @(F1.2,AGC ON),
0 Lux with IR

11. Resolution WD1 (960×480)

12. Automatic shutter Required

562
Sr. No. Description Requirement

13. Backlight compensation Required

14. Wide dynamic range (WDR) Required

15. Signal to noise ratio (SNR) > 50dB (minimum)

16. Auto contrast adjustment Required

17. Horizontal & vertical angle 700 Horizontal Minimum

of view

18. White balance Required

19. Video compression Bidder to specify

H.264
Motion JPEG

20. Video data rate range Bidder to specify

21. Frames per second for 25 FPS

viewing

22. Frames per second for 15 FPS Minimum

recording

23. Automatic gain control Bidder to specify

(AGC) 20 dB Minimum

24. Power supply UPS Power

25. Housing Box camera housing for indoor and outdoor use
shall be vandal proof, rugged, durable, industrial
grade,
M.O.C is cast aluminium, with in-built heater
/blower & sunshield.

26. IP Rating for indoor camera IP52

27. IP Rating for outdoor IP66

camera

28. Operating temperature -100C to 600C For Outdoor camera

-100C to 500C For Indoor camera

29. Operating humidity 95 RH

30. Mounting accessories All necessary accessories are required

31. Tampering alarm Required (tampering such as dis-focus/ move

563
Sr. No. Description Requirement
viewing direction/ masking)

32. Spares 10% or 1 no. (whichever is higher) shall be

provided for each type of camera

33. Standards UL, CE Required

8.4.3.2. CCTV MONITOR SPECIFICATION

Sr. No. Description Requirement

A. GENERAL

1. Make Bidder to specify

2. Model No Bidder to specify

3. Display size 32”

4. Resolution 1920 X 1080

5. Dynamic contrast ratio Required

6. Wide colour enhancer Required

7. Aspect ratio 16:9

8. Audio Not required

9. Connectivity: Required
VGA
HDMI : 2 ports (Minimum)

10. Mounting Wall

Desk

11. Power supply 110 V AC

230 V AC

12. Power consumption Bidder to specify

13. Dimensions : (W x H x D) Bidder to specify

14. Weight Bidder to specify

15. Accessories As required for proper operation

564
8.4.3.3. DVR (Digital Video Recorder) SPECIFICATION

Sr. No. Description Requirement

A. GENERAL

1. Make Bidder to specify

2. Model No Bidder to specify

B. Video Input

1. Video Compression H.264

2. Video Input 4 Channel

8 Channel
16 Channel

C. Video Output

1. HDMI/VGA Output 1920 X 1080

2. Encoding Resolution WD1

3. Frame Rate 25 FPS or better

D. Hard Disk

1. SATA 2 SATA Interface

2. Capacity Minimum 30 Days

E. External Interface

1. Network Interface RJ45

2. Serial Interface RS-485

3. USB Interface USB 2.0

F. Power

1. Power Supply 12 VDC

2. Consumption 20 W

G. Mechanical Properties

1. Dimensions Bidder to Specify

2. Weight Bidder to Specify

H. Environmental Properties

565
Sr. No. Description Requirement

1. Temperature -100C to 500C

2. Humidity 95 RH

8.4.4 RECORDING SYSTEM FEATURES

8.4.4.1. The recording system shall be based on DVR (Digital Video Recorder) technology
and must support the following features:
a) Event based recording
b) Alarm activated recording
c) Customizable alarm specific recording
d) Continuous (24 X 7) recording

8.4.4.2. There shall be a facility for regular back-up of the recorded data. Back-up facility
shall be deployed automatically when the recorder has reached particular data size or
other operator set parameters like date / time etc. The system shall also be provided
with a DVD burn /DAT recording facility for backing up particular incident data
from the processor.
8.4.4.3. The replay mode shall be password protected and should not interrupt the ongoing
recording of video and data.

8.4.5 SCHEDULE FOR SUBMISSION OF DATA AND DRAWINGS BY

CONTRACTOR (DATA TO BE FURNISHED AFTER THE AWARD OF
CONTRACT)

The CONTRACTOR shall submit the following drawings / documents after award
of contract for review & approval by Department. CONTRACTOR shall adhere to
the delivery schedule as submitted alongwith the BID. CONTRACTOR shall also
refer to data sheets for list of deliverables to be submitted for various instruments/
panels.

Sr.
No. Details
(a) Bar chart for the design, manufacturing, erection, commissioning,
trial operation and performance testing of the system offered.
(b) Overall System Configuration Diagram indicating all components
including networking.
(c) Unpriced purchase order copy for various bought out /sub
contracted equipment / services.
(d) Following drawings for panels:

 Front facia layout showing all instruments with cut-outs,

bezel dimensions, construction details, foundation details and
interior G.A. drawings showing interior layout of various modules,

566
 Sr.
No. Details
instruments etc.

 Internal wiring diagrams indicating termination details of

each component.

 Bill of Material (B.O.M.) indicating tag no., quantity,

service & model no. of the various modules/instruments/items.

(e) Make, Model No., Catalogues, data sheets for each item/ sub-item
of CCTV System.
(f) CCTV Configuration and Layout drawings.
(g) Data Sheets & catalogues for I&C cables & power cables.
(i) Earthing diagrams
(j) Cable Schedules and Interconnection cable schedules.
(k) Load calculations for each system
(l) QAPs for all instruments & panels for each system, I&C cables,
power cables & fibre optic cables.
(m) Standard SAT for the specified systems
(n) „As Built‟ drawings
(o) Instruction manual for installation and start-up (for each system)
(p) System operation and maintenance manual

8.4.6 TRAINING

1 No. Contractor‟s engineer shall be made available for 2 weeks for assistance in
operation, maintenance, tuning & training of Employer‟s personnel at Site after
commissioning of each system. The rates of the engineer shall be indicated Schedule
of personnel for supervision of erection, start-up, commissioning and performance.
Training shall be required on both hardware & application software development.

8.4.7 TESTING, INSTALLATION, COMMISSIONING AND ACCEPTANCE

8.4.7.1. General
On the basis of guidelines specified in this specification Bidder shall submit their
own testing, installation, commissioning and acceptance procedure. The procedure
shall include purpose of test, test definition, results expected and acceptance criteria.
For software it shall include details of the method, list of tests, sequence of
execution, results expected and acceptance criteria.
8.4.7.2. Site Acceptance Tests (SAT)
Full integrated site acceptance test shall be performed before hand over of total
system to the EMPLOYER. The test shall demonstrate functionality of the entire
system supplied & erected by the Contractor. The Contractor shall provide all
personnel, test facilities, equipment and tools etc. for the same. All test instruments

567
 shall have calibration certificates from approved test house, valid for minimum 6
months. A test procedure is required for approval 2 weeks prior to the schedule start.
8.4.7.3. Testing Requirements
Tests on cables
 Check details are in accordance with the specification.
 Check for physical damage.
 Megger test between each core and armour/sheath (For electrical cables)
 Continuity check including screen continuity (For electrical cables)
 Terminations of the cables at both ends.
8.4.7.4. It shall be ensured that erection of all panels is as per approved layout drawings.
Checking for tagging/identifications of all the panels shall be done. Checks for
continuity and termination of all power, signal, control and fibre optic cables shall be
carried out as per approved drawings. All the panels supplied & erected by the
Contractor shall be checked at site by carrying out the following tests:
 Visual & Mechanical testing.
 Power up tests
 Checks on incoming voltage and power distribution
 Checking of incoming power supply to the panels supplied & erected by the
Contractor.
 Switching on the incoming supply to panels by switching on MCCBs/MCBs
one after the other.
 Power „ON‟ PCs for CCTV System.
 Demonstration of all system functions of CCTV System.
 Checking of all HMI screens, alarms etc.
 Integrated testing of the IBMS and CCTV System.
 Checking of proper functioning of all Printers with printouts of alarm lists,
reports, important alarms etc.
8.4.7.5. The Contractor shall co-ordinate with other Contractors for the other systems and
integration with IBMS system.
8.4.7.6. Tests on electrical installation
 Checking of closing, tripping, supervision and interlocking of control devices.
 Checking operation of all alarm circuits.
8.4.7.7. Test on complete control system.
 On completion, the functioning of all systems shall be tested to demonstrate
its correct operation in accordance with the Specification.
 For testing, the Contractor may provide temporary means to simulate
operating conditions, but the system will not be finally accepted until correct
operation has been demonstrated to the satisfaction of the Employer.
8.4.7.8. Commissioning
a. Commissioning Procedure shall be carried out in a methodical sequence as
follows
568
  Start-up,
 Initial running,
 Operability adjustment,
 Stable operation
 Final adjustment
b. The Contractor shall check the operating conditions by constantly monitoring
operating data.
c. The Contractor shall specify for each discrete part of the system for which the
operational data has to be recorded and the manner in which the data is to be
taken. All the operating data shall be recorded, evaluated and submitted to the
Employer.

8.4.8 SPARES AND MAINTENANCE TOOLS AND TACKLES

8.4.8.1. GENERAL
a) All spares and maintenance tools and tackles shall be designed to enable
maintenance to be carried out in the least time and at the least cost and support
resources without affecting the performance and safety aspects.
b) All the spares and maintenance tools and tackles supplied shall be new and
unused.
8.4.8.2. The VENDOR/CONTRACTOR shall guarantee that before going out of production
of spares and maintenance tools and tackles for the equipment furnished, he shall
give at least 12 months advance notice to the EMPLOYER, so that the latter may
order his requirement in one lot, if so desired.
a) All spares supplied shall be strictly inter-changeable with the parts for which
these are intended to be replacements. The spares shall be treated and packed for
long term storage under the climatic conditions prevailing at the site e.g., small
items shall be packed in sealed transparent plastic bags with desiccator packs as
necessary.
b) Each spare shall be clearly marked or labelled on the outside of its packing with
its description and purpose. When more than one spare is packed in a single case,
a general description of the contents shall be shown on the outside of such case
and a detailed list enclosed. All cases, containers and other packages shall be
suitably marked and numbered for the purposes of identification.

8.5. ACCESS CONTROL SYSTEMS

8.5.1 Scope of Work

8.5.1.1. The scope of work shall include the design, preparation of detailed drawings,
manufacture, testing at manufacturer‟s works, testing at manufacturer‟s works,
inspection at Vendor‟s/Sub-Vendor‟s works, packing, forwarding, transportation,
loading, unloading, transit insurance, delivery at site, supply, installation,
commissioning, integrating, testing at site guaranteeing and maintenance of an
integrated access control system. Scope shall also include laying of cabling,
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 necessary for installation of the system as indicated in the specification and Bill of
Quantities. Any openings/chasing in the wall/ceiling required for the installation
shall be made good in appropriate manner.
8.5.1.2. Access control system shall be provided at Administration Building and Training &
Production Building.
8.5.1.3. Attendance monitoring facility shall be provided at Entrance of Administration
Building and Training & Production Building. The system shall be interfaced with
Finance software for recording in/out time of employee and generate salaries
accordingly.
8.5.1.4. Access control system shall be integrated with Fire alarm system. In case of fire
occurrence, all door access shall be disabled for uninterrupted and fast evacuation of
occupants.
8.5.1.5. This document is specifying the minimum criteria for the Design, Supply,
Installation and Commissioning & Maintenance of Access Control System. Bidder
shall be responsible for detailed engineering based on products proposed.

8.5.2 System Description

8.5.2.1. Access control system (ACS) shall be provided for the Training & Production Block
and Administration Block and will be a part of the Integrated Building Management
System. Integrated Building Management System (IBMS) mainly integrates the data
/ information from various sub systems and facilitates smooth, effective and efficient
administration of day-to-day activities. It also stores the information obtained from
various systems and compiles them to generate the reports for management
information in a required format. It also facilitates in regulating safety and security
of specified area of Training & Production Block and Administration Block.
8.5.2.2. A stand alone ACS shall be provided for the Training & Production Block and
Administration Block. The ACS shall comprise of
a. Smart Cards
b. Smart Card readers
c. Controller
d. Electro Magnetic locks
e. Exit push buttons
f. Central server PC and printer.

8.5.2.3. The ACS server shall be located in the Server Room at 2nd Floor, Administration
block. Reports like time-in, time-out, attendance etc. shall be generated and stored in
the system. The ACS shall be provided with complete required software and
hardware.
8.5.2.4. All doors shall be either wooden / aluminium. In case of glass doors, a U-clap and
L-Bracket shall be provided around the door. Maximum thickness in either case will
be 2”. Doors will open only in one direction and will be equipped with automatic
door closer of suitable size (depending on the type of door). Doors will be single
leafed. If they are double leafed then one leaf of the door will be permanently bolted
and entry for access control purposes will be necessarily through the other leaf.

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8.5.2.5. Magna locks will be installed on the door frame at the top and will give a feedback
on the door position also.
8.5.2.6. Exit push button will be installed just beside the door on a wooden boxing.
8.5.2.7. Controller for Access Control System shall be mounted on each block of each floor
in the Electrical room/server room/data room. The controller shall be a compact
panel mounted, stand-alone type of access controller with provision for controlling
the doors. The Controller shall allow the opening and closing of the door with the
event of authorised read for an adjustable time.
8.5.3 Access Control System Hardware Specification:
8.5.3.1. Operator Workstation – Man Machine Interface (MMI)
The function of the MMI is to provide a user friendly operator interface (GUI) and to
provide data archiving facilities. For system reliability, the MMI shall not be
required to perform any of the data processing for the regular functioning of the
Access Control System.
8.5.3.2. Operator Interface
The entire database of the central access controller shall be definable at the operator
workstation.
8.5.3.3. Operator Commands
The operator interface shall allow the operator to perform commands including, but
not limited to the following
 Operator Log and Access Privileges
 Override all doors to Access Mode of Operation
 Release Overrides
 Command Door to Access Mode
 Command Door to Secure Mode
 Command Door to Temporarily open
 Silence Local Alarms
 Manage Personnel Access Levels & Time Zones
 Control Remote Processors
 System operators shall, from the operator interface, be able to manually
unlock controlled doors for a variable time period, or program an event to
automatically unlock and lock doors during a particular time period.
8.5.3.4. Logs & Summaries
Reports shall be generated and directed to MMI, printers or disk files. At minimum,
the system shall allow the user to easily obtain the following:
 List of all cardholders
 List of all transactions currently available (Audit Trail)
8.5.3.5. Access Controllers
a. The Access Control System Controller shall be configurable, distributed
processing access control panel that communicates with a host computer and
dedicated peripheral devices to perform access control functionality. It
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 monitors a wide variety of access control input devices such as readers, door
contacts, request to exit switches, etc. and controls output devices such as
door locks and alarms.
b. Built-in programming shall allow the system controller to maintain its
operation in the event of loss of communications with the host computer. The
system shall be modular in structure for ease of installation, maintenance and
future expansion.
c. The System shall be configured by selection of plug-in modules that offer
these advantages:
 Plug-in reader and I/O modules shall be used to configure each panel
on an individual basis to satisfy the requirements for that area. Facility
expansion shall be possible by adding modules to an existing panel or
by adding more panels. Technicians shall troubleshoot and replace
plug-in modules without disrupting the entire system. Pluggable
terminal blocks shall allow modular removal without disturbing wiring
connections
 All access controller panels shall be housed in a cabinet designed for
mounting directly to a wall or vertical surface. Its door shall contain a
key lock. To eliminate the possibilities of compromises, due to the
accessibility of the electronics, the access controller should contain a
tamper switch to protect against unauthorised enclosure access. The
field controller shall provide, or be capable of expansion to, the
following capacities:
i. Card Readers Minimum 8
ii. Card Capacity 500 (minimum)
iii. Alarm Points 8
iv. Access Levels 256
v. Time Zones 256
vi. Password Levels 25
vii. Card Transaction 4000 with lithium battery (Buffer)
for storage and battery back up
viii. Real Time Clock Yes
ix. Battery Back Up Yes
x. The system shall be capable of storing 4000 transactions per
access controller
d. The access controller shall communicate with the Reader. When a card is read
at a reader, the card number and issue level are sent to the controller. The
controller shall be programmed to process this data and after comparing it
with the card data base resident in the access controller, shall grant access to
the card holder. If access is granted, the controller shall send a signal to the
appropriate electronic lock to activate the door. If access is denied, the
transactions will be recorded in the controller and an alarm is raised
identifying time date, Controller name & card name at HMI.
e. The system shall be flexible to designate certain readers to control entry or
exit, and shall require a card holder using a card at any entry reader to

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 subsequently use it at any exit reader before again entering the secured area.
This shall prevent “passing back” a card to an un-authorised second user.
Individual cards may be programmed for special privileges to override access
level and time zone parameters. In event of a power loss, a battery backup
shall be provided full controller operation for up to 8 hours. Cards shall be
programmed into system / controller individually.
f. The access controller shall provide a buffer to store 4000 historical
transactions if communication is lost with the MMI.
8.5.3.6. Reader Interface Modules (RIM)
a. The Smart type Card Readers shall be attached to the RIM. The RIM shall
control the electric lock, visual access indicators, access and shunt timers. The
RIM shall monitor door status via a door contact sensor and lock status via a
lock contact. An alarm shall be reported when the door is not closed or when
the door is forced open. An alarm shall be reported when the lock is not closed
properly. Readers shall be flush mounted.
b. In case RIM is not provided a multipair cable shall be laid from the Door lock,
Card reader‟s up to the Controller in the Control room.
8.5.3.7. Smart Cards & Card readers
a. The cards for this access control system shall be of top quality, highly durable
and resilient material designed for use with Smart card readers. Each card
shall be encoded with a digit unique to the access system, and individual card
number. Supply of suitable programming device and printing units for the
cards shall be included in the scope of bidder, so that no external agencies
shall be involved after getting the basic equipment for ACS except the dummy
cards. The manufacturer shall have the capability to provide custom printed
dummy cards, in accordance to the manufacturer‟s guidelines, to meet the
needs specified by the system Employer.
b. Cards shall be size of a credit card and have the feature to laminate a photo or
other identifying information on it. The cards should be ISO thickness capable
of being printed directly. The access cards must have the ability to print the
card holder‟s video image directly on the cards surface. The card is simply
presented within 100 mm of the reader. The reader as a minimum must have
LED indication upon presentation of the Access card.
8.5.3.8. Basic Access Control Software Features:
The basic access control software features shall be as follows:
a. User database
b. Database system settings & partitioning
c. Control access to areas via text
d. Timed control access
e. Backup and archive
f. Password protection and operator level privileges
g. Data import / export
h. Anti Pass back – Soft or Hard
i. Personnel movement tracking

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 j. Display of alarm & sensor status
k. Context sensitive help screens
l. Audit Trail archiving & retrieval
m. Custom reports such as attendance statement with first in and last out timings,
weekly/quarterly/monthly/summaries based on employees‟
code/plant/area/gate/ time or any other parameter that is tagged in to the
database.
n. Networkable either via a LAN, WAN or leased line
8.5.3.9. Electro Magnetic Lock
600lbs / magnetic lock, Single / Double EM locks should be designed to meet
fire/life safety applications by providing an auxiliary locking mechanism that has no
moving parts to bind or wear out for trouble free operation. This should ensure
inhibited release at all times where they have become extremely prevalent in
applications other than fire/life safety. Suitable for access controlled & secure areas
within buildings with Single / double leaf doors. The Magnetic Lock should consist
of Magnet mounted frame onto door frame and a steel plate attached to the top of the
door. This will be strongly bonded when magnet get energized and holding the steel
plate. Instant release should be possible when power supply is cut-off, in an
emergency situation.
 Holding Force – 600 lbs / magnet
 Operating Voltage – 12V / 24V Selectable
 Current Draw – 300-500 mA
 Operating Temperature - -10 to 55 Deg C
8.5.3.10. Exit Push Button
Exit Push Button with Includes break glass switch assembly use to egress swinging
or sliding doors that are electrically or electronically locked. In perimeter protection
systems that involve the central control of electric locking devices, an on-site
emergency release may be required. The “break glass” concept may be preferred
over the pull station, because it is less vulnerable to misuse or tamper actuation. It
shall be Surface mount in a standard 3-gang enclosure. It shall be Compatible with
all Fail Safe type electronic locking systems. It shall be Models with LED or audible
alarm. Also clearly marked signage indicating purpose of the release.
8.5.4 Power Supply
8.5.4.1. Feeders (1 no.) of 230 V AC, UPS power shall be made available in the UPS Room
for the Access Control System. UPS will be located in the Electrical room as shown
in the Location layout drawing. Contractor shall lay cables from UPS to each of the
system panels.
8.5.5 Power Cables
8.5.5.1. The specifications for power cables shall be as below:
 Conductor Material : Stranded Copper
 Insulation Material : Cables shall be PVC insulated as per application.
 Voltage Grade : 1100 V
 Armouring : All power cables will be GI wire armoured.
 Sheathing Material : Inner & Outer sheaths shall be FRLS PVC

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8.5.6 I&C Cables
8.5.6.1. All multipair & multicore cables shall be provided with 20% (of used pairs/cores)
spare pairs & cores for future use. Cables for Ethernet connectivity shall be CAT 6
cables which shall be armoured. Cables for RS-485 connection shall be twisted pair
cables, shielded & armoured.
8.5.6.2. Cable Glands
All cable glands shall be of double compression type with high quality neoprene
gaskets. Cable glands shall be of brass with nickel plating.
8.5.6.3. Cable trays
Cable trays shall be perforated of hot dipped galvanized steel. Cable trays shall have
50 mm collar height. The cable trays shall be covered type.
The cables coming in the beam area shall be allowed to pass through conduits.
The cables laid between two different buildings shall be laid in conduits in cable
trenches.
I&C Cables and power cables shall be routed through different cable trays to avoid
Electromagnetic Interference.
Minimum 300 mm distance shall be maintained between I&C cables / 24 V DC
power supply cables and 415 V AC/ 230 V AC power cables.
All cable trays shall be provided with 20% spare space for future use.
8.5.6.4. Fire proof Sealing for Cable penetration
Cables/ cable tray openings in walls and floors or through pipe sleeves from one area
to another or one elevation to another shall be sealed by a fireproof sealing
compound. The fire-proof sealing compound shall effectively prevent the spread of
fire from the flaming to non-flaming side, in the event of fire.
8.5.6.5. The specifications of cables shall be as mentioned below.

Description Power Control Signal cable Triad

Cable cable Cable
GENERAL 1. Type Armoured Screened, Twisted, screened,
armoured armoured
2. Voltage grade 1100 V 1100 V 660 V
3. Material Annealed Tinned Copper
4. Shape of Stranded circular
CONDUCT
conductor
OR
5. Size
6. No. of strands 7 nos.
7. Material Extruded Polyethylene (PE) as per BS-EN 50290-2
8. Thickness of 0.8 mm
insulation
PRIMARY
(Nominal)
INSULATIO
9. Colour code Grey White +ve, Brown,
N
Black –ve Black and
(For each blue
pair)
INDIVIDUA 10. Twist NA NA Min. 10 nos. twist / meter
L PAIRS / for each pair

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TRIADS 11. Identification NA NA Numbers at not more than
250mm length
12. Material NA NA AL Mylar tape applied
helically with metallic
side down in contact with
drain wire
13. Tape thickness NA NA Minimum 0.075 mm thick
for single pair cables
Minimum 0.05 mm thick
for multipair cables
INDIVIDUA
14. Overla NA NA Min 100% Min 100
L PAIR /
p .25 . %
TRIAD
% 25
SCREENIN
%
G
15. Polyester tape NA NA Polyester tape of 0.05 mm
thick each. two tapes with
min. 25% overlap &
100% coverage
16. Drain wire
17. Material NA NA Annealed Tinned Copper
18. Size NA NA 0.5mm2, with 7 strands,
each of 0.3 mm dia.
19. Material NA AL Mylar tape applied helically with
metallic side down in contact with drain
wire
20. Tape thickness NA Minimum 0.075 mm
21. Overlap Cover NA Min 100% Min. 100 Min 100
OVERALL
age . 25% % . %
SCREENIN
25 25
G
% %
22. Drain wire NA
23. Material NA Annealed Tinned Copper
2
24. Size NA 1 mm , with 7 strands, each of 0.3 mm
dia.
25. Type Non-Hygroscopic, two tapes with min. overlap of 25%
BINDER
& 100% coverage
TAPE
26. Tape Thickness Each tape of min. 0.023 mm thick
27. Material Extruded flame retardant PVC type ST-2, 90oC as per
IS-5831 ,
oxygen index over 30% and temp. index over 250 deg
C.
28. Thickness As per BS-EN 50288 part 7 (Note-2)
INNER (Nominal)
SHEATH 29. Colour Black
30. Diameter over Bidder to Specify
inner sheath Note:- Cable dimensions (OD under armour, OD over
armour, overall OD) shall be as per BS-EN-50288-7.
Maximum tolerance in dimensions shall be +/- 2 mm.
31. Rip Chord Non-metallic required under inner sheath
ARMOURIN 32. Material Galvanised steel
G 33. Size As per BS-EN 50288

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 34. Diameter over Bidder to Specify
armour Note:- Cable dimensions (OD under armour, OD over
armour, overall OD) shall be as per BS-EN-50288-7.
Maximum tolerance in dimensions shall be +/- 2 mm.
35. Material Extruded flame retardant PVC IEC-332, Type ST-2,
90oC as per IS-5831
36. Thickness As per BS-EN 50288 part 7 (Note-2)
(Nominal)
37. Colour Black Black, for Intrinsic Black
OUTER safe light blue
SHEATH 38. Overall Bidder to Specify
Diameter Note:- Cable dimensions (OD under armour, OD over
armour, overall OD) shall be as per BS-EN-50288-7.
Maximum tolerance in dimensions shall be +/- 2 mm.
39. Cable Running length printed at min. every 1 metre interval
identification
40. Conductor As per BS-EN 50288 part 7
resistance
41. Drain wire NA < 30 ohms/km @ 20 deg c. Noise
resistance rejection ratio > 76 db.
42. Insulation 1 G Ω/KM as per BS EN 50288
ELECTRIC
resistance
AL
43. Mutual NA < 110 nF/KM @ 1 KHz
PROPERTIE
capacitance
S
44. Capacitance NA < 400 nF/KM @ 1 KHz
between core
and screen
45. Inductance NA < 1 mH/KM @ 1 kHz
46. L/R Ratio NA As per BS-EN 50288 part 7

8.5.7 Panels Accessories & Wiring

8.5.7.1. Wiring
All inter cubical and internal wiring for all panels shall be carried out with 1100V
grade, stranded tinned copper conductors with PVC insulation. The minimum size of
the stranded copper conductor used for the panel wiring shall be 0.5 sq. mm for
analog signals and 1.0 sq. mm for commands. For power supply, the conductor size
shall be provided as per the load rating (min. 2.5 mm for 230 V AC). Control &
Power wiring shall be segregated and routed in PVC troughs. Different colour wires
shall be used for different voltages.
Engraved core identification plastic ferrules, marked to correspond with the panel-
wiring diagram shall be fitted at both ends of each wire. Cross ferruling shall be done.
This shall also be applicable for fibre optic cable & cores.
All spare contacts and spare terminals of the panel mounted equipment and devices
shall be wired to the terminal blocks.
8.5.7.2. Relays
All relays used for interposing shall have at least 2 nos. changeover contacts. The
relays shall have status indication and shall be provided with free wheeling diodes.
8.5.7.3. Labels

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 All front mounted equipment, as well as equipment mounted inside the panels/control
desks shall be provided with individual labels with equipment designation engraved.
These shall be phenolic overlays (1.6 mm thick) with black background and white
lettering and shall be fixed to the panel by stainless steel screws (counter sunk). The
panels shall also be provided at the top with a label engraved with the designation.
Lettering for panel designation shall be 6 mm.
The minimum lettering size for instrument/device labels shall be 3mm. The lettering
on the labels shall be subject to EMPLOYER'S approval. Labels of internally
mounted equipment shall be clearly visible.
8.5.7.4. Earthing
Each panel shall be provided with a safety ground bus & system ground bus made of
copper securely fixed along the inside base of the panels. These buses shall be
typically of 25 mm wide and 6 mm thick of copper. The safety ground bus shall be
properly secured to the plant safety earthing. All metallic cases/frames of relays,
instruments, other panel mounted equipment shall be connected to the safety ground
bus and shields & drain wires of signal/control cables shall be connected to the
system ground bus by independent copper wires of not less than 2.5 sq. mm. The
system ground bus shall be electrically isolated from AC mains earthing bus. The
system ground bus shall be insulated from the panel body. The insulation colour code
for earthing wires shall be green with yellow bands.

8.5.8 SUMMARY OF DATA TO BE FURNISHED ALONG WITH BID AND AFTER

ACCEPTANCE OF PURCHASE ORDER
The BIDDER shall ensure the following documentation are prepared and submitted to
EMPLOYER for his review / record.
8.5.8.1. Technical Bid
The following drawings/ documents shall be submitted:
a. Data sheet an catalogs of instruments/ equipments
b. Dimensional Drawings of Panels along with estimated BOQ for each of the
systems.
c. Overall System Configuration Diagram
d. Engineering activity and manufacturing schedule giving activity wise breakup to
meet the delivery schedule.
e. Testing & Evaluation plan for the systems offered.
8.5.8.2. Final Documents
a. Operation and maintenance manuals.
b. Quality assurance documentation specific for the project.
c. Final as built documentation folder containing all items for future reference.

8.5.9 SCHEDULE FOR SUBMISSION OF DATA AND DRAWINGS BY

CONTRACTOR (DATA TO BE FURNISHED AFTER THE AWARD OF
CONTRACT)
The CONTRACTOR shall submit the following drawings / documents after award
of contract for review & approval. CONTRACTOR shall adhere to the
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delivery schedule as submitted along with the BID. CONTRACTOR shall also refer
to data sheets for list of deliverables to be submitted for various instruments/ panels.

Sl. Details
No.

(a) Bar chart for the design, manufacturing, erection, commissioning, trial
operation and performance testing of the system offered.

(b) Overall System Configuration Diagram indicating all components

including networking.

(c) Unpriced purchase order copy for various bought out /sub contracted
equipment / services.

(d) Following drawings for panels:

 Front facia layout showing all instruments with cut-outs, bezel

dimensions, construction details, foundation details and interior G.A.
drawings showing interior layout of various modules, instruments etc.

 Internal wiring diagrams indicating termination details of each

component.

 Bill of Material (B.O.M.) indicating tag no., quantity, service

& model no. of the various modules/instruments/items.

 Make, Model No., Catalogues, data sheets for each item/ sub-
item of Access Control System.

 ACS Configuration and Layout drawings.

 Data Sheets & catalogues for I&C cables & power cables.

 Data sheets & catalogues for Fibre Optic cables, RS-485 to

Fibre Optic Converters, F/O convertors & all connectors.

 Earthing diagrams

 Cable Schedules and Interconnection cable schedules.

(e) Load calculations for each system

(f) QAPs for all instruments & panels for each system, I&C cables,
power cables & fibre optic cables.

(g) Standard FAT & SAT for the specified systems

(h) „As Built‟ drawings

(i) Instruction manual for installation and start-up (for each system)

(j) System operation and maintenance manual as described in

specification.

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8.5.10 TRAINING
8.5.10.1. 1 No. Contractor‟s engineer shall be made available for 2 weeks for assistance in
operation, maintenance, tuning & training of Employer‟s personnel at Site after
commissioning of each system.
8.5.10.2. Training shall be required on both hardware & application software development.

8.5.11 TESTING, INSTALLATION, COMMISSIONING AND ACCEPTANCE

8.5.11.1. General
On the basis of guidelines specified in this specification Bidder shall submit their
own testing, installation, commissioning and acceptance procedure. The procedure
shall include purpose of test, test definition, results expected and acceptance criteria.
For software it shall include details of the method, list of tests, sequence of
execution, results expected and acceptance criteria.
8.5.11.2. Factory Acceptance Tests (FAT)
a. Contractor shall demonstrate functional integrity of the various items in the
systems supplied by him, including the system hardware and software covered in
this specification. No material or equipment shall be transported until all required
tests are completed & Employer gives the dispatch clearance.
b. Employer reserves the right to involve and satisfy himself at each and every stage
of testing. They shall be free to request specific tests on equipment considered
necessary by them, although not listed in this specification. The cost of
performing all tests shall be borne by the Contractor.
c. Bidder to note that acceptance of any equipment or the exemption of inspection
testing shall in no way absolve the bidder of the responsibility for delivering the
equipment meeting all the specified requirements.
d. It shall be Contractor's responsibility to modify and/or replace any item (hardware
or software) if the specified functions are not completely achieved satisfactorily
during FAT.
e. Contractor shall not replace any component/module/subsystem unless it has failed
and a log of such failures & analysis of the failure generated in form of a report
shall be maintained during FAT. If a malfunction of module/component in a
subsystem repeats, the test shall be terminated and contractor shall replace the
faulty component/module. Thereafter test shall start all over again. If a subsystem
fails during FAT and is not repaired and made successfully operational within 4
hours of active repair time after the failure, the test shall be suspended and
restarted all over again only after contractor has replaced the device into
acceptable operational condition.
f. The FAT for the various items shall be performed in accordance with the
approved QAPs.
g. Testing & FAT shall be carried out in two phases. The minimum requirement for
testing during these two phases shall be as follows:
Under the first phase bidder shall perform tests at his works to ensure that all
components function in accordance with the specifications. A test report shall be
submitted for the Employer‟s review within one week of completion of this test.
Bidder shall perform the following minimum tests for the various systems and
reports shall be forwarded to the Employer:

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 i.Quality control test which shall be carried out to assure quality of all components
and modules
ii.Visual check of panels, all instruments, all modules, fibre optic converters etc.
iii.High voltage test as per relevant IS standard
iv.Megger test
v.System power-up test, which shall test functionally all hardware, racks, cabinets
etc.
vi.Functional testing. This shall include the simulation of each item in the various
systems supplied & wired by the Contractor and achieving the functional
requirements as called for in the specifications and to verify proper system
response. This is applicable for the Fire Alarm System. All testing for fire alarm
system shall be in accordance with NFPA 72.
vii.Functional testing of networking.
8.5.11.3. After the Contractor has performed the tests satisfactorily, the Contractor shall
perform tests on all the items to be witnessed by Employer as per approved QAPs.
Contractor shall notify the Employer at least three (3) weeks prior to factory
acceptance test. This shall be the second phase of testing which shall be carried out
systematically, fully and functionally test all hardware and software in the presence
of Employer‟s representative.
All test instruments shall have calibration certificates from approved test house,
valid for minimum 6 months.
8.5.11.4. Site Acceptance Tests (SAT)
Full integrated site acceptance test shall be performed before hand over of total
system to the EMPLOYER. The test shall demonstrate functionality of the entire
system supplied & erected by the Contractor. The Contractor shall provide all
personnel, test facilities, equipment and tools etc. for the same. All test instruments
shall have calibration certificates from approved test house, valid for minimum 6
months. A test procedure is required for approval 2 weeks prior to the schedule start.
8.5.11.5. Testing Requirements
a. Tests on cables
 Check details are in accordance with the specification.
 Check for physical damage.
 Megger test between each core and armour/sheath (For electrical cables)
 Continuity check including screen continuity (For electrical cables)
 Terminations of the cables at both ends.
b. It shall be ensured that erection of all panels is as per approved layout
drawings. Checking for tagging/identifications of all the panels shall be done.
Checks for continuity and termination of all power, signal, control and fibre
optic cables shall be carried out as per approved drawings. All the panels
supplied & erected by the Contractor shall be checked at site by carrying out
the following tests:
 Visual & Mechanical testing.
 Power up tests
 Checks on incoming voltage and power distribution

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  Checking of incoming power supply to the panels supplied & erected by
the Contractor.
 Switching on the incoming supply to panels by switching on
MCCBs/MCBs one after the other.
 Power „ON‟ PCs for Access Control System.
 Demonstration of all system functions Access Control System.
 Checking of all HMI screens, alarms etc.
 Integrated testing of the IBMS and Access Control System.
 Checking of proper functioning of all Printers with printouts of alarm lists,
reports, important alarms etc.
c. The Contractor shall co-ordinate with other Contractors for the other systems
and integration with IBMS system.
d. Tests on electrical installation
 Checking of closing, tripping, supervision and interlocking of control
devices.
 Checking operation of all alarm circuits.
e. Test on complete control system
 On completion, the functioning of all systems shall be tested to
demonstrate its correct operation in accordance with the Specification.
 For testing, the Contractor may provide temporary means to simulate
operating conditions, but the system will not be finally accepted until
correct operation has been demonstrated to the satisfaction of the
Employer.

8.5.12 Commissioning
8.5.12.1. Commissioning Procedure shall be carried out in a methodical sequence as follows
 Start-up,
 Initial running,
 Operability adjustment,
 Stable operation
 Final adjustment

8.5.12.2. The Contractor shall check the operating conditions by constantly monitoring
operating data.
8.5.12.3. The Contractor shall specify for each discrete part of the system for which the
operational data has to be recorded and the manner in which the data is to be taken.
All the operating data shall be recorded, evaluated and submitted to the Employer

8.5.13 EQUIPMENT & SERVICES TO BE PROVIDED BY THE CONTRACTOR

8.5.13.1. This specification covers specific requirements of design, preparation of detailed
drawings, manufacture, testing at manufacturer‟s works, inspection at Vendor‟s/Sub-
Vendor‟s works, packing, forwarding, transportation, transit insurance, delivery at
site, installation, testing at site, erection and commissioning of Access control
System (ACS) as per specification and data sheets enclosed.

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8.5.13.2. The following shall be in the scope of the CONTRACTOR
ACS comprising of Access cards (smart type), card readers, magna locks, exit push
buttons, Access Management controller, PC with 15” Flat TFT LCD monitor,
software, all associated cabling and installation hardware for the system.
8.5.13.3. Cabling
a) Contractor shall supply & lay the following cables along with all the
installation hardware and accessories:
 UPS to ACS panel
 ACS system cabling
b) Cable Trays & Conduits shall be routed above the false ceiling.
8.5.13.4. Earthing
a) Earthing for the entire system to be provided by the Contractor. Separate
electrical & instrumentation earth pits shall be provided by Others. This earth
pit shall be interconnected with electrical earth pit. Contractor shall connect
the safety ground bus & system ground bus for the systems supplied by him to
the respective earth pits.
b) Single point earthing configuration shall be followed for the cable shields i.e.
all signal and control cables shields shall be grounded at one end only to avoid
ground loop.
8.5.13.5. Interfacing with third party devices
The Access control system shall be interfaced with the Integrated Building
Management system (IBMS) at the Server Room, 2nd Floor, Admin Block.

8.5.14 SPARES AND MAINTENANCE TOOLS AND TACKLES

8.5.14.1. GENERAL
a) All spares and maintenance tools and tackles shall be designed to enable
maintenance to be carried out in the least time and at the least cost and support
resources without affecting the performance and safety aspects.
b) All the spares and maintenance tools and tackles supplied shall be new and
unused.
c) The VENDOR/CONTRACTOR shall guarantee that before going out of
production of spares and maintenance tools and tackles for the equipment
furnished, he shall give at least 12 months advance notice to the EMPLOYER,
so that the latter may order his requirement in one lot, if so desired.
8.5.14.2. SPARES
a) All spares supplied shall be strictly inter-changeable with the parts for which
these are intended to be replacements. The spares shall be treated and packed for
long term storage under the climatic conditions prevailing at the site e.g., small
items shall be packed in sealed transparent plastic bags with desiccator packs as
necessary.
b) Each spare shall be clearly marked or labelled on the outside of its packing with
its description and purpose. When more than one spare is packed in a single case,
a general description of the contents shall be shown on the outside of such case

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and a detailed list enclosed. All cases, containers and other packages shall be
suitably marked and numbered for the purposes of identification.

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8.6. IT & TELEPHONE SYSTEMS

8.6.1 Scope of Work

New Technology Centre (TC) is planned at Pudi, Visakhapatnam. TC shall have
building blocks like Admin Building, Canteen Area, Boys Hostel, Girls Hostel and
Staff accommodation, Guest House, Utility Area and Training & Production Area.
These blocks shall have data connectivity for operating computer System, Network
Equipment and also provide connectivity to safety and security system such as CCTV
Surveillance system, Access control System, Fire Alarm System, Time & Attendance
System and telephone and intercom system for communication. System Architecture
for data network is shown in figure 1.1 and data and intercom telephone points are
listed in Table 1.1 below.

Figure: 1.1: Architecture Diagram for Data Network

Table 1.1: Data and Telecom points

Sr. Location / Area Qty Connections Total Connections

No. required required
DATA Tele TV DATA Tele TV
1 Admin & Conference Block
1.1 Ground Floor
a Sr. Manager/ DGM Sr. Engg. 6 2 2 0 12 12 0
Cabin
585
Sr. Location / Area Qty Connections Total Connections
No. required required
b Office Area 4 3 2 0 12 8 0
c Conference Room 2 1 1 1 2 2 2
l Reception 1 2 2 1 2 2 1
8 7 2 28 24 3
1.2 First Floor
a Conference Hall 1 2 2 0 2 2 0
b Pantry 1 0 1 0 0 1 0
c Lunch Room 1 0 1 1 0 1 1
d Housekeeping Room 1 0 1 0 0 1 0
2 5 1 2 5 1
1.3 Second Floor
a Server Room 1 12 2 0 12 2 0
b IT Department 1 4 2 0 4 2 0
16 4 0 16 4 0
Total Admin Block 46 33 4

2 Training & Production

Block
2.1 Ground Floor
a HOD & Sr. Manager Cabin 2 2 2 0 4 4 0
b Manager Room 1 2 2 0 2 2 0
c Training Office 1 9 2 0 9 2 0
d Placement Cell 1 4 2 0 4 2 0
e Reception Training Block 1 2 2 0 2 2 0
f Counseling & Room 2 1 1 0 2 2 0
g Training Block 1 12 6 0 12 6 0
h Production Block 1 24 10 0 24 10 0
y Utility Block 1 8 4 0 8 4 0
64 31 0 67 34 0
2.2 First Floor
a Class Rooms 8 2 0 0 16 0 0
b Labs 16 10 1 0 160 16 0
d Production Office 1 30 15 0 30 15 0
e Faculty Room 1 6 2 0 6 2 0
48 18 0 212 33 0
2.3 Second Floor
a Library 1 4 2 0 4 2 0
4 2 0 4 2 0
Total Training Block 283 69 0

3 Canteen Building 1 2 4 2 2 4 2
4 Executive Hostel 1 0 4 4 0 4 4
5 Staff Accommodation 1 0 8 8 0 8 8
586
Sr. Location / Area Qty Connections Total Connections
No. required required
6 Hostel 2 6 6 2 12 12 4
Total 14 28 18
Total 343 130 22

8.6.2 Technical Specifications of the components required

8.6.2.1. Layer 3 Core Switch Specifications
1. 24 1G SFP slots equipped with 12 1G copper ports for server connectivity, additional
4 10G SFP+ slots, equipped with internal Redundant Power System(RPS)
2. Should support active-active clustering Virtual Switching System (VSS) / equivalent
technology for higher availability of Layer 2 and Layer 3 (RIP, RIPng, OSPF,
OSPFv3, BGP, PIM) including video applications
3. The switch should have provision to support VSS/ equivalent clustering bandwidth
80Gbps per switch with two switches in virtual chassis
4. Layer 2 Features: GVRP, VLAN creation based on protocol and Ports, IEEE
802.1Q Virtual LAN (VLAN) bridges, IEEE 802.1v , port IEEE 802.3ac VLAN
tagging, Q In Q, Up to 4K configurable VLAN's, IEEE 802.1D MAC bridges, IEEE
802.1s Multiple Spanning Tree Protocol (MSTP), IEEE 802.1w Rapid Spanning Tree
Protocol (RSTP)
5. Layer 3 Features: Should support Static routing, RIP, RIPng, OSPF, OSPFv3, PIM
v4 SM, DM and SSM, PIMv6-SM, BGP, BGP4, IEEE 802.3az, IEEE 802.3ac
6. Should support IEEE 802.17/ERPS/equivalent for sub 50ms ring protection in
following scenario : single, dual fibre cuts in ring and when fibre cut at common
shared link in between two or more rings
7. Security: Should support ACLs, DHCP snooping, IP source guard and Dynamic
ARP Inspection (DAI), MAC address filtering and MAC address lock-down, Tri-
authentication: MAC-based, web-based and IEEE 802.1x,
8. Management : CLI, GUI, USB interface for taking backup of software release files
configurations, digital optical monitoring, time domain reflectometry (TDR)
diagnostic, sFlow or equivalent
9. The High available switch shall also act as an Centralized management / provisioning
console for dynamic policy roll out across the switches or for selected switches in the
network using instant access/equivalent technology
10. The High available switch shall support automated scheduled back up of running
configuration files from all the network switches which will be deployed in network
to ensure ease of management.
11. The High available switch shall also act as an Centralized management / provisioning
console to ensure Zero touch replacement of field switches across network in case of
any switch failure and also ensure the last running configuration is pushed through
the central chassis upon successful detection of the new replaced field unit without
any human intervention

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 12. The Virtual chassis cluster should also provide the functionality of centralized
Software firmware roll and management to all the switches across the network to
ensure consistent software image is maintained centrally across the network switches.
13. The Centralized Management / Provisioning console for Zero touch replacement ,
Dynamic Policy roll out , Dynamic Network provisioning / Centralized Software
Firmware roll out shall support these technical functionalities over the LAN and
WAN network
14. Switch should be capable of inbuilt wireless controller functionality for the
management of min 40 Wi-Fi access points.
For ease of integration, all switches, AP, firewall, SFP‟s should be of same OEM.
Approved Makes: Cisco, HP, Juniper, Allied Telesis

8.6.2.2. 48 Port Access Switch

1. 48 100/1000 Base-T Ports Additional 4x1G SFP slots. The 4 1G SFP ports should be
scalable to support 10G SFP+ modules
2. Switching Capacity: Non-Blocking Forwarding Rate: Wire Speed
3. Should support active-active clustering VSS / equivalent technology for higher
availability of Layer 2 and Layer 3 including video applications
4. The Active - Active Virtual chassis cluster should support technology functionality
locally or over geographically diversified locations For Diversified Data centre high
availability operations
5. The Active - Active Virtual chassis bandwidth between the 2 high available cluster
switches should be of min of 20Gbps when clustered locally or over geographically
diversified locations
6. Layer 3 Features: Should be upgradable to support Static routing, RIP, RIPng,
OSPF, OSPFv3, PIM v4 SM, DM and SSM, PIMv6-SM,
7. Layer 2 Features: GVRP, VLAN creation based on protocol and Ports, IEEE
802.1Q Virtual LAN (VLAN) bridges, IEEE 802.1v VLAN classification by protocol
and port IEEE 802.3ac VLAN tagging, Q In Q, Up to 4K configurable VLAN ' s,
IEEE 802.1D MAC bridges, IEEE 802.1s Multiple Spanning Tree Protocol (MSTP),
IEEE 802.1w Rapid Spanning Tree Protocol (RSTP), IEEE 802.3az, PVST+
compatibility mode
8. Resiliency: Should support IEEE 802.17/equivalent for sub 50ms ring protection in
following scenario : single, dual fibre cuts in ring and when fibre cut at common
shared link in between two or more rings
9. Security: Should support ACLs, DHCP snooping, IP source guard and Dynamic
ARP Inspection (DAI), MAC address filtering and MAC address lock-down, Tri-
authentication: MAC-based, web-based and IEEE 802.1x, DHCPv4 (server, relay and
client)
10. IPv6 Features: DHCPv6 relay, DHCPv6 client, DNSv6 relay, DNSv6 client, IPv4
and IPv6 dual stack, IPv6 QoS and hardware ACLs, SNMPv6, Telnetv6, SSHv6 and
Syslogv6, NTPv6 client and server, IPv6 static unicast and multicast routing

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 11. Multicast Features: IGMP snooping (v1, v2 and v3), MLD snooping (v1 and v2),
PIM-SM and SSM for IPv6, Bootstrap Router (BSR) mechanism for PIM-SM IGMP
query solicitation, PIM Dense Mode (DM)
12. Management Features: SNMPv1, v2c and v3, IEEE 802.1AB Link Layer Discovery
Protocol (LLDP), Web GUI, sFlow, CLI, GUI, SNMPv3, SNMP Console
management port, Port mirroring locally with in switch and across Virtual chassis
cluster, TFTP, NTP, Syslog , An USB or equivalent memory card socket , allowing
software release files, configuration and other files to be stored for backup and
distribution to other switches, DDM – Optical digital diagnostic monitoring as per
SFF – 8472 or equivalent standards, time domain reflectometry (TDR) diagnostic
13. Should support functionality to continuously monitor the received optical power of
fibre ports and send SNMP trap when received optical power crosses predefined
threshold level to avoid physical intrusion on fibre links
14. Should seamlessly integrate with core switch
15. Certifications: UL,
16. Approved Makes: Cisco, HP, Juniper, Allied Telesis

8.6.2.3. 24 Port Access Switch

1. 24 100/1000 Base-T Ports Additional 4x1G SFP slots. The 4 1G SFP ports should be
scalable to support 10G SFP+ modules
2. Switching Capacity: Non-Blocking Forwarding Rate: Wire Speed
3. Should support active-active clustering VSS / equivalent technology for higher
availability of Layer 2 and Layer 3 including video applications
4. The Active - Active Virtual chassis cluster should support technology functionality
locally or over geographically diversified locations For Diversified Data centre high
availability operations
5. The Active - Active Virtual chassis bandwidth between the 2 high available cluster
switches should be of min of 20Gbps when clustered locally or over geographically
diversified locations
6. Layer 3 Features: Should be upgradable to support Static routing, RIP, RIPng,
OSPF, OSPFv3, PIM v4 SM, DM and SSM, PIMv6-SM,
7. Layer 2 Features: GVRP, VLAN creation based on protocol and Ports, IEEE
802.1Q Virtual LAN (VLAN) bridges, IEEE 802.1v VLAN classification by protocol
and port IEEE 802.3ac VLAN tagging, Q In Q, Up to 4K configurable VLAN ' s,
IEEE 802.1D MAC bridges, IEEE 802.1s Multiple Spanning Tree Protocol (MSTP),
IEEE 802.1w Rapid Spanning Tree Protocol (RSTP), IEEE 802.3az, PVST+
compatibility mode
8. Resiliency: Should support IEEE 802.17/equivalent for sub 50ms ring protection in
following scenario : single, dual fibre cuts in ring and when fibre cut at common
shared link in between two or more rings
9. Security: Should support ACLs, DHCP snooping, IP source guard and Dynamic
ARP Inspection (DAI), MAC address filtering and MAC address lock-down, Tri-
authentication: MAC-based, web-based and IEEE 802.1x, DHCPv4 (server, relay and
client)

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 10. IPv6 Features: DHCPv6 relay, DHCPv6 client, DNSv6 relay, DNSv6 client, IPv4
and IPv6 dual stack, IPv6 QoS and hardware ACLs, SNMPv6, Telnetv6, SSHv6 and
Syslogv6, NTPv6 client and server, IPv6 static unicast and multicast routing
11. Multicast Features: IGMP snooping (v1, v2 and v3), MLD snooping (v1 and v2),
PIM-SM and SSM for IPv6, Bootstrap Router (BSR) mechanism for PIM-SM IGMP
query solicitation, PIM Dense Mode (DM)
12. Management Features: SNMPv1, v2c and v3, IEEE 802.1AB Link Layer Discovery
Protocol (LLDP), Web GUI, sFlow, CLI, GUI, SNMPv3, SNMP Console
management port, Port mirroring locally with in switch and across Virtual chassis
cluster, TFTP, NTP, Syslog , An USB or equivalent memory card socket , allowing
software release files, configuration and other files to be stored for backup and
distribution to other switches, DDM – Optical digital diagnostic monitoring as per
SFF – 8472 or equivalent standards, time domain reflectometry (TDR) diagnostic
13. Should support functionality to continuously monitor the received optical power of
fibre ports and send SNMP trap when received optical power crosses predefined
threshold level to avoid physical intrusion on fibre links
14. Should seamlessly integrate with core switch
15. Certifications: UL,
16. Approved Makes: Cisco, HP, Juniper, Allied Telesis

8.6.2.4. Firewall Specifications:

1. Internet Gateway router / Next Generation Firewall and Security gateway device with
min 2 * 10/100/1000 T or 2 * SFP combo WAN ports and Min 8 * 10/100/1000T
LAN ports with 2 * WAN By Pass ports for high availability
2. Performance Requirements:
a. Min Firewall throughput of 1500 Mbps or more
b. Min Concurrent sessions support up to 1,00000 sessions
c. Min IPS throughput of 600 Mbps or more
d. Min IP Reputation throughput of 800 Mbps or more
e. Min Malware Throughput of 1180 Mbps or more
f. Min VPN Throughput of 700 Mbps or more
3. Layer 3 features:
a. Static routing, RIP and RIP ng, OSPFv2 and OSPFv3, BGP4 and BGP4+
b. IGMP, PIMv4 and PIMv6 , Bridging (LAN / WAN)
c. PPPoE , DHCPv4/v6 client, server, relay, Static, IPsec traversal, Dynamic
NAPT, RADIUS / TACACS+
4. Network Resilience: VRRP and VRRPv3 , Spanning Tree, RSTP, MSTP
5. Firewall Features
a. DPI firewall, Application control , web control, Traffic shaping
b. DMZ, Port forwarding, Dynamic NAT
c. Static PPP, L2TPv3 Ethernet pseudo-wires, GRE for IPv4 and IPv6
6. Management features
a. USB Slot media, RADIUS, TACACS+, SNMP v1 / v2 and V3 support
b. SSHv1/v2, Syslog & Syslogv6, SNMPv2 & v3
c. Full environmental monitoring of PSU, fan, temperature and internal voltages.

590
 d. Should be able to send SNMP traps alert to network managers in case of any
failure
e. Safety Standards: UL60950-1, CAN/CSA-C22.2 No. 60950-1-03, EN60950-
1, EN60825-1, AS/NZS 60950.1, UL,
7. Approved Makes: Cisco, HP, Juniper, Allied Telesis

8.6.2.5. Network Management System Specifications:

1. Automatic topology discovery and creation of network maps for Layer 3 and Layer 2
network , All the available VLANS
2. Should have high level Network Inventory polling capability for IP Network nodes
including the security appliance, All available line cards , Modules , ports , Physical
links , VLAN interfaces and all the other SNMP capable devices in the network
3. Should have powerful administration control
4. Detailed performance monitoring and management
5. Should have extensive fault management capabilities with Real time Event and Alarm
notifications , System Logs and Audit trials
6. Creation and management of security and QOS policies
7. Scheduled Device configuration back-up and restore functionality
8. Automatic Detection of configuration changes for easy trouble shooting and Isolation
9. Should support 3rd party devices and end points
10. Should have the functionality of Group provisioning / Scheduled configuration roll
out management
11. Should have the ability to perform scheduled or unscheduled network wide software
or Firmware upgrades
12. Should have the ability to customize the NMS dash boards as per the requirements of
technical team
13. Should have the ability to perform / create group of devices for applying same task
14. Should have extensive Event notification capability
15. Should provide the flexibility to the network administrator to assign task to an
Individual network engineer and assign ownership / track the status of the issue
resolution
16. Should have extensive centralized trouble shooting tools in built
17. The NMS solution should be preferably from the same Active switching vendor , in
case vendors proposing for 3rd party NMS solution should provide all the interop
reports certified by both the NMS vendor and Active switching on seamless
interoperability
18. All the required Hardware / Software licenses for the NMS solution should be
proposed by the bidder
19. Approved Makes: Cisco, HP, Juniper, Allied Telesis

8.6.2.6. Specifications for 12C Single Mode Fiber Optic Cables:

12C Single mode Optical Fiber cable shall have following features,

591
 Gel-free design for water blocking capability using craft-friendly water-swellable
materials
 Flexible, craft-friendly buffer tubes to route in closures easily
 S-Z stranded, loose tube design which isolates fibers from installation and
environmental rigors and facilitates mid-span access
 Dielectric central strength member and requires no bonding or grounding
 Medium-density PE jacket to be rugged, durable and easy to strip
 Meets industry standards and specifications including ICEA-640, Telcordia GR-
20

Typical Outdoor Fiber Cable Loose Tube

Following are the typical specifications for OS2 Outdoor Single mode Fibre
supporting speeds in excess of 10Gbps:

General Specifications:
- Cable Type Stranded loose tube
- Construction Type armoured
- Subunit Type/Buffer tube Gel-free

Construction Materials:
- Cable Type zero water peak single mode fiber
(G.652.D or G.652.D | OS2)
- Jacket Material PE
- Fiber Type, quantity 12
- Jacket Color Black
- Jacket UV Resistance UV stabilized

Physical Characteristics:
- Cladding Diameter 125.0 ± 0.7 μm
- Core/Clad Offset ≤ 0.5 μm
- Coating Diameter (Uncolored) 245 ± 1 0 μm
- Coating Diameter (Colored) 254 ± 7 μm
- Coating/Cladding Concentricity Error, 12 μm
Max.
- Clad Non-Circularity ≤1%

Optical Characteristics, General:

- Point Defects, Max. 0.10 dB
- Cut-off Wavelength ≤ 1260
- Zero Dispersion Wavelength 1,302-1,322 nm
- Zero Dispersion Slope, Max. 0.090 ps/[km-nm-nm]
- Polarization Mode Dispersion ≤ 0.06 ps/sqrt (km)Link Design Value
- Backscatter Coefficient -79.6/-82.1 dB @ 1310/1550 nm
- Index of Refraction 1.467/1.468 @ 1310/1550 nm

Environmental Characteristics:
- Temperature Dependence -76°F to 185°F ≤ 0.05 dB (-60 to 85°C)
- Temperature Humidity Cycling 14°F to 185F ≤ 0.05 dB up to 95% RH

592
 - Water Immersion, 73.4°F (23C) ≤ 0.05 dB
- Heat Aging, 185°F (85C) ≤ 0.05 dB

8.6.2.7. Specifications for EPABX System:

Required EPABX System shall support for minimum 1 PRI, 8 Trunk, 140 Analog Extension,
10 VoIP extensions, 4 Digital Extensions. ISDN-GSM-VoIP PBX with DC Power Supply &
CPU Card, Single Cabinet, 10 universal slots, Built-in auto attendant, Ethernet Port, Remote
Programming, Inbound & outbound Conference facility, Hot swappable,

1. The equipment shall be electronic type. It shall have microprocessor / micro

controller based on Stored Program Control Technique.
2. It shall employ PCM/TDM, 100% non-blocking, digital switching technology.
3. It shall have distributed processing architecture, SLIC and SMT Design.
4. System power supply should be inbuilt and SMPS type.
5. The system should be built on a universal slot architecture and modular in design to
enable seamless growth, by adding the desired necessary cards as and when required.
Any peripheral card can be inserted in any slot of the platform, whereby it is possible
to increase or decrease the trunk lines or subscriber lines of the system as per the
requirement in future as per mentioned maximum requirement.
6. It should be suitable for DTMF as well as the FSK type of telephone instruments.
7. The EPABX system supplied shall be with 150 extensions, 1 PRI, 8 C.O. lines and
can scale up to 200 extensions, 6 PRI and 100 C.O. lines on the same platform
8. It should have built-in conference facility
9. EPABX shall support E & M Port to connect E & M Lines
10. System Shall support Intercom Line Card
11. The system shall have the inbuilt auto attendant facility and shall be able to answer
minimum 5 calls simultaneously.
12. The system shall have an ISDN Digital platform and shall be compatible with ISDN
PRI line of Local Service Provider.
13. The system shall have multiple port interfaces such as analog extension lines, digital
key phone, IP Extension, C.O. Line, GSM/3G, E & M Line, PRI/E1 and VoIP. All
interfaces shall be in the form of expansion cards and can be plugged into the
universal slots of the system as and when require in the future.
14. The system should have in-skin GSM card so that the multiple SIMs can be inserted
on the GSM card plugged on to the PBX platform. Hence, the calls on GSM mobile
can be routed through this SIMs and contribute in reduction of overall telecom bill.
15. All the peripheral cards (extension cards, trunk cards (GSM/VoIP/ISDN etc.) should
be hot-swappable.
16. The EPABX should support Radio Connectivity with the in-skin card.
17. The offered exchange should be an ISDN & VoIP ready switch. The system platform
should always be ready for ISDN & VoIP and only the necessary in skin ISDN &
VoIP
cards need to be added for functionality.
18. The system should support SMPP protocol to send/receive SMS using in-skin GSM
SIMs within EPABX. Any software required to send/receive SMS shall also to quote
separately.
19. The system shall have at least 2 RS232 ports for SMDR/PMS/CAS Interface.
20. The system shall have a built-in remote maintenance facility. The system can be
programmed remotely over the internet without any modem required on the PBX
side.

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21. The call ringing sequence would be programmable and have options such as
simultaneous, hunting off, round robin and delayed simultaneous.
22. EPABX should have built-in one number of public address port and external music
port.
23. Caller line identification (CLI) on Analog and digital/PRI trunks shall be built-in for
both DTMF and FSK telephone instrument.
24. The system shall integrate in-skin voice mail card with 72 hours of storage capacity
and dedicated mailbox for each extension.
25. Detail reports of all system parameters should be generated through the SMDR or
CDR port of EPABX.
26. The offered system should be QSIG ready (for PRI) for Networking and Feature
Transparency between two or more exchanges.
27. Each port of the system shall be programmable. It shall have programmable features
port-wise/extension-wise.
28. The system shall support flexible numbering for extensions such as it may have
extensions with 1 digit, 2 digits and up to 6 digits numbers as well as in combination
of all.
29. The system shall have built-in web based software programming tool for system
administration.
30. Access codes, system timers and access to features shall be programmable.
31. Storage of outgoing, incoming and internal call reports shall be generated on SMDR
port of the system. It shall also be available online through Ethernet Port.
32. The system should have built-in outgoing Call Log buffer of 2000 calls, incoming call
log buffer of 2000 and call log buffer of 1000 internal calls.
33. Features given to an extension shall be accessed from any other extension by dialling
the secret codes.
34. System features shall have class of service, night service, conference, auto diagnostic
etc. Class of service shall be unrestricted. STD restricted and semi restricted.
35. Extension features shall have an extension to extension call, extension to central
office, extension to operator, automatic call back, call transfer, call forward, follow
me, executive/secretary, do not disturb, barge-in, raid, Boss ring, Priority, emergency
reporting etc.
36. Operator features shall have the assistance to extension, attended call transfer, call
intercept, indication of call waiting, night service control etc.
37. The system shall have features as CLI based routing, call duration control, least cost
routing i.e. time, number or combination of both.
38. The system shall have a conversational recording in the mail box should be available
with voice mail system card of EPABX. Conversation recording should be possible
on
Analog/Digital/IP as well as Mobile SIP Smartphone (Android/iPhone).
39. The system shall provide IP functionality to support IP extensions and trunks over
SIP protocol. It should be possible to support IP Trunks and Extension with the single
VoIP expansion card further expansion of VoIP channels shall be possible with an
expansion card.
40. Varied type of open SIP IP Terminals such as IP Phone, SIP soft phone and Mobile
SIP Client shall be supported.
41. The manufacturer should also have an application for Android and iPhone so that the
enterprise mobility can be extended for the Smartphone users.
42. The system shall also be required to supply IP Phones of the same manufacturer.
43. IP functionality of the system shall be in the form of in-skin interface card and can be
inserted in the any slots on the platform.

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44. The system must support following features of IP telephony: Dynamic DNS,
Registrar Server, Proxy Server, Presence Server, NAT and STUN.
45. The system must have following features:
 Modular architecture, Gateway Functionality, Built-in Auto-Attendant
 Easy integration with other SIP devices such as VoIP gateways, SIP
servers and SIP phones
 Built-in auxiliary ports (Analog Input-Output ports)
 Hybrid expansion card to meet any requirement
 Networking of multiple sites and offices
 Mobile Close User Groups (CUG)
 On-site and Off-site Mobility
 Multiple Call Groups
 Open standard SIP support
 Least Cost Routing Algorithm
 Centralized Maintenance and Administration
 Unified Messaging – Voice mail to Email
 Call back on trunk, Return call to original caller (RCOC), DID
 Automatic DISA with Built-in DISA card
 Multi-party conference
 Conference Dial-in
 Built-in CLI (DTMF and FSK) on ISDN and analog trunk lines
 CLI based routing
 Conversation recording
 Allowed and Denied call lists
 Call logs to identify missed Calls
 Emergency numbers
 Voicemail system
 Handover and Handoff support with Android/iOS Soft phone Application
 Return call to original caller (RCOC)
 Failover resiliency
 Multiple systems networking through ISDN QSIG and SIP
 SNMP v1/v2c/v3
 Mobile Extension through GSM/3G Mobiles
 Third-party PMS/CAS support
 CTI (TAPI 2.1)
 Routing of calls to only permissible legal networks (Logical Partitioning)
 SMDR though Ethernet Port

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8.7. APPROVED LIST OF MAKES
NOTE:
- All materials and products shall conform to the relevant standards and shall be of
approved make and design. A list of manufacturers/ vendors is given separately
herein below for guidance. The Engineer shall give the approval of a manufacturer/
vendor/ only after review of the sample/ specimen. In case the same is not available in
the market or in case of change in trade name, equivalent makes/ re-designated
manufacturer then an equivalent approved make shall be used with the approval of
Employer/ Engineer. The complete system and installation shall also be in conformity
with applicable Codes & Standards and Tender specifications.
- Only “First” class quality materials shall be used.
- Employer reserves the right to choose any of the approved make / vendors as per this
list.
- In case of products not indicated in this list, bis marked products shall be preferred.
- Specification of manufacturer‟s item shall be checked against tender item /
specifications before selecting any product or brand name. In case of any discrepancy,
tender item/ specifications shall prevail, and any such brand of item shall not be used
which is not conforming to tender specifications even if it is listed in this list.
- For use of material from a bis listed/ certified manufacturer, the contractor shall
furnish a copy of the BIS certificate to Employer before procuring the material.
- In case non-availability of any item/ material among approved manufacturers/ brands
at a particular site/ region, alternate manufacturers/ brands conforming to BIS/ BS etc.
shall be used subject to approval by Employer.
- In case of non-availability of any manufacturer among approved manufacturers at a
particular site/ region, alternate manufacturer‟s name shall be proposed along-with
required credentials for Employer‟s approval.
- In case of any item/ product neither covered in this list nor having A BIS
specifications, the contractor shall submit the proposed item/ product along-with
technical details/ specifications (as per bid), test certificates etc. And other credentials
of the manufacturer for Employers approval.

LIST OF APPROVED MAKES FOR PRODUCTS AND MATERIALS FOR BMS

AND RELATED WORKS ARE INDICATED IN THE TABLE BELOW.
HOWEVER, ANY OTHER MAKE WHICH IS EQUIVALENT AND MEETING
THE TENDER SPECIFICATIONS ARE ALSO ACCEPTABLEWITH PRIOR
APPROVAL OF THE ENGINEER

Item Makes

Control Panel Enclosure Rittal / APW President / Pyrotech

PC for IBMS Server/Operator Compaq / HP

Station

Printer HP-Laserjet

596
Item Makes

Cable Glands Comet/ Baliga

BMS Honeywell / Siemens / Johnson
Controls
Push Buttons L&T / Siemens / Tecknic / Kaycee

I&C cables & Power cables Delton/ Associated Flexibles &

Cables/ Finolex/ Universal/ Uniflex

Cable trays Indiana/ West Coast Engg. Pvt. Ltd.,

Cable Glands Comet/ Baliga

Relays OEN/ Siemens / Omron

Fire Detection and Alarm System Cooper / Edwards EST3 / Ravel / GST
PA System Bosch limited / Honeywell / Nelco
Fibre Optic Cables Finolex/ Uniflex
CCTV System HIKVISION / CP PLUS / Dahua
Access control system Bosch/ GODREJ and
Boyce/Honeywell
Layer 3 & Layer 2 Switches Cisco, Juniper, HP, Allied Telesis
Network Rack WQ, Rittal, Valrack
EPABX Progility, Panasonic, Matrix
CAT6 Cable Molex, Dlink, Belden
Connectors & Accessories Molex, Legrand, DigiLink

597
TECHNICAL SPECIFICATION

EOT CRANES

598
 EOT CRANES

9.1. EOT CRANES

Electrical overhead travelling cranes of 20 Tonne & 7.5 Tonne safe working load is included
in the Contract. The Contractor shall provide all the necessary weights for the Tests on
completion. The crane shall conform to IS 3177 or BS 466, Class 2, medium duty, and shall
meet the operational requirements shown in the schedule of particulars. The crane shall be
designed of welded box girder construction. The bridge shall be designed to carry safely the
loads specified in IS 807 or BS 2573. Steel used in the manufacture of the crane shall be
tested quality steel conforming to IS 2062 Gr.B for ASTM A36 except that, plates that have
to be welded such as for plate girders etc. and those more than 20 mm thick shall conform to
IS 2062 or BS 4360.

The crane shall be operated from the floor level of pump set by a single mobile
multiway pendant, suspended independently of the electrical cable from the crane girder
incorporating not more than 110 V single phase controls. The pendant station shall be
earthed separately independent of the suspension. The main power supply will be 415 V,
AC. All crane movements shall be clearly indicated on the pendant. The pendant shall be so
designed that the operator has full control of the crane during operation. All motors shall be
designed for S2, intermittent duty.

Broad parameters of the two EOT cranes are as under:-

Crane 1 Crane 2
Capacity 20 Ton 7.5 Ton
Span 18 mtrs 18 mtrs
Lift 6.5 mtrs 4.5 mtrs
Long travel 66 mtrs 66 mtrs

9.2. APPROVED LIST OF MAKES

NOTE:
- All materials and products shall conform to the relevant standards and shall be of
approved make and design. A list of manufacturers/ vendors is given separately
herein below for guidance. The Engineer shall give the approval of a manufacturer/
vendor/ only after review of the sample/ specimen. In case the same is not available in
the market or in case of change in trade name, equivalent makes/ re-designated
manufacturer then an equivalent approved make shall be used with the approval of
Employer/ Engineer. The complete system and installation shall also be in conformity
with applicable Codes & Standards and Tender specifications.
- Only “First” class quality materials shall be used.
- Employer reserves the right to choose any of the approved make / vendors as per this
list.
599
- In case of products not indicated in this list, bis marked products shall be preferred.
- Specification of manufacturer‟s item shall be checked against tender item /
specifications before selecting any product or brand name. In case of any discrepancy,
tender item/ specifications shall prevail, and any such brand of item shall not be used
which is not conforming to tender specifications even if it is listed in this list.
- For use of material from a bis listed/ certified manufacturer, the contractor shall
furnish a copy of the BIS certificate to Employer before procuring the material.
- In case non-availability of any item/ material among approved manufacturers/ brands
at a particular site/ region, alternate manufacturers/ brands conforming to BIS/ BS etc.
shall be used subject to approval by Employer.
- In case of non-availability of any manufacturer among approved manufacturers at a
particular site/ region, alternate manufacturer‟s name shall be proposed along-with
required credentials for Employer‟s approval.
- In case of any item/ product neither covered in this list nor having A BIS
specifications, the contractor shall submit the proposed item/ product along-with
technical details/ specifications (as per bid), test certificates etc. And other credentials
of the manufacturer for Employers approval.

LIST OF APPROVED MAKES FOR PRODUCTS AND MATERIALS EOT

CRANE WORKS ARE INDICATED IN THE TABLE BELOW. HOWEVER, ANY
OTHER MAKE WHICH IS EQUIVALENT AND MEETING THE TENDER
SPECIFICATIONS ARE ALSO ACCEPTABLEWITH PRIOR APPROVAL OF
THE ENGINEER

Item Makes

EOT Cranes Henbencraft, Bradys, Unitek, Grip

Engineers, Aditya Cranes, Indef,
Armsel , Eddy Cranes

600
TECHNICAL SPECIFICATION

EXTERNAL SERVICES

601
 EXTERNAL SERVICES WORKS

SEWAGE TREATMENT PLANT

10.1. SCOPE

i. This specification covers the general requirements of design, preparation of detailed

drawings, construction, supply of material, manufacture, testing, inspection at
BIDDER‟S works, packing, forwarding, transportation, transit insurance, delivery at
site, erection / installation, testing, commissioning at site and carrying out performance
/ acceptance tests of the equipment, materials and services for Sewage Treatment Plant
(STP).
ii. Prepare and submit as-built drawings as per document and drawing submission &
distribution schedule.
iii. Piping inside and around pump house including suction and delivery piping, delivery
header, recirculation piping.
iv. All the valves in above piping.
v. Supporting arrangements needed (indoor & outdoor) for the piping, valves and
instrumentation mentioned above.
vi. The equipment to be supplied and erected under this specification is detailed in BOQ
and these shall be in accordance with Specification and the relevant data sheets section.
vii. Any item which may not have been specifically mentioned herein but are needed to
complete the equipment / system shall also be treated as included and the same shall
also be furnished and erected, unless otherwise specifically excluded as indicated.
viii. STP has to be constructed underground under vehicle parking area.
ix. 100% power backup is to be provided.
x. A 50 KLD treated wastewater storage tank has to be provided to meet flushing and
horticulture demand.
xi. An overflow pipe from the treated wastewater tank has to be connected to the existing
sewerage line/ nala located outside the boundary of plot.
xii. Space for treated water pump has to be provided. (A treated water pump has been
proposed for pumping of treated wastewater into the recycled water network. The water
has to be use for flushing and horticulture purpose.
xiii. Cut-outs have to provide in the roof slab of STP for operation and maintenance
purposes and for lifting of pumps.
xiv. Entry and Exit staircase have to be provided to access the STP.
xv. Minimum 2.0 m level difference should be provided in between the bottom of STP top
slab and top of tanks for movement of workers/supervisors.

10.2. SPECIFIC REQUIREMENTS / INSTRUCTION TO BIDDERS

10.2.1 WASTEWATER QUANTITY AND CHARACTERISTICS

602
 The total maximum waste water inlet at Wastewater Treatment Plant (STP) has been
calculated as 100 KLD. The STP is being proposed to be constructed on Moving Bed
Bio Reactor (MBBR) technology. The treatment plant should be of modular type and
should be capable of handling flow variations up to 60% of the maximum capacity.

The expected Characteristics of the wastewater generated as are as given below

(Table 1.1)

Table 1.1: Characteristics of Wastewater

S. no. Parameter Unit Quantity

1 pH - 6.5 – 8.5
3 TSS mg/L 250
4 COD (max) mg/L 450-500
5 BOD (5 days) mg/L 250-300
6 Oil & Grease mg/L 45
7 Feacal Coliform MPN/100 ML 1012 - 1016

10.2.2 TREATMENT SCHEME:

The treatment scheme would in essence comprise of the following:-
a) Coarse Screen, Oil and grease trap, Grit Chamber and Fine Screen
Mechanical screens of 20 mm openings are proposed to effectively remove material that
could interfere with the satisfactory operation of the treatment plant or equipment. It
would also reduce clogging by rags and other floating material which could affect
functioning efficiency of downstream units.
Considerations in the design of screening installations should include:
 Location
 Approach Velocity
 Clear Openings Between Bars or Mesh Size
 Head Loss Through The Screens
 Screenings Handling, Processing, and Disposal
 Controls
The screen channel should be designed to prevent the settling and accumulation of grit
and other heavy materials.
Grit chamber is proposed to remove grit, consisting of sand, gravel, cinders or other
heavy solid materials that have subsiding velocities or specific gravities substantially
greater than those of the organic putrescible solids in wastewater. Grit removal is
proposed to protect the downstream units with moving mechanical equipment and pump
elements from abrasion and accompanying wear and tear. Removal of grit reduces the
outage for cleaning of settling tanks and digesters. The Waste water flow should pass
through an oil & grease trap for removal of all oil and grease content present in waste
water prior to entering in fine screen.

603
 Mechanical screens of 6 mm openings and a standby manual screen of 10 mm openings
are proposed to effectively remove material that could interfere with the satisfactory
operation of the treatment plant or equipment.

b) Collection / Equalisation Tank

The wastewater flow generated from the plant facility shall be received in the
equalisation chamber after coarse screen, oil and grease trap, grit chamber & fine screen.
Collection / Equalization tank would serve the purpose of dampening the flow
fluctuations. It would be sized keeping in consideration the range of fluctuation between
the peak and lean period flows and it would be designed for ultimate flow. Wastewater
from equalisation tank will be pumped into Moving Bed Bio Reactor (MBBR) tank
through submersible pump (2 Nos, 1W+1S). Coarse bubble aeration is proposed in the
equalization tank for mixing removing any smell in the fresh wastewater.

Biological Treatment

The secondary treatment proposed would include a MBBR tank and a secondary tube
settler clarifier. The MBBR is an aerobic, attached growth, fluidized bed system
employing structured Polypropylene (PP) Fill media (cylindrical shaped) with high
specific surface for developing and retaining bacterial mass. The MBBR shall be
designed by selecting suitable BOD loading rate by the bidder. Maximum BOD loading
rate proposed is 5.0 Kg BOD/m3/d. The minimum specific area proposed for media is
400 m2/m3

Oxygen is proposed to be supplied diffused air aeration systems employing diffusers. The
type and material of construction of diffusers shall be decided by the Bidder.

c) Secondary Clarifier
A hopper bottom clarifier would be provided for this purpose. A sludge return line shall
be provided. There should be provision for recirculation / waste pumps for sludge
circulation is required. The inlet in the clarifier would be from side through inlet baffle.
The efficiency of the secondary settling tanks defines the final quality of the treated
effluent. The clarifier should be fitted with tube settler made of UV stabilized PVC. The
maximum surface loading rate (SLR) proposed is 2.0 m3/hr/m2. The length of settlers
and installed should be decided to achieve maximum removal efficiency.

Hopper bottom in the clarifier should be designed for sludge removal without mechanical
arrangement.

d) Disinfection / Chlorination Tank

The secondary treated wastewater shall be disinfected by using chlorine in a chlorine

contact tank. Chlorine shall be added here from chlorine dosing tank by means of
Chlorine dosing pumps.

e) Polishing
604
 The disinfected wastewater after chlorine contact tank shall be pumped through filter
feed pumps to Pressure Sand filter (PSF) and Activated Carbon Filter (ACF) in order to
meet stringent discharge standards. Final effluent will then be stored in Treated Waste
water Tank which may either be used for horticulture or for flushing purpose.

f) Sludge Handling

The waste sludge from secondary clarifier shall be pumped to sludge holding tank for
thickening of sludge. The supernatant of the sludge holding tank shall be recycled back to
Equalization tank. The sludge from the SHT shall be well digested and shall be fed to
Filter Press for dewatering and forming dry sludge cakes. This dried sludge can either be
used as manure or can be disposed off in designated secured landfill site.
The process flow diagram for the proposed STP is attached (refer drawing no.
TCE.10106A-162-GA-6001)

g) Disposal of Treated Effluent.

The treated effluent from Treated Wastewater Tank is proposed to be either used for
horticulture or used for flushing purpose.

10.2.3 TREATED WASTE WATER CHARACTERISTICS:

The treated wastewater should conform to characteristics given below (Table 1.2)

Table 1.2: Characteristics of treated wastewater

S. no. Parameter Unit Quantity

1 pH - 6.5-7.5
2 TSS mg/L <10
3 BOD (5 days) mg/L <10
4 COD mg/L <50
5 Faecal Coliform < 100/100 ml*
Note: *The microbial quantity to be achieved would be as per Category A after chlorination
as per WHO guidelines

10.2.4 STP - CIVIL WORKS

The scope of work will consist of sizing of various units as per the list given below along
with preparation and submission of civil GA and RCC/ Structural drawings on the basis of
which the construction work shall be carried out.

The design calculations will be submitted by the BIDDER along with the drawings for
approval.

The various tanks/chambers needed to be constructed for the wastewater treatment system
and their details are as follows-
605
 SR. DESCRIPTION SIZE/ QTY. M.O.C.
NO. CAPACITY Nos.
1 Coarse screen, Oil and By Bidder 1 R.C.C. / As
grease trap, Fine screen specified/approved by client.
and Grit Chamber
2 Equalization Tank By Bidder 1 R.C.C./ As
specified/approved by client.
3 MBBR Tank By Bidder 1 R.C.C./As
specified/approved by client
4 Secondary Clarifier By Bidder 1 R.C.C./ As
(tube settler with specified/approved by client
hopper bottom)
5 Chlorine Contact Tank By Bidder 1 R.C.C. / As
specified/approved by client.
6 Treated Waste Water By Bidder 1 R.C.C/ As
Tank specified/approved by client.
7 Sludge Holding Tank By bidder 1 R.C.C/ As
specified/approved by client.
In addition the following works shall be carried out by the Bidder:

SR. DESCRIPTION SIZE/ QTY. M.O.C.

NO. CAPACITY Nos.
1 Foundation of all pumps By Bidder As required during As specified/
& motors, tanks, skids detailed approved by
and pipe work, engineering the Client
2 All drain trenches up to By Bidder As required As specified/
battery limit (Bidder‟s during detailed approved by
scope) engineering the Client
3 Supports for electrical By Bidder As required As specified/
cables and during detailed approved by
pipes engineering the Client

10.2.4.1 Equipment, Piping, Electrical and Instrumentation Work

The scope of work will consist of design, engineering, manufacture/procurement, supply

erection and commissioning of various components as per the lists given subsequently.
The various equipments required to be provided for the wastewater treatment system and
their details are as follows-

SR. DESCRIPTION SIZE/ QTY. M.O.C.

NO. CAPACITY Nos.
(PROPOSED)
1 Coarse Screen (For ultimate flow) 20 mm opening 1 SS-316
2 Mechanical screens of 6 mm 6 mm opening 1 SS-316

606
SR. DESCRIPTION SIZE/ QTY. M.O.C.
NO. CAPACITY Nos.
(PROPOSED)
openings and a standby manual
screen of 10 mm
3 Media for MBBR 400 m2/m3 Cum (By PP
surface area Bidder)
(Minimum)
4 Tube settler media By Bidder Cum (By UV stabilized
Bidder) PVC
5 Air Blowers for Equalization By Bidder (1W + By Bidder
Tank & MBBR Tank 1S)
6 Coarse Bubble Air Diffusers for By Bidder By By Bidder
Equalization Tank. Bidder
7 Air Diffusers for MBBR Tank By bidder By By Bidder
Bidder
8 Submersible pump (with VFD, to 5-7 m3/hr @ 12 1W + 1S SS 316
work between 5 to 7 m3/hr) m head / bidder
to reconfirm
9 Chlorine dosing system By Bidder 1 Set By Bidder
consisting of 1 no. Dosing tank
and 1 no. Hypochlorite dosing
pump
10 Pressure Sand Filter By Bidder 1 MS Epoxy
Coated / FRP
11 Activated Carbon Filter By Bidder 1 MS Epoxy
Coated / FRP
12 Sludge recirculation / Waste By Bidder 1W+1S By Bidder
Pump
13 Pressure Sand Filter (PSF) and By Bidder 1W+1S By Bidder
Activated Carbon Filter (ACF)
feed pump
14 Supernatant transfer Pump from By Bidder 1 By Bidder
Sludge Holding Tank to
Equalization Tank if required
15 Treated sewage transfer pump By Bidder 1 By Bidder
16 Filter Press Feed Pump By Bidder 1 By Bidder
17 Filter Press By Bidder 1 By Bidder
18 Drain pit Pump By Bidder 1 By Bidder
19 Mechanical Ventilation System By Bidder 1 Set By Bidder

607
In addition to the above listed equipments, the following would be in the scope of the bidder:
SR. DESCRIPTION SIZE/ QTY. M.O.C.
NO. CAPACITY Nos.
1 Interconnecting piping & Valves By Bidder 1 Lot Jindal Hissar /
as required Prince / Supreme

2 ELECTRICAL WORK
2a Power cables from main STP By Bidder 1 Lot Specification as
Panel (provided by client) to all approved by Client
motors.
2b Push button stations near each By Bidder 1 Lot Specification as
motor. approved by Client
2c Control cables By Bidder 1 Lot Specification as
approved by Client
2d Earthing By Bidder 1 Lot Specification as
approved by Client
2e Separate KWh Meter (provided By client 1 Lot
by client)
3 INSTRUMENTS
3a Level switches in tanks with By Bidder 1 Lot Specification as
provision for alarm at high level approved by Client
in the tank and alarm as well as
tripping of pumps at low level
3b Flow meter magnetic type with By Bidder 1 Lot Specification as
indicator and totalizer approved by Client
3c Pressure gauges By Bidder 1 Lot. Specification as
approved by Client
Note:
The Bidder should design and arrive at the sizing, capacities, MOC, type and other details of
various equipments as listed above.
The bidder is required to bring out the disparity/ ambiguity (if any) in the information
mentioned herein before submission of the bid. The design philosophy mentioned is tentative
and can be changed at the Bidder‟s end (with proper justification) to achieve the desired
treated effluent characteristics.

10.2.4.2 Following activities / items will be in the scope of the Bidder.

a) Foundation bolts for all equipments, companion flanges with nuts, bolts, gaskets at
terminal points.
b) Final painting at site.
c) Packing, forwarding, delivery to site, unloading at site.

608
 d) All consumables till the plant is handed over to the EMPLOYER/ENGINEER.
Chemicals, Instruments and equipment required for the installation and performance
test should be arranged by Bidder.
e) Provision of auxiliary steel/supporting steel for supporting the equipment and piping,
Access platforms, ladder, handrail and steel supporting base etc. common for all
accessories as well as related drilling, welding work, painting of supports etc.
f) All erection tools and tackles, cranes, hoisting equipments, etc as required.
g) One (1) set of commissioning spares and maintenance tools.
h) One (1) set of essential spares.
i) Service water shall be made available by EMPLOYER/ENGINEER at one point of
STP limit.
10.2.4.3 Erection and Commissioning Services

Following activities / items will be in the scope of the Bidder.

1. Receiving material/ equipment at site, unloading all the equipment and material at
site from carriages, checking against damages, storing in storage area provided by
the EMPLOYER/ENGINEER, shall be in the in the scope of bidder.
2. Movement of equipment and materials to erection at site by bidder.
3. Minor modification on the foundation as required such as chipping, levelling etc
required to install the pumps.
4. Erection of all equipments and materials supplied under this contract.
5. Grouting of equipment foundations.
6. Hydro test and air leak test at site after completion of erection.
7. Trial runs, testing, start-up, performance recalibration, commissioning and
performance / Acceptance tests covered in the specification
8. Proper tagging of all civil units, equipments should be done by Bidder with much
care
9. The Bidder shall arrange following at his own cost.
a) Adequate quantum of welding electrodes including special electrodes and
welding units required for erection.
b) All consumable required for erection and commissioning.
c) All erection tools and tackles, cranes, hoisting equipment, etc as required
d) All skilled, semi-skilled and unskilled labour required for erecting any facility,
as required, for the labour force such as accommodation, transport, medical
facility, insurance etc.
e) First fill of lubricants and grease etc.
f) Commissioning of the entire STP and accessories and handing over to
EMPLOYER/ENGINEER.
g) Training of the STP personnel for proper operation and maintenance.

609
10.2.4.4 Layout

The Bidder should provide the area required for the plant. All Supports for all
equipment and platforms, walkways, stairways for all equipment as required are in
bidder‟s scope.

The interconnecting pipe shall be laid out in such a way that they are easily accessible
for any maintenance or repair and also permits easy movement of the personnel.
Easily accessible dismantling joints shall be provided for maintenance purposes.

The exact layout considering the actual equipment dimensions, handling facilities,
clearances as required for easy operation and maintenance, pipe support locations etc
shall have to be firmed up by the bidder for satisfactory operation of the systems
covered under the scope of work.

The proposed layout for STP is attached (refer drawing no. TCE.10106A-161-SI-
6003)

10.2.4.5 Piping Material Specification

All the material of construction of piping should be should be compatible with the
requirement.

10.2.4.6 Painting

All surfaces such as light gauge / glasses, required for clear visual observation shall
be cleaned after paint application.

Special care shall be taken to avoid any paints from dropping on the machined
moving parts of equipment, name plates or indicator dials of instruments and control
valves. Prior to paint application or spraying paint removable adhesive tape shall be
used to cover these.

On final completion of all work, the BIDDER shall leave the entire premises within
the site of his operation clean and free from all rubbish resulting from his painting
operation and shall remove any paint or other blemishes caused by him on adjacent
walls, windows, equipment and finished surface.

All piping shall be painted after hydro test only. The iron and steel surfaces shall be
thoroughly cleaned of all rust, scale, grease or oil and then primer coat shall be
applied.

The EMPLOYER/ENGINEER reserves the right to inspect the cleaning down and
painting operations at any stage and if required by EMPLOYER/ENGINEER
unsatisfactory surface preparation or paint application shall be remedied at
BIDDER‟S expense.

610
 On job site, no painting shall be carried out in a dust laden atmosphere or under
unsuitable weather conditions viz. when raining or when metal surfaces are damp or
when condensation is likely to affect the paint film before it is dry.

All the exposed non-insulated carbon steel surfaces of equipment, piping and
structural & auxiliary steel for pipe and equipment support shall be painted as
indicated below:
(a) Surface preparation – removal of dust, dirt, oil, grease, scale and other foreign
material by manual or power tools.
(b) Primer –2 coat of red oxide primer (conforming to IS: 2074) with minimum
dry film thickness (DFT) 25 microns per coat.
(c) Finish–2 coat of synthetic enamel (conforming to IS: 2932) with minimum
dry film thickness (DFT) 50 microns per coat.

10.2.4.7 Codes and Standards

All the equipment, systems and works covered under this specification shall comply
with the relevant Indian Standards, regulations and prevailing safety codes in the
locality where the equipment will be installed. All the equipment shall comply in all
respects with the requirements of latest edition of codes and standards.
In the event of any conflict between the codes and standards referred to in the
specification and the requirements of this specification, the more stringent of this
requirement shall govern.

10.2.4.8 Performance Test And Guarantees

The BIDDER/Contractor shall guarantee the outlet requirements of the STP system as
specified in the section and shall carry out performance guarantee tests for a
minimum period of one month (1 month) continuous operation to prove the following
performance guarantees (a) Throughout (capacity) of the STP in m3/day (b) treated
water parameters.

Quality of the treated water at the outlet shall be as specified in “Treated Wastewater
Quality”. (The quality requirement as specified above shall be confirmed by the
BIDDER/Contractor).

Guaranteed power and chemical consumption of STP per day in kWh (as measured at
a point before input into MCC). The BIDDER/Contractor shall guarantee the
power/chemical consumption for the STP Plant.

In case the performance guarantee cannot be proved due to the reasons attributable to
the BIDDER/Contractor, then the BIDDER/Contractor shall carry out the required
modifications/repairs/replacement to the plant at BIDDER‟s cost expeditiously and
repeat the performance test runs until all specified guarantees are fully met.

611
 The time period allowed for modifications/repairs/replacement of the STP system in
the case as described in above shall be two months (60 days) from the date of
commencement of performance tests.

The BIDDER/Contractor shall incorporate features including necessary

instrumentation and controls to run the plant at lower loads and at the same time shall
maintain the quality of treated water at the battery limit of STP as stipulated in this
specification. The necessary sensors required for loading the plant at lower loads shall
be in the BIDDER/Contractor‟s scope of supply.

10.2.4.9 Uptime Guarantee

The contractor shall guarantee for the installed system an uptime of 98%. In case of
shortfall in any month during the defects liability period, the Defects Liability period
shall get extended by a month for every month having shortfall and no reimbursement
shall be made for the extended period.

10.2.4.10 Maintenance Requirements

In order to carry out preventive maintenance, it should be possible to readily

disassemble, repair, and reassemble the equipment in the shortest period and to attend
to any defect by a minimum disassembly.

The Bidder shall furnish one complete set of any special maintenance tools required
for normal maintenance of equipment.

The Bidder shall confirm that space shown for the equipment is adequate from point
of view of access, easy maintenance and for day to day operation.

All system must have convenient maintenance characteristics including:

Care should be taken to cause minimum disturbance to production during preventive
maintenance.

The bidder shall ensure easy access to replacement part, which can be installed by
personnel of minimum skill.

10.2.4.11 Availability Requirements

All equipment and accessories shall be designed for maximum reliability and
availability, particularly in respect of the following:

The equipment shall be of proven design, using materials established as appropriate

to the service intended. Fabrication / manufacturing processes shall be subjected to
quality surveillance and tests.

10.2.4.12 Noise and Vibration

612
 Noise level produced by any equipment individually or collectively shall not exceed
85 dB (A) measured at a distance of 1.5 metres from the source in any direction.
The overall vibration level shall be as per zones A and B of ISO 10816-1. Vibration
isolators shall be provided.

10.2.4.13 Chemical Consumption and Power Requirement

Bidder has to indicate the Chemical consumption and the Power required for the plant
in the following format.
CHEMICAL CONSUMPTION
Sl. No. Chemical Consumption (g/m3) kg/day

1.

2.

3.

4.

POWER CONSUMPTION
Total
No. of
Sl. Numbers Numbers kW I.kW Power
Equipment BkW Working
No. Working Standby (Rating) (Input) Consumption
Hours
(Kwh)
1.

2.

3.

4.

Bidder to furnish the above information for each of the equipment in the STP system

10.2.4.14 Data to Be Furnished By Bidder

SUMMARY OF DATA TO BE FURNISHED ALONG WITH BID AND AFTER

ACCEPTANCE OF PURCHASE ORDER

The BIDDER shall ensure the following documentation are prepared and submitted to
EMPLOYER/ENGINEER for his review / record.

ALONG WITH BID:

a) Description of the systems offered along with P&IDs, catalogues, leaflets, layout
drawings, area requirements etc. The P & I diagram shall clearly indicate all the
equipment, line sizes, valves, instrumentation and controls etc. which form a part of
the system offered by the BIDDER. The STP BIDDER shall tag all lines, instruments
613
 and valves as per the guide lines.
b) All DATA SHEETS duly filled in. The BIDDER has to attach additional data sheets
for the items which are not covered in the attached data sheets. Technical details of all
the items should be described comprehensively in the offer.
c) Layout drawing enclosed for locations of equipment & provision of space for
operation & maintenance.
d) Bar chart schedule indicating the date of completion of various activities so as to
complete the contract within the time frame stipulated in the tender specification.
e) Performance curves / rating charts used for selection of equipment for all the systems
shall be furnished along with the bid, with the duty points duly marked on them.
f) Guaranteed Chemical consumption for the STP plant.
g) Makes of all bought out equipment, piping and instruments.
h) Control Philosophy

AFTER AWARD OF CONTRACT:

a) Foundation details and drawings for all equipment in the system in scope with
loading details.
b) General Arrangement drawing of the agreed scheme with the client showing all
equipment, drains, pipe/cable trench, operation / maintenance space. The Bidder shall
check with the EMPLOYER/ENGINEER for the land allocated to set up the STP and
prepare the GA drawings and other details in conformance with the same.
c) Piping layout drawing (Plan & sections) for all piping within scope of the BIDDER
clearly indicating locations of supports & loading details.
d) The P & I diagram clearly indicating all the equipment, line sizes, valves,
instrumentation and controls etc. which form a part of the system offered by the
BIDDER. The BIDDER shall tag all lines, instruments and valves as per the guide
lines.
e) Isometric drawing up to battery limit
f) Maximum allowable loads and moments (as applicable)
g) Drawings and data sheets for all equipment as listed in various data sheet C enclosed
with specification.
h) Quality assurance plan
i) As-built drawings.
j) Basic Engineering Package (BEP) including unit sizing and hydraulic calculations
and Structural design of STP units.
The BIDDER/Contractor shall furnish calibration certificates for the instruments to be
used for inspection, testing and commissioning at shop & site. The calibration
certificates furnished by the BIDDER/Contractor shall not be more than 12 months
old.

10.2.4.15 Final Documents:

BIDDER shall submit the three copies of operation and maintenance manuals at the
time of commissioning in addition to one copy two weeks before despatch. The
614
 manual shall be in sufficient detail with step by step instructions to enable others to
inspect erect, commission, maintain, dismantle, repair, reassemble and adjust all parts
of the equipment. Each manual shall also include a complete set of approved as built
drawings together with performance / rating curves / charts of the equipment,
maintenance schedule and test certificates wherever applicable.

The BIDDER shall submit Quality assurance documentation specific for the project.

10.3. STP-ELECTRICAL REQUIREMENTS

10.3.1 SCOPE AND BRIEF DESCRIPTION OF WORK

The scope of Contractor shall include supply, installation, testing and commissioning
all electrical systems and equipment required for the STP.
The major equipment/system covered under scope of work shall be as follows:
(a) 415 V switchgear

(b) LT power & control and instrumentation cables and cable trays, trenches, cable
racks with necessary fire barriers, fire proof sealing and coating systems,
Supporting structures, cable laying & Termination and all other cable accessories.

(c) Control Panel

(d) Drive motors (LT) for all rotating mechanical equipment.
(e) Total illumination system with LDB lighting fixtures, lamps etc.
(f) Earthing and lightning protection.
(g) Electrics for mechanical equipment (Feeders for hoists, ventilation system and
welding).
(h) Civil works for electrical equipment such as foundation, panel opening, trenches,
etc.
(i) Essential spares and special tools and tackles required for installation, operation
and maintenance of electrical equipment.
10.3.2 DETAILED SCOPE OF WORK - ELECTRICAL

a. Power Supply Scheme

The 415 V supply is used to feed the pump motors at pumping station.
b. Lt Switchgear
415 V, 3 phase, 3 wire LT PMCC shall feed all LV loads of each pump house
auxiliary loads. The PMCC shall have incomer and required number of outgoing
feeders. The LT PMCC shall be sheet metal enclosed, compartmentalised and draw
out type. Fault interrupting rating shall be 50 kA for 1sec for 415V switchgear.
c. Motors
Induction motors for the pumps shall be rated for 415 V, 3 phase, 50 Hz. All the
motors shall be suitable for supply variation conditions of +/- 10% voltage, +/- 5%

615
 frequency and 10% combined voltage and frequency. Starting current of the motors
rated up to 60kW shall be 700% of full load current inclusive of tolerance.
d. Cables
LV cables shall be of 1100V grade, copper conductor, XLPE insulated, PVC inner
sheath, armoured/unarmoured and FRLS PVC outer sheath. The control cables shall
be 1100 V, 1.5 sq.mm stranded copper conductors, PVC insulated, PVC inner
sheathed, armoured and FRLS PVC outer sheathed. All power cables shall be sized
based on continuous current capacity, short-circuit rating and voltage drops. The
suitable derating factors to account for grouping of cables, depth of lying, etc. shall be
considered.
e. Lighting System
All indoor and outdoor areas shall be provided with AC lighting. The lighting system
shall comprise of HPSV, medium bay fixtures for pump houses, fluorescent/LED
fixtures for indoor rooms and HPSV street light fixture for road lighting. The wiring
of lighting circuit shall be done by wires in GI conduit for indoor areas and by
armoured cables as per clause 2.4 above in outdoor areas. The illumination levels for
various areas shall be as per BIS.
f. Earthing And Lightning
Earthing system shall be generally designed on the basis of IS 3043 code of practice
for safety earthing. The material of earthing conductors above ground shall be
galvanised steel to prevent atmospheric corrosion and shall be of mild steel when
buried in the ground or embedded in concrete. The earthing conductor shall be sized
considering system fault level, corrosion factor and fault clearing time. Lightning
protection shall be provided for buildings/structures covered under this package as
applicable as per relevant standards.
g. Civil Buildings And Connected Civil Works
All civil works for electrical equipment, i.e. foundations, rooms, buildings, etc.,
covered under this package shall be carried out by the Contractor. Switchgear room
shall be pressurised ventilated. The layout of this building shall consider operation /
maintenance space as per IE rules. The dimension of building shall be subject to
Purchaser‟s approval.

10.3.3 ELECTRICAL SYSTEM DESIGN

a) General Standards
The design, manufacture, assembly and testing as well as performance of the
equipment shall conform to the relevant IS specifications (latest revision). In case the
Contractor is not in a position to comply fully with certain IS specifications, or in
respect of certain items for which there are no IS specifications, the Contractor may
base his proposals on IEC/BS/VDE/DIN recommendations or other reputed national
or international standards subject to the approval of the purchaser.
All equipment supplied and all work done including system design and detailed
engineering shall also comply with the statutory requirements of Indian Electricity
Rules.
b) Climatic Conditions
The climatic conditions generally prevailing at site have already been described in
main volume. Electrical equipment selection and derating shall generally be based on
616
 ambient temperature of 50 deg. c. For specific hot areas the ambient temperature
conditions shall be taken into consideration and equipment suitably derated where
necessary. In hot areas of higher temperature conditions, the equipment shall be
adequately protected against damage from radiant heat and hot air.
The equipment offered shall be suitable for smooth efficient and trouble free service
in the vicinity of sea.

c) Make and Interchangeability

The make of major equipment shall be limited to preferred makes indicated under
chapter „List of preferred makes‟. If the Bidder prefers to supply other than from the
Preferred Makes list, it should be with the approval of the Purchaser.
Makes of all other equipment and accessories are subject to prior approval by the
purchaser. Similar equipment and components shall be of same make, equipments of
same type and rating shall be interchangeable.
The purchaser has the option of selecting the manufacturers of electrical equipment,
instruments and controls and any other specialized items in the interest of
standardization and the Contractor shall have to supply equipment of the particular
make, if so required.

10.3.4 DESIGN CRITERIA

Standard voltage levels
The standardised voltage levels as given in the Table below shall be adopted:
Sl. No. Description Voltage level

1. Incoming supply 415 V, 3 phase, 3 wire, 50Hz,

effectively earthed.
2. A.C. Drive motors 415 V, 3 phase, 3 wire system
effectively earthed.

Permissible variations:
The system unit/plant equipment shall be designed suitable for variation in voltage
and frequency as indicated in the table below:
Variation in voltage and frequency
Basic insulation levels
SL. Description Voltage Frequency
No
1. Permissible variation with rated +/– 10% +/– 3 Hz
performance/rated current

2. Permissible voltage dip at LT -15% -

switchgear bus for starting of LT
motors

617
 Symmetrical short circuit ratings
The three phase symmetrical short circuit ratings of the switchgear at 415 V shall be
as indicated in the Table below:
Symmetrical short circuit rating
Sl. No. Voltage level Symmetrical Making
Breaking capacity Capacity
1. 415 V 50 kA 125 kA
The rated short circuit withstand duration for 415V shall be 1 sec.

Criteria for selection of voltage levels for motors: A.C squirrel cage induction
motors of ratings up to 7.5 kW shall be fed at 415 V, 3 phase, 50 Hz, with DOL
start as applicable.
Degree of protection for various electrical equipment shall be as follows
Sl. No. Equipment Degree of Protection

1 Motors located Indoor IP 54/55

2 LT Switchgear IP 54

10.4. LIST OF APPROVED BIDDERS \ MAKES FOR STP

10.4.1 GENERAL
This section provides details of the Approved BIDDERs \ Approved makes for
bought-out items, which form a part of this enquiry package.
BIDDER shall clearly indicate the makes of all bought-out items and at no point in
time during execution shall deviate from those indicated in the offer document.
10.4.2 LIST OF APPROVED BIDDERS \ MAKES FOR STP
List of approved makes for products and materials for STP are indicated in the table
below. However, any other make which is equivalent and meeting the tender
specifications are also acceptablewith prior approval of the engineer.

SL ITEMS MANUFACTURER
1. Butterfly valves Audco/ Tyco/ Kirloskar/ Fouress Eng./
Hawa or Equivalent
2. Ball valves BDK/ KSB/ Audco/ Venus/ Hawa/
IVC/ Leader or Equivalent
3. Paint\ Epoxy Berger / Asian paints/ Shalimar paint/
Nerolac or Equivalent
4. Level Switch Pune Techtrol\SB
Electromechanical\Fitzer

618
 SL ITEMS MANUFACTURER
5. Electromagnetic Flow meter Krohne Marshall\Rockwin Flowmeter
6. Sight Flow indicator Techno flow or Equivalent
7. Valves
a) CI Gate valve\Check L&T\Kirloskar\BDK\AUDCO
Valve
b) Non Return Valve Audco\BDK\Fischer\Intervalve
8. Pumps
a) Pumps Mather & Platt\Becon\GRUNDFOS\
Kirloskar\ KSB
b) Dosing Pump Asia LMI\ Milton roy or Equivalent
9. Motors Siemens\ Crompton Greaves\ NGEF\
ABB
10. Air Blower Kay\ Everest\USHA
11. Pipes and Accessories
12. MS / GI / uPVC Jindal Hissar / Prince / Supreme

13. Pressure gauges Wika\ Stauff\ Bell\ Forbes Marshall\ H

guru (K.I )\ General Instruments
14. Diffusers OTT\ Misuzu\Equivalent
15. Level indicator\ Transmitter LEVCON or Equivalent
16. Electrical Wiring Polycab / Finolex

10.5. AIR BLOWER

SCOPE

This specification covers the general design, materials, construction features,

manufacture, shop inspection and testing at the manufacturer‟s works and delivery at
site of Air Blowers.

CODES AND STANDARDS

The design, materials, construction, manufacture, inspection, testing and performance

of air blowers shall comply with all currently applicable statutes, regulations and
safety codes in the locality where the equipment is to be installed. The equipment
shall also conform to the latest applicable Indian or equivalent standards. Other
international standards are also acceptable, if these are established to be equal or
superior to the listed standards. Nothing in this specification shall be construed to
relieve the BIDDER of this responsibility.

619
CONSTRUCTION FEATURES

Each air blower shall be a complete unit with casing, inlet and outlet, impeller or
rotor, shaft, stuffing box and drive unit etc

CASING

Casing shall be of robust construction. It shall be made from casting or fabricated

from heavy gauge steel sheets or plates. Castings shall be free from all defects and
blowholes and shall be machined to close tolerance. In case of fabricated casings, it
shall be rigidly reinforced and supported by structural members. Weld seams shall be
continuous to have air-tight enclosure. Casings shall also have smooth interior to
avoid accumulation of dense particles. Inlet shall be spun to have a smooth contour.
For large blowers, gasketed and bolted split casings are preferable. Using gaskets
shall prevent leakage of air from casing joints.

If necessary, provision for ready access to the interiors of casings and other possible
trouble points shall be made by means of readily removable, bolted on plates or by
hinged and latched doors.

IMPELLER OR ROTOR

Impeller or rotor shall have die formed blades welded to the rim and back plate. Rim
shall be spun to have a smooth contour. Blades shall be of backward, radial or
forward type. Rotor assembly shall be securely keyed to the shaft by key and/or nuts.
Suitable means shall be provided to prevent loosening during operation. Rotor along
with any other rotating parts shall be statically and dynamically balanced to ensure
efficient, vibration-free performance and long bearing life.SHAFT, SLEEVES AND
BEARINGS

The shaft shall be finished to close tolerance at the rotor, coupling, pulley and bearing
diameters. The size of shaft shall be calculated on the basis of maximum combined
shear stress. This shear stress shall not exceed 30 percent of the elastic limit in tension
or 18 percent of ultimate tensile strength.

The design of shaft shall also take into consideration the critical speed of the shaft,
which shall be at least 20% above the operating speed or 60 to 75% of the operating
speed, to minimise vibrations.

Replaceable shaft sleeves shall be provided to protect the shaft where it passes
through stuffing box. The end of the shaft sleeve shall extend through the packing
gland. Shaft sleeves shall be securely locked or keyed to the shaft to prevent
loosening or rotating.

The bearings may be ball, roller or sleeve bearing. If sleeve bearings are used these
shall be machined for close running fit. The bearings shall be designed to take the

620
necessary radial load as well as the net axial thrust. Bearings shall be lubricated
properly and sized for a minimum of 40,000 hours of continuous operation.

STUFFING BOX

Stuffing box shall be provided to ensure leak-proof seal between shaft and casing.
Stuffing box shall be designed such that it can be repacked without removing any part
other than the gland.

DRIVE-UNIT

The drive-unit shall be complete with drive motor and coupling or secondary
transmission. Secondary transmission may be chain drive with chain and sprocket or
belt drive with V-belts and pulleys. Coupling shall be of flexible type. The BIDDER
shall furnish both halves of the coupling. Coupling halves shall be bored and keyed to
fit shafts of the blower and the motor by BIDDER. A common base plate shall be
provided for blower assembly and motor. It shall be rigidly constructed, adequately
braced and provided with finish pads for mounting the motor and blower. Suitable
holes shall be provided for grouting and these shall be so located that the base plate
can be grouted in place without disturbing the blower and motor. Even if the
PURCHASER supplies drive motor, the BIDDER shall supply both the halves of
coupling duly machined and keyed and base plate with motor mounting bolt holes.

GENERAL REQUIREMENTS

Blower shall also be suitable to operate as an exhauster for the vacuum specified.

Air filter if specified in data sheet A shall have filtering efficiency of 99% down to a
particle size of 5 microns.

Drive motor shall be rated as least 15% higher than the power requirement at duty
point or 10% higher than the maximum power requirement at selected speed,
whichever is higher. Starting torque requirements of blower shall also be considered
while selecting the motor.

All rotating parts such as coupling, chain or belt drives etc. shall be covered with
suitable protective guards. Guards shall be easily removable type.

Noise level produced by any rotating equipment individually or collectively shall not
exceed 85 dBA measured at a distance of 1.5 metres from the source in any direction.
The overall vibration level shall be as per zones A and B of ISO 10816-1. Balance
quality requirement shall be G-6.3 conforming to ISO 1940/1. Vibration dampening
pads if required, shall be provided.

Suitable drain connection shall be provided.

PERFORMANCE GUARANTEE

621
Performance parameters to be guaranteed by the BIDDER and tolerances permitted
shall be as indicated in section C. The BIDDER shall confirm acceptance of these by
indicating values in data sheet B. Blower or any portion thereof is liable for rejection,
if it fails to give any of the guaranteed performance parameters.

DATA SHEET C

DATA TO BE FURNISHED BY THE BIDDER

AFTER THE AWARD OF CONTRACT

1. List of drawings and documents to be submitted for review, approval, and

information with scheduled submission dates

2. Quality Assurance Plan (QAP)

3. Calculations for capacity, drive motor rating, selection of speed reducers and
couplings

4. Performance curves for blower with duty point marked. In addition to curves for
operating conditions, characteristic curves shall be submitted considering minimum
and maximum ambient temperature, minimum and maximum humidity and minimum
and maximum frequency conditions

5. Torque - Speed curve

6. Detailed to-scale dimensioned general arrangement drawing of blower and motor

giving foundation details, loading data like static and dynamic loads, unbalanced
forces and moments if any, pocket details etc. Drawings shall also include all data and
information furnished in data sheets B

7. Part list of blower components such as casing, impeller or rotor, inlet and outlet,
shaft etc. with materials and codes of construction

8. Overall space and headroom requirement with details of handling during erection,
operation and maintenance of the equipment

9. Relief valve and other instrument data sheets, if applicable

10. Erection, operation and maintenance manual with lubrication schedule.

622
 DATA SHEET A
SHEET: 1 OF 2
AIR BLOWERS
1. DESIGNATION: Refer Table-1 20. MAXIMUM SPEED OF BLOWER: RPM

DESIGN DATA
(CONTD.)
2. NUMBER REQUIRED: Refer Table-1 21. SPARK RESISTANT CONSTRUCTION
3. TAG NUMBERS: By Bidder TYPE AS PER AMCA:  A/B/C

22.

MATERIALS AND CODES OF

4. LOCATION: INDOOR 23. CASING: PP
GENERAL

5. DUTY: CONTINUOUS 24. IMPELLER OR ROTOR: PP

CONSTRUCTION
Hrs/Day
6. LOCATION IN HAZARDOUS AREA: 25. SHAFT: EN-8
NO 26. SHAFT SLEEVE: 
7. HAZARDOUS AREA CLASSIFICATION 27. STUFFING BOX: IS 2062/ 
AS PER IS 5572 ZONE 0/1/2/ 28.
8. ARRANGEMENT NUMBER AS PER 29. INLET GUARD: YES/ NO
AMCA: (NOTE 1) 30. INLET VANE: YES/ NO
9. 31. INLET BOX: YES/ NO
10. TYPE OF BLOWER: CENTRIFUGAL 32. AIR FILTER - PAPER/HDPE: YES/ NO
33. INLET CONNECTION: FLANGED/
11. TYPE OF BLADE: BACKWARD/
ACCESSORIES

RADIAL/FORWARD 34. OUTLET CONNECTION: FLANGED/

12. MEDIUM HANDLED: AIR/AIR WITH
DUST (NOTE 2) 35. RELIEF VALVE: YES/NO
13. SUCTION TEMPERATURE: Ambient °C 36. OUTLET DAMPER: YES/ NO
14. DESIGN TEMPERATURE: Ambient °C 37. VIBRATION DAMPENING PADS:YES/
DESIGN DATA

NO
15. SUCTION PRESSURE: Kg/cm²g/ 38. COMMON BASE FRAME: YES/ NO
TO CREATE _________ cm.Hg. VACUUM 39. FOUNDATION BOLTS: YES/ NO
WHEN USED AS AN EXHAUSTER 40.
16. SUCTION HUMIDITY (RH %): MAX 41.
17. SPECIFIC GRAVITY OF MEDIUM AT 42. MOTOR: VENDOR
SUCTION TEMPERATURE: AS PER TCE.M4-203-01/02
DRIVE DATA

18. CAPACITY (FAD) 43. STARTER: /VENDOR

3
18.1 NORMAL: M /Hr 44. TYPE OF COUPLING: FLEXIBLE/
18.2 MAXIMUM: M3/Hr V BELT/ 
19. DISCHARGE PRESSURE: Kg/cm²g 45.

623
 DATA SHEET A
SHEET: 2 OF 2
AIR BLOWERS
46. PRIMER: RED OXIDE/EPOXY 50. TCE.M4-904 AND/OR TCE.M4-185-01

INSPECTION
TESTS AND
46.1 NUMBER OF COATS:  AND TCE.M4-185-39 OR TCE.M4-186-08
46.2 DRY FILM THICKNESS PER COAT:  (NOTE 3)

PAINTING

51.
47. FINISH PAINT:  52.
53. FOR DESIGN, TESTING AND

STANDARDS
CODES AND
47.1 NUMBER OF COATS:  INSPECTION: IS 4894/BS 848/
47.2 DRY FILM THICKNESS PER COAT: AMCA 203/AMCA 210
 54.
48. REFER TCE.M4-907 55. CAPACITY (FAD):
49. ESSENTIAL SPARES  PERFORMANCE (+) () M3/Hr
GUARANTEES
SPARES AND MAINTENANCE

49.1 56. DISCHARGE PRESSURE:

TOOLS AND TACKLES

49.2 (+) () Kg/cm2g

49.3 57. POWER CONSUMPTION:
49.4 (+) () KW
49.5 58.
LOADING AND

49.6 59. POWER CONSUMPTION:

PENALTY
COST

49.7 Rs. /KW

49.8 60.
49.9 61.
NOTES:
1. REFER AMCA STANDARD 99-2404-78 IN AMCA STANDARDS HANDBOOK.
2. COMPOSITION OF AIR WITH DUST:
3. FOLLOWING ADDITIONAL TESTS INDICATED AS „B‟ IN TCE.M4-186-08 SHALL ALSO BE
CARRIED OUT WHEN TCE.M4-186-08 IS APPLICABLE
 Indicates Bidder to Specify
TABLE – 1
Sl. No. Item Description Quantity Capacity(Cum/hr) Head(M)
1 Air Blowers for Equalization Tank & 1W+1S By bidder By bidder
MBBR Tank

624
10.6. HORIZONTAL CENTRIFUGAL PUMPS

10.6.1 SCOPE

This specification covers the general design, materials, construction features,

manufacture, shop inspection and testing at manufacturer‟s works and delivery at site
of Horizontal Centrifugal Pumps.

10.6.2 CODES AND STANDARDS

The design, materials, construction, manufacture, inspection, testing and performance

of horizontal centrifugal pumps shall comply with all currently applicable statutes,
regulations and safety codes in the locality where the equipment is to be installed.
The equipment shall also conform to latest applicable Indian or equivalent standards.
Other international standards are also acceptable, if these are established to be equal
or superior to the listed standards. Nothing in this specification shall be construed to
relieve the VENDOR of this responsibility.

10.6.3 DESIGN REQUIREMENTS

a) Pumps of a particular category shall be identical and shall be suitable for parallel
operation with equal load division. Components of identical pumps shall be inter-
changeable.

b) Flow rate versus head curve shall have stable and continuously rising characteristics
towards the shut-off head. In case of unstable (drooping) characteristics the duty
point shall be well away from the unstable region. Besides the actual flow rate versus
head curve, curves for minimum and maximum impeller diameters shall also be
shown.

c) The shut-off head shall be at least 110% of the differential head.

d) The required NPSH at duty point shall be at least one (1) metre less than the
available NPSH.

e) The rating of the pump driver shall be the larger of the following :

The maximum power required by the pump from zero discharge to run-out discharge
at site climatic conditions.

110% of the power required at the duty point at site climatic conditions.

a) The corrosion allowance for pressure parts shall be 3 mm.

b) Pumps shall run smooth without undue noise and vibration. Noise level produced
individually or collectively shall not exceed 85 dB(A) measured at a distance of
1.86 metres from the source in any direction. The overall vibration level shall be
as per zones A and B of ISO 10816-1.

625
 c) In case of fire water pumps, pumps and drivers with all the accessories shall meet
the requirements of Tariff Advisory Committee (TAC). Pump type shall be as
approved by TAC.

10.6.4 CONSTRUCTION FEATURES

a) In addition to static balancing, impeller and balancing drum shall be balanced

dynamically at or near the operating speed.

b) Pump shall be provided with renewable type casing ring. Pump having capacity
1,000 M3/Hr and above shall be provided with impeller ring in addition to casing
ring. The hardness of impeller ring shall be 50 BHN higher than that of casing
ring.

c) Pump casing shall be provided with drain and vent connection with plugged or
valve connection.

d) Bearing shall be oil-lubricated or grease-lubricated and shall have a life of 40,000

hours of working. In case of oil-lubricated bearing, constant oil leveller with
magnetic drain plug shall be provided.

e) Replaceable shaft sleeves shall be provided to protect the shaft where it passes
through stuffing box.

f) Stuffing box shall be of such design that it can be repacked without removing
any part other than the gland and lantern ring.

g) Mechanical seals shall be provided. If required, a flushing line shall be furnished,

complete with strainer and orifice, from the pump discharge to the sealing face.
When pumping liquid is not suitable for this purpose, a flushing connection shall
be provided so that it can be connected to an external source. Auxiliary piping
and plan shall be in accordance with appendix - D of API 610.

h) The allowable loads on the pump nozzles shall be at least twice the values listed
in the relevant tables of API 610 without reference to any other criterion. The
base plate shall be designed to cater to the above increased loads.

i) All pumps, except for back-pull out type, shall be provided with flexible
coupling. Back-pull out type pumps shall be provided with spacer type coupling.

j) Coupling guard made of expanded metal and bolted to the base plate shall be
furnished for all coupled pumps.

k) All incidental piping and valves required for sealing, lubrication and cooling for
stuffing box packing and/or bearing of pump shall be furnished by the VENDOR.

l) Leakage from the pump shall be led to the nearest surface drain by OTHERS.
Pump VENDOR shall provide necessary arrangement like drip tray, base plate
drain connection etc.

626
10.6.5 TESTS AND INSPECTION

a) Hydro test pressure on casing shall be 1.5 times maximum discharge head or
twice differential head whichever is higher. (Maximum discharge head = shut-off
head + maximum suction head). Unless otherwise stated in data sheet A, the
hydrostatic tests on the casing shall be conducted for a minimum duration of 30
minutes.

b) The pumps shall be tested as per IS 5120, at rated speed at MANUFACTURER's

works to measure capacity, total head, efficiency and power. The negative
tolerance on efficiency shall be limited to 2.5% and not 5% as indicated in IS
5120. These tests shall form the basis for acceptance of pumps except for
vibration and noise. The pumps shall be tested over the range covering from
shut-off head to the maximum flow. The duration of the test shall be minimum
one (1) hour. Minimum five (5) readings approximately equidistant shall be
taken for plotting the performance curves.

c) After installation, the pumps shall be subjected to testing at site also. If the site
performance is found not to meet the requirements regarding vibration and
noise as specified, the equipment shall be rectified or replaced by the
VENDOR, at no extra cost to the PURCHASER.

10.6.6 PERFORMANCE GUARANTEE

Performance parameters to be guaranteed by the VENDOR and tolerances permitted
shall be as indicated in section C. BIDDER shall confirm acceptance of these by
indicating values in data sheet B. Pump or any portion thereof is liable for rejection, if
it fails to give any of the guaranteed performance parameters.

10.7. SUBMERSIBLE PUMPS

10.7.1 SCOPE

This Specification covers the requirements of design, material, construction features,

manufacture, inspection and performance testing of Submersible Pump for Waste
Water.

10.7.2 DESIGN FEATURES

a. Pump shall be submersible & non-clog type. Pump shall be suitable for wet or dry
pit installation, fixed or portable type and shall be suitable for working with the
minimum liquid level. Components of identical pumps shall be interchangeable.

b. The pump shall be designed to handle solid sizes as required in design.

c. Fixed type pump set shall be with control panel with all safety devices.

10.7.3 FEATURES OF CONSTRUCTION

627
 a. Impeller shall be non-clog type with smooth blunt edges and large water ways so
as to allow free passage of the large size solids. It shall be free from sharp corners
and projections likely to catch and hold rags and stringy materials. The impeller
shall be statically and dynamically balanced.

b. Double Mechanical seals shall be provided to protect the motor from ingress of
waste water along the shaft. The preliminary and secondary seals shall be oil-
lubricated with tungsten carbide or silicon-carbide faces and they should be
equipped with an electrical monitoring system for seal failure detection.

c. Motor and pump shall have a common shaft with bearings. The bearing shall be
permanently greased and maintenance free.

d. Portable type submersible pump should be equipped with pump base stand / legs,
adequate length of chain and flexible type discharge hose pipe suitable for directly
lowering into the well.

e. Fixed type submersible pump shall be provided with a 90° duck foot bend for
fixing to the concrete floor of the well. The joint between the pump discharge
flange and the delivery piping shall be made by merely lowering the pump into
guide system at the access level. It shall be provided with all necessary fixings for
guiding the pumps during lifting/lowering.

10.7.4 INDUCTION MOTOR FOR SUBMERSIBLE PUMPS

The submersible motor shall confirm to IS:9283:1995.

10.7.5 PERFORMANCE AND CHARACTERISTICS

a. Motors shall be capable of giving rated output without reduction in the expected
life span when operated continuously under varying voltage and frequency supply
conditions as called for in Data Sheet.

b. Motors shall be suitable for full voltage direct-on-line starting or star-delta starting.

c. The starting current of motor shall not exceed 200% of rated full load current for
star/delta starting and 600% of rated full load current for DOL starting, under any
circumstances.

d. Motors shall be capable of starting and accelerating the load with the applicable
method of starting, without exceeding acceptable winding temperatures, when the
supply voltage is in the range 85% of the rated motor voltage to maximum
permissible voltage, for category B type motors.

e. The locked rotor current of the motor shall not exceed 600% of full load current
(subject to tolerance as per the applicable standard).

628
 f. Motors shall be designed to withstand 120% of rated speed for two minutes
without any mechanical damage, in either direction of rotation.

g. The motor vibrations shall be within the limits specified in applicable standard
unless otherwise specified for the driven equipment.

h. Except as mentioned herein, the guaranteed performances of the motor shall be

met with tolerances specified in applicable standard (IS:9283:1995).

i. Protection against increase in stator winding temperature, bearing temperature,

leakage in stator housing and terminal box shall be provided. Minimum 3 nos.
thermistors in series to be provided to sense the stator winding temperature.
Sensors to be provided to detect leakage of waste water into oil housing.

10.7.6 SUBMERSIBLE CABLE

a. The cable shall be PVC insulated and PVC sheathed, flexible, 3 core flat type. The
size of the conductor shall be adequate for continuous use under water and air.

b. In case a joint is required to be made between the lead cable supplied with the
motor and the user's cable connectors, a detailed procedure of cable jointing to
make a watertight joint shall be provided by the manufacturer.

c. The size of the conductor and length of cable should be suitably selected so that
the voltage drop at motor terminals does not exceed 3 percent of the rated voltage.

10.7.7 EARTHING

a. Earthing of the motor shall be done in accordance with the relevant provisions of
IS: 3043:1987.

b. For fixed installation, earthing connection may be made to discharge pipe clamp.

10.7.8 INSULATION

a. Any joints in the motor insulation such as at coil connections or between slot and
end winding sections shall have strength equivalent to that of the slot sections of
the coil.

b. The insulation shall be given tropical and fungicidal treatment for successful
operation of the motor in hot, humid and tropical climate. The tropicalising
treatment shall be as per the applicable standard.

629
10.7.9 TEMPERATURE RISE

The temperature-rise test of the motor shall be taken with the motor coupled to the
suitable pump to give the full load output of the motor. When the various
temperatures are stabilized, the set is stopped and the temperature-rise of the stator
winding by the resistance method shall not exceed 35°C at rated voltage and 45°C at
85% of the rated voltage. During the test, the temperature of the cooling water may
not exceed 45°C. As the cable resistance will also be substantial, it is necessary that
while calculating the temperature rise by resistance method, due care is taken to
account for the correct hot and cold resistance of windings.

10.7.10 CONSTRUCTION FEATURES

The motor shall be suitable for continuous use in fully or partially submerged
condition. A built-in cooling system if required shall be provided to allow the motor
to operate continuously at its rated output regardless of whether the electric motor is
submerged or not by providing either external or internal cooling arrangement.

10.7.11 TESTS AND INSPECTION

Pump testing and inspection shall be as per manufacturer recommendation.

10.7.12 DRAWINGS

1. The following drawings shall be submitted by the BIDDER along with their proposal.

2. Preliminary outline dimensional drawing showing details of pump set, installation

details, civil foundation, clearances, minimum submergence, etc.

3. Performance curves for capacity vs. total head, efficiency, and input to motor. The
capacity range shall be zero flow to run out flow.

4. Typical cross sectional drawing showing constructional details.

10.8. VALVES AND SPECIALITIES GENERAL REQUIREMENTS

10.8.1 SCOPE

The following paragraphs describe general requirements for valves and specialities.

CODES AND STANDARDS

Valves and specialities shall be generally as per the following standards:

1 ANSI B16.1 : Cast Iron Valve Ratings

2 ASME B16.34 : Ratings of Valves-Flanged, Threaded and Welding Ends

630
 3 API 594 : Wafer and Wafer - Lug Check Valves

4 API 600 : Steel Flanged and Butt Welding End Gate Valves

5 API 602 : Steel Gate Valves, Threaded and Socket Welding Ends

6 API 609 : Butterfly Valves

7 BS 1414 : Steel Gate Valves, Flanged and Butt Welding Ends

8 BS 1868 : Steel Check Valves, Flanged and Butt Welding Ends

9 BS 1873 : Steel Globe Valves, Flanged and Butt Welding Ends

10 BS 5156 : Diaphragm Valves

11 BS 5351 : Steel Ball Valves

12 BS 5352 : Steel Gate, Globe and Check Valves, 50 mm and Smaller

13 IS 778 : Bronze Valves

14 MSS-SP 67 : Butterfly Valves

2.0 GEAR OPERATORS

Gear operators shall be provided on the following basis:

2.1 GATE AND GLOBE VALVES

Up to and including ANSI 300 class - 350 mm and larger

600 class and higher - 200 mm and larger

2.2 OTHER VALVES

Plug and ball - 150 mm and larger

Butterfly - 200 mm and larger

2.3 Gear operators shall be suitable for a differential pressure corresponding to the
maximum valve rating at room temperature.

2.4 All gear operators shall be of the enclosed type.

3.0 INTEGRAL BYPASS

3.1 Gate valves shall be provided with integral bypass valve, as per MSS-SP 45, as
follows:

Classes 150 and 300 - 350 mm and larger

Class 600 and higher - 200 mm and larger

631
3.2 Type of bypass valve shall generally be the same as the main valve. Bypass pipe shall
be at least schedule 80 and material of construction of bypass valve and pipe shall be
compatible with the main valve.

4.0 VALVE STEMS

Valve stems shall be of wrought materials. Castings are not acceptable.

5.0 BACKSEAT

All gate, globe and piston valves shall be provided with back seating arrangement to
facilitate replacement of gland packing with the valve in service.

6.0 CHECK VALVES

Check valves of sizes 350 mm and larger shall be provided with features to prevent
slamming and hammering. These can be in the form of springs or external dash pot.

7.0 HARDNESS

13% chromium steel seat surfaces shall have a minimum hardness of 250 BHN and a
differential hardness of 50 BHN.

8.0 NAME PLATES

The details on name plates shall be as per MSS-SP 25.

9.0 TAG PLATES

Tag plates shall be of stainless steel type 304 or aluminium.

10.0 TESTING

Strength and leak tests shall be as per any of the standards MSS-SP-61, API 598 or
BS EN 12266-1 and 2 at the test pressures indicated in data sheet-A. Stainless steel
valves shall be tested using potable water.

11.0 NDT REQUIREMENTS

11.1 All cast steel valves shall be subject to radiography in all accessible areas, as defined
in ASME B16.34, on the following basis:

(a) Class 600 and higher - All sizes

(b) Class 300 - Sizes 450 mm and larger
(c) Class 150 - Sizes 600 mm and larger

11.2 All cast steel valves of class 600 and higher shall also be subject to magnetic particle
or liquid penetrant examination as per ASME B16.34.

632
 11.3 All cast steel valves of class 300 shall have radiography quality castings irrespective
of size.

11.4 Acceptable levels of defects shall be as per ASME B16.34.

12.0 FACE-TO-FACE OR END-TO-END DIMENSIONS

12.1 Face-to-face dimensions of flanged-end valves and end-to-end dimensions of butt

welding-end valves shall be as per ASME B16.10.

12.2 For valves not covered by ASME B16.10, the dimensions shall be as per applicable
valve standards.

13.0 PREPARATION FOR DESPATCH

13.1 COATING

All carbon steel and cast iron exposed surfaces shall be given one coat of primer and
two coats of aluminium finish paint after release has been given for painting and
before despatch. Machined surfaces shall be coated with easily removable rust
protective except that this is not applicable for austenitic stainless steel components.

13.2 END PROTECTION

After completion of the requirements of para 14.1, body end ports, flange faces and
welding ends shall be covered with suitable close fitting protectors to protect the
machined ends and prevent ingress of dirt and moisture.

13.3 DISC

The disc shall be closed before despatch except in the case of soft-seated valves
where the disc shall be backed off to relieve the pressure on the seal.

13.4 PACKING

Valves and specialities shall be so packed as to minimise the possibility of damage

during storage or transit. The packing shall be suitable for tropical conditions.

DATA SHEET A SHEET : 1 OF 1

BUTTERFLY VALVES
FLUID
1. TAG NO.: NIL 4. WATER
:
GENERAL

SIZE QUANTITY
SIZE  50 NB & DES. PR. 7.0 Kg/
2. 5.
RANGE: < 150 NB : cm2(g)
DES.
3. RATING: PN 1.0 6.
TEMP. :
AMBIENT mm P0

633
 7. GRADE: CT
8. ENDS : WAFER TO SUIT ANSI B 16.5, 150# RF FLANGE
9. ALLOWABLE LEAKAGE : NIL Bidder to
10. OPERATOR : THROTTLING LEVER FOR SIZES  150 mm (6") estimate
CONSTRUCTION
FEATURES

11.
12.
13. OTHER REQUIREMENTS :

14. BODY : CAST IRON IS 210 Gr. FG 260

15. DISC : CAST IRON IS 210 Gr. FG 260
BODY SEAT
16. : SS AISI 304
MATERIALS

RING
17. SHAFT : SS AISI 410
BEARING
18. PTFE OR EQUAL
BUSH
19.
20.
21. :
22. :
SHELL
23. : 10.5 Kg/ cm2(g)
INSPECTION

HYDRO
TESTS &

SEAT
24. : 7 Kg/ cm2(g)
HYDRO
25. INSPECTION :AS PER (a) TCE.M4-185-30
TCE.M4-186-04

NOTES: 1. GENERAL REQUIREMENTS: AS PER TCE.M4-103-99.

2. THE FOLLOWING ADDITIONAL TESTS, INDICATED AS "B" IN TCE.M4-186-04, SHALL ALSO BE
CARRIED OUT WHEN TCE.M4-186-04 IS APPLICABLE

DATA SHEET A SHEET :

1OF 1
BALL VALVES
1. TAG NO. :
GENERAL

SIZE SIZE QUANTITY

2. : Refer table
RANGE
3. RATING : 150 CLASS
mm P0 R0 R1 R2
4. GRADE : CA

5. PORT : FULL 15
6. STEM : BLOW OUT PROOF 20
CONSTRUCTION

7. ENDS : RF 25 Bidder to
FEATURES

8. OPERATION :  100 mm (4" ) – LEVER 40 estimate

9. ANTISTATIC FEATURE : REQUIRED 50
10. FIRE SAFE DESIGN (API 607) : NOT REQUIRED 80
TWO PIECE
11. OTHER REQUIREMENTS :
CONSTRUCTION

12. BODY : ASTM A105

MATERIA

13. BALL (MIRROR FINISHED) : SS 304

LS

14. STEM : SS 304

15. SEAT : PTFE SEAT
16. SEAL (STEM & BODY) : -DO-

634
 ASTM A 193 Gr.
17. BOLTS, STUDS & NUTS :
B7 / A 194 Gr. 2H
18.
19. SHELL HYDRO : By Bidder
INSPECTION
20. SEAT HYDRO : By Bidder
TESTS &

21. SEAT AIR : By Bidder

22. INSPECTION :AS PER (a) TCE.M4-904 AND (b)
TCE.M4-185-30
TCE.M4-186-04 (STRIKE OUT WHAT IS NOT
APPLICABLE)

NOTES: 1. GENERAL REQUIREMENTS : AS PER TCE.M4-103-99.

2. THE FOLLOWING ADDITIONAL TESTS, INDICATED AS "B" IN TCE.M4-186-04, SHALL ALSO BE
CARRIED OUT : NIL

DATA SHEET A SHEET : 1 OF 1

CHECK VALVES
1. TAG NO. :
GENERAL

SIZE QUANTITY
2. SIZE RANGE :  50 NB
3. RATING : PN 1.0
mm P0 R0 R1 R2
4. GRADE : GA, CA

5. TYPE : DUEL PLATE WAFER 50

CONSTRUCTION FEATURES

WAFER TO SUIT ANSI B 16.5, 150#

6. ENDS :
RF FLANGE
65 Bidder to
estimate
7. CAP/ COVER : BOLTED 80
8. SEAT : BODY : RENEWABLE 100
: DISC : INTEGRAL
9. DASH POT ARRANGEMENT FOR SIZES

OTHER
10. :
REQUIREMENTS

11. BODY/ CAP/ COVER : CI IS 210 GR FG 260

MATERIALS

12. DISC : CARBON STEEL

13. BODY SEAT : NITRILE
14. DISC SEAT : NYLON EPDM
15. HINGE PIN : SS 304
CAP/ COVER SPIRAL WOUND SS304 +
16. :
GASKET ASBESTOS
17. SPRING : SPRING STEEL
18. SHELL HYDRO : By Bidder
INSPECTION

19. SEAT HYDRO : By Bidder

TESTS &

12. INSPECTION :AS PER (a) TCE.M4-904 AND (b) TCE.M4-185-

30
OR TCE.M4-186-04 (STRIKE OUT WHAT IS NOT
APPLICABLE)
NOTES: 1. GENERAL REQUIREMENTS : AS PER TCE.M4-103-99.
2. THE FOLLOWING ADDITIONAL TESTS, INDICATED AS "B" IN TCE.M4-186-04, SHALL ALSO BE
CARRIED OUT WHEN TCE.M4-186-04 IS APPLICABLE : FOLLOWING TESTS ARE APPLICABLE
A) RADIOGRAPHY FOR PRESSURE PARTS
B) DYE PENETRANT TEST FOR PRESSURE PARTS
C) HARDNESS TEST FOR TRIMS.

635
636
TECHNICAL SPECIFICATION

LANDSCAPE WORKS

637
 LANDSCAPE WORKS

11.1. SCOPE OF WORK

1.1 The Scope consists of clearance of the Site of Works and preparation of the same to
commence the proposed landscape execution activities. Wherever applicable, this is
deemed to include all preliminary works like Dismantling/Demolition, Site
Clearance, and General Leveling etc.
1.2 The drawings shall be read in conjunction with the specifications and matters referred
to, shown or described in one are not necessarily repeated in the other.
1.3 In the event of any element of specification not available in any of the documents the
instructions of the Engineer-in-Charge in writing shall be followed by the Contractor.
1.4 The work shall be carried out in accordance with the drawings and designs as would
be issued to the Contractor by the Project manager duly signed and stamped by him.
The Contractor shall not take cognizance of any drawings, designs, specifications,
etc. not bearing Project manager signature and stamp.
1.5 The work shall be executed and measured as per metric dimensions given in the
Schedule of Quantities, drawings etc.

11.2. GENERAL ITEMS

The more important Codes, Standards and publications applicable to this section are
listed hereinafter.
11.2.1 Setting out the works

- The Contractor shall supply without additional charges the requisite number of persons
with the means and material necessary for the purpose of setting out works and
checking, weighing and assisting in the measurement or examination at any time and
from time to time, of the work or the materials. Failing this, the same may be provided
by the client‟s designated representative In-charge at the expense of the Contractor and
the expenses shall be deducted from any money due to the Contractor under the contract
or from his security deposit.

- The Contractor shall arrange for a qualified surveyor to set out the works and obtain
certification of its accuracy from the surveyor. The Contractor shall then set out the
works and shall be responsible for the true and perfect setting out of the same and for the
correctness of the positions, levels, dimensions, and alignment of all parts thereof and for
provision of all necessary instruments, appliances and labour in connection therewith.
The Contractor shall submit to the client and the Landscape Architects, margins and the
verifications of layout within seven days from the date of getting site layout from
Landscape Architects / client.

- Mark the layout on the site. All bench marks, levels should be properly established and
preserved for future use.

638
- Clearly check the surveyed map provided by the client and mark all drainage lines, water
pipe lines, electrical lines, etc. client has been asked to remove the electrical lines and
electrical poles. It needs to be checked by Contractor to satisfy him / herself from safety
point of view before starting of work.

- The checking of any setting out or of any line or level by the Landscape Architects and
CLIENT‟s representative or their representative shall not in any way relieve the
Contractor of his responsibilities, for the correctness thereof. The Contractor shall
carefully protect and preserve all benchmarks and other things used in setting out of the
work.

11.2.2 Site Clearing / Excavation / Site Grading

- Light irrigation, by flooding the whole site with water. The water should penetrate up to
depth of 15-20 cm only so that the weeds can germinate. Remove all grasses, small
shrubs/weeds etc. with roots. Excavating the site as marked on the drawing/as instructed
at the site, up to any lead and lift.

- Verify the levels and bench-marks from the up-dated surveyed drawing made available
by the client. If there are any discrepancies between the site and the survey drawing, the
same are to be brought to the client‟s notice by addressing a letter to the client and copy
marked to the Landscape Architects.

- Grading and levelling of site as shown in drawing / specified on site by Landscape

Architects. This will include spreading manually or by help of soil unloaded at different
working areas in the site so as to obtain basic datum levels and grades.

- Excavated material shall be stacked off in the manner indicated at the site including
stacking of excavated material up to any lead and lift. The rate shall only cover the cost
of excavation, stacking and/or spreading of the material, if required at the site.

- Clearing the area of unwanted materials including the weeds, stones, masonry pieces etc.
and all such matter that may cause damage to growth of the plant materials immediately
or in future.

11.3. EARTH WORKS

- Earthworks shall involve the grading of soil for earth mounding, the excavation of
trenches and soil for formation levels of pathways and foundations, and the fine grading
of earth banks and landscape areas roughly graded by others.

- Excavation shall be carried out to the depth shown on or implied in the drawings or to
such greater or lesser depths as the Landscape Architect may direct. The Contractor
shall supply and fit all shoring, sheeting, strutting and walling required to maintain the
sides of excavations as long as necessary and to remove them as required. The
Contractor is to allow for making all necessary adjustments to existing manholes in
accordance to bring them to the same level as the required profiled grades. No claim
shall be entertained for either bulking or compacting and all other quantities shall be
measured net from the drawings.

- The stripping and replacement of the subsoil shall only be done in dry weather and
ground conditions unless in exceptional circumstances the Landscape Architect
authorizes otherwise. Subsoil in heaps or dumps shall not be sited so as to damage or

639
 impede water courses or other drainage so long as they are capable of remaining in
operation. Any weeds which may grow on the heaps of subsoil shall be sprayed with an
approved selective weed-killer to prevent seeding.

- Notwithstanding the general description for the type of material to be excavated, if

original bed rock is encountered during these operations which can only be removed by
blasting or compressed air tools this work will be paid for separately as an extra over
item for that given for normal excavation. This work shall only be undertaken when
authorized in writing by the Landscape Architect.

- During excavation it is expected that the Contractor will take every prudent step or
precautions such as tests or borings in order to prove the nature or type of material
underneath or the ground bearing capacity in order to protect his workmen, plant or
machinery employed in these operations.

- In the event of the Contractor excavating below the proper levels or otherwise in excess
of the dimension given, he shall at his own expenses, remove all loose excavated
material and replace the soil excavated in error.

- If, in the opinion of the Landscape Architect the bottoms of any excavation or any
material to be excavated become unsuitable due to the Contractor‟s operations, the
Contractor shall, at his own expenses, carry out any necessary excavation and make up
in a similar manner to the above.

- If, in the opinion of the Landscape Architect the weather conditions are such as to
preclude the satisfactory completion of any operation or cause unnecessary nuisance or
disturbance to other parties, the Contractor shall, on receiving directions from the
Landscape Architect suspend operations on that particular portion of the work until the
Landscape Architect considers that weather conditions are satisfactory, or issues a
direction to re-commence operations. The absence of such a direction shall in no way
constitute the basis of a claim for delay or remedial work to a formation which is
unsuitable.

11.3.1 Major Grading

- Site shall be complete with rough dressing including the base levels by civil contractor
before handed over to landscape contractor for execution.

- Role of Landscape contractor involves major grading forming earth mounds / hillocks
from imported fill materials where specified, or from the site debris and soil generated
by excavations. The soil shall be graded using suitable earth moving machinery to the
contoured earth forms indicated on the drawings. Soil, when in a dry enough state for
easy working, shall be distributed to the correct areas and laid in layers not exceeding
100mm thick and compacted by at least 2 passes of the earth moving machine in each
direction for each 100mm layer.

- Earth slopes are to be formed from the compacted mounds to the gradients and levels
shown on the drawings, accounting for the topsoil depths to be included after subsoil
formation is complete. If insufficient fill is available to complete the levels shown,
additional suitable subsoil is to be imported to make up the required quantities.
Importation of additional fill shall only be carried out with written permission of the
Landscape Architect.

640
- Earthworks levels are to be carried out to the contours shown on the drawings to a
maximum tolerance of 150mm measured vertically, and to a maximum gradient of 1:2.
All subsoil levels are to account for the later additional of specified depths of topsoil.

- The Contractor shall be responsible for protection of completed subsoil mounds and
shall take preventative measures to control erosion and siltation restore or replace any
portion of the earthwork areas which erodes, slumps, silts or is otherwise damaged by
the out-washing of soil.

11.3.2 Excavation for Formation Levels and Trenches

- For footpath areas or other paving areas, excavate subsoil to create a smooth formation
for taking the sub-base for the paved area, to levels shown on the drawings accounting
for the depth of the paving build up.

- Firmly compact sub-grade with a smooth wheeled vibratory roller to achieve an even
level. Finished sub-grade is to be protected until the path sub-base or other construction
such as pool sub-base is laid. If sub-grade is too dry to be compacted, water shall be
added until suitable texture is achieved. If sub-grade is too wet, the material shall be left
to dry out until workable.

- A completed sub-grade/formation on which there is standing water, soft spots or slurry

shall be deemed to be unsuitable and shall be rectified at the Contractor‟s expense
including making up of additional material as required to bring the formation to line and
level again.

- Where soft or wet ground is encountered prior to preparation of the sub-grade and this
soft or wet ground cannot satisfactorily be compacted, the Contractor shall submit a
written request for this to be inspected and the area to be dug out and replaced with
suitable material shall be evaluated by the Landscape Architect and directed accordingly.

- Surplus material resulting from excavations for path formation or drainage trenches shall
be taken off site at Contractor‟s own expense unless otherwise directed by the Landscape
Architect in writing.

- Excavation of drainage or formation trenches shall be carried out after the major grading
has been completed and approved. Trenches shall be cut to lines and gradients shown on
the drawings. Planking and strutting shall be carried out as required to make the sides of
the trenches safe. The Contractor will be responsible for ensuring that drainage trenches
are kept free from mud and water and side slippage.

11.3.3 Fine Grading and Shaping

- Slight unevenness, ups and downs and shallow depressions shall be removed by fine
dressing the surface to the formation levels of the adjoining land, as directed by Project
manager and adding suitable quantities of Good earth, brought from approved source, if
necessary.

- Fine grading shall be carried out using small sized earth moving equipment or by hand,
and shall involve final modeling of the earth contours produced by the major grading
exercise. The shaping will follow the contours shown on the plans in general terms, but
the final forms will be developed by eye to create smoothly flowing and pleasing
contours.

641
- The Fine Grading will provide the detailed earth contouring prior to cultivation of soil.
Soil cultivation and the application of topsoil mixes shall not take place until the Fine
Grading is completed.

11.4. SOILS: MATERIALS AND PREPARATION

11.4.1 Soils: Subsoil

- Subsoil shall be a free draining soil, generally from horizon over 300mm below the
original surface to be used as fill materials, either excavated from areas of the site, or
imported.

- The Contractor shall:

I. Furnish the source of top soil to Client.
II. Study the soil report provided with the tender document, providing soil details
such as pH, alkalinity, total soluble salts, porosity, sodium content and organic
matter.
III. Use the restored soil at site for landscape purpose, manure mixture,
Neemcake, weedicide shall be added if required.
IV. Not consider any external soil source unless the existing soil conserved from
site is lacking in quality and/or quantity.

11.4.2 Topsoil Mixes

- The components of the Topsoil Mixes shall be as follows:

- Topsoil shall be a free draining organic soil from horizons less that 300mm from the
original surface, of a workable crumbly and lump free loamy character and shall contain
no grass or weed growth of any kind or other foreign material or stones exceeding 25mm
in diameter. Total stone content shall be no greater than 15% by volume. A 1 litre
sample with back up soil test data is required before installation, or mixing.

- TOPSOIL SPECIFICATION: The following criteria shall be tested at an approved

laboratory before use on site.

 pH: 5.5 - 7.8

 Electrical conductivity: 1:2.5 (w/v)
 Soil-water extracts not exceeding 1500 micromho/cm (1500 micro-Siemens/
cm)
 Soil texture:
Sand (0.05 - 2.00mm): Max. 75% Min. 20%
Silt (0.002 - 0.05mm): Max. 60% Min. 5%
Clay (less than 0.002mm): Max. 30% Min. 5%
- Soil Conditioner shall be dried treated sludge, organic compost or other fibrous approved
organic matter suitable for mixing with topsoil to make a friable growing medium for

642
 plants, resistant to rapid decay, free of soluble salts below 900ppm, pH 6-7, free of large
lumps or debris.

- Organic Compost shall be organic vegetable compost produced by a thorough

horticultural or industrial composting process or Farm Yard Manure (Cow Dung
Manure). Compost is to have a clean, un-decomposed smell free from any rotting
substances, debris, refuse, clay or visible fungus. A sample is to be submitted for
approval before usage. All composts are to be sterilised before being packed for
transport and odorous materials used on site will be rejected. Any vermin resulting from
use of organic composts will have to be controlled by the Contractor within 12 hours of
any infestation.

- Sand shall be a clean, coarse grained and angular material sourced from a river bed with
a minimum 1mm diameter section. It shall be well graded, free from soluble salts
ranging in size so that 80-100% passes the 3mm sieve and 0-50% passes the 2mm sieve,
with 0% passing through a 1mm sieve.

- Lightweight Aggregate shall be an approved low density inert material such as expanded
shale or clay or volcanic scoria or other porous aggregate capable of being compacted
within the soil zone to 90% compaction without being crushed, free from dust and
debris, pH 6-6.5, free of soluble salts. A 2 litres sample shall be submitted and tested as
part of the soil mix for physical and chemical performance. Materials are to be approved
in writing before installation.

11.4.3 Soil Mixes

- The following soil mixes are to be used for different areas and for different types of
planting. Minor changes to the proportions shown for particular species may be required,
as specified by the Landscape Architect from time to time.

i. Soil Mix A: for use in natural ground level areas shall comprise the components listed
below, which shall be mechanically cultivated to the correct proportions, prior to
placement on site or backfilling. Soil Mix A shall comprise the following proportions by
volume:
Topsoil: 50%
Sand: 20%
Soil Conditioner: 15%
Organic Compost: 15%
ii. Soil Mix B: for use in podium area shall be prepared under controlled mixing conditions
such as a concrete floor to ensure even mixing. Soil Mix B shall comprise the following
proportions by volume:
Topsoil: 30-50%
Sand: 10-30%
Conditioner: 0-20% (as required)
Lightweight Aggregate: 0-20% (as required)
Organic Compost: 20%

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iii. Soil Mix C: for use in planter boxes. Soil Mix C shall comprise the following
proportions by volume:
Topsoil: 40%
Sand: 30%
Charcoal: 20%
Organic Compost: 20%

11.4.4 Soil Preparation and Application of Soil Mixes

- All subsoil areas to be topsoiled shall be cleaned free of rubbish, weeds, all stones
exceeding 50mm in diameter and builders debris shall be removed from site. Any areas
which are contaminated by petrol, soil or other toxic substances shall be excavated to
300mm below the contamination and have the excavated material removed form site.
The excavated areas shall be back filled with imported topsoil as specified. These
operations shall take place immediately before topsoiling (with soil mixes) commences.

- Where directed by the Landscape Architect, the ground shall be decompacted by ripping
to a depth of 300mm. All obstructions to cultivation or deleterious material brought to
the surface shall be removed from the site and any voids left by this operation shall be
backfilled with imported subsoil as specified.

- Subsoil shall be formed to the finished levels and contours after settlement and with
overall even compaction.

- No topsoil or soil mixes shall be spread or cultivation carried out until the subsoil
operations have been approved by the Landscape Architect.

- Topsoil or soil mixes shall be spread on the designated areas to the depth shown on the
drawings. The loose depth of the topsoil shall be sufficient to allow the area to conform
to the levels shown on drawings after natural settlement has taken place. Soil Mixes
shall not be compressed or rolled to achieve levels. Conversely if levels drop below
specified levels, additional soil mixes are to be added to achieve levels.

- Soil Mixes are to be carefully spread by machine or hand in a moist condition. Very wet
or dry soil mixes must not be used. Heavy compaction of soil mixes is to be prevented
and compacted soil will be rejected. Soil Mixes are to be spread to the following
minimum depths in open ground areas:

i. Lawn / Turf areas: 300mm

ii. Shrub areas: 450mm deep
iii. Tree pits: 1000 x 1000 x 1000mm
Unless directed otherwise or as shown on the drawings
- The prepared topsoil mix shall be compacted to 80% of maximum density to the depth
shown on the drawings in 150mm layers. When planter is filled, water topsoil mix
thoroughly to ensure proper and uniform compaction. After 2 weeks, fill with additional
topsoil mixture and compact to level and before pavers are laid indicated on drawings.

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- When in the opinion of the Landscape Architect site conditions are unsuitable for
working, soiling operations shall cease and shall only be resumed when authorized by
him.

- Contractor shall be responsible for soil protection and shall take preventative measures
to control erosion and siltation of all areas and shall restore or replace any portion of the
site which erodes, silts up or is otherwise damaged by out-washing of soil.

11.4.5 Fertilizers
- Chemical fertilizers shall be approved granular slow release compound fertilizers. They
shall be stored in waterproof sealed bags under shelter away from water and direct
sunlight. Samples of the same to be submitted by contractor before use at site.

- Organic fertilizers shall be organic products such as organic liquid fertilizer, pellets or
granules manufactured primarily from organic materials. These products are to be from
accredited sources and technical data indicating sources or origin and manufacturing
process must be submitted before use. Animal by products must be sterilized before
being packed for transport and odorous materials used on site will be rejected. Any
vermin resulting from use of organic fertilizers will have to be controlled by the
Contractor within 12 hours of any infestation. A sample shall be submitted for review
by the Landscape Architect before use on site.

11.4.6 Mulches
- Mulches shall be approved friable composted organic materials. Coco-Peat will not be
allowed on its own unless mixed in a proportion of 50-50 with another mulching
material free from soluble salts or toxic materials and resistant to rapid decay. Mulches
shall have a pH of between 5.5 - 7.0. Samples to be submitted and approved before use.

- Mulches are to be applied in a minimum 50mm layer over the entire surface of shrub and
ground cover areas.

- Mulches is to be re-applied to all planting areas every 3 months after initial installation
until the end of the maintenance period or until complete surface cover by vegetation is
achieved.

- Initial mulching is to take place within 2 days of installation of planting.

11.5. SUBSOIL DRAINAGE

11.5.1 Subsoil, Field Drains and Trench Drains

- Before beginning installation of drain lines establish invert elevation of city storm drains
at points where tree drains will tie in and prepare schematic layout for approval of
Landscape Architect before digging trench.

- Surplus material resulting from excavations shall be carted to other fill areas within the
site. If no additional fill sites are available the Contractor shall remove all surplus
material from site and deposit it in a Local Authority approved tip.

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- The Contractor shall survey the gradient levels of all trench bases to ensure that all falls
are continuous from the highest point down to the outlet point at the sump. These
findings shall be submitted to the Landscape Architect for verification before any further
work is undertaken, either pipe laying or backfilling.

- All trenches when completed and approved shall be lined with approved filter membrane
laid over the base of the trench and up the sides with sufficient membrane to wrap over
the top of the gravel backfilling with a minimum overlap of 300mm.

- The base of each drainage trench shall have a layer not less than 30mm and not more
than 50mm depth of fine stone chippings 8-12mm diameter or coarse sand laid to
accurate falls for bedding the perforated pipes.

- The drainage pipes to the sizes shown on the drawings shall be prefabricated subsoil
drainage system or similar approved type. PVC pipes with drilled holes will not be
permitted. Drainage pipes shall be laid to the lines to the falls shown on the drawings
and accurately boned in to correct gradients before backfilling.

- All pipe junctions shall be as supplied by the selected manufacturer and shall be fitted to
the manufacturer‟s instructions to provide smooth flow and to fit the correct pipe sizes.
Where changes in pipe diameters occur the correct junctions shall be used to match the
changed pipe diameters.

- Connect drainage system to percolation pits.

- Where subsoil drainage pipes pass under paths or structure the pipe shall be of non
perforated pipe joined at either end to the perforated pipe, and be surrounded by 100mm
of concrete haunching.

- Trenches shall be backfilled to within 100mm of the finished level with clean coarse
grained sand or crushed stone chippings 8-12mm diameter free of any fine particles.
The gravel backfill shall be lightly compacted in 100mm depth layers.

- All drains shall be tested on completion to ensure a satisfactory water flow. Any pipes
that do not flow are to be taken up and re-laid at the Contractor‟s expense.

- After testing has been approved, remaining depth of the trench shall be filled with a layer
of coarse grained sand up to the finished soil level (after final settlement). Where the top
layer is specified as such, clean graded gravel 20-40mm stone chippings free from fine
particles shall be placed up to the finished surface mix, free from clay lumps or any item
likely to inhibit drainage.

11.6. HARDSCAPE FINISHES

11.5.2 Paver Blocks / Interlocking Concrete Block Pavement:

- The concrete pavers should have perpendiculars after release from the mould and the
same should be retained until the laying. The surface should be of anti-skid and anti-
glare type. The pave should have uniform chamfers to facilitate easy drainage of surface
run off. The pavers should have uniform interlocking space of 2mm to 3mm to ensure
compacted sand filling after vibration on the paver surface.

- The concrete mix design should be followed for each batch of materials separately and
automatic batching plant is to be used to achieve uniformity in strength and quality.

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- The pavers shall be manufactured in single layer only.

- Skilled labour should be employed for laying blocks to ensure line and level for laying,
desired shape of the surface and adequate compaction of the sand in the joints.

- The pavers are to be skirted all round with kerbing using solid concrete blocks of size
100mm x 200mm x 400mm or as directed by the Engineer. The kerbing should. be
embedded for 100mm depth. The concrete used for kerbing shall be cured properly for 7
days minimum.

11.5.3 Bedding Sand Course :

- The bedding sand shall consist of a clean well graded sand passing through 4.75mm
sieve and suitable for concrete. The bedding . should be from either a single source or
blended to achieve the following grading.

Bedding Sand Requirement

In Sieve Size % Passed
9.52mm 100
4.75mm 95-100
2.36mm 80-100
1.18mm 60-100
600 Microns 25-60
300 Microns 10-30
150 Microns 5-15
75 Microns 0-10

- Contractor shall be responsible to ensure that single-sized, gap-graded sands or sands

containing an excessive amount of fines or plastic fines are not used. The sand particles
should preferably be sharp not rounded as sharp sand possess higher strength and resist
the migration of sand from under the block to less frequently areas even though sharp
sands are relatively more difficult to compact than rounded sands, the use of sharp sands
is preferred for the more heavily trafficked driveways. The sand use for bedding shall be
free of any deleterious soluble salts or other contaminants likely to cause . efflorescence.

- The sand shall be of uniform moisture content and within 4% - 8% when spread and
shall be protected against rain when stock piled prior to spreading. Saturated sand shall
not be used. The bedding sand shall be spread loose in a uniform layer as per drawing.
The compacted uniform thickness shall be of 45mm and within +/- 5mm thickness
variation shall not be used to correct irregularities in the base course surface.

- The spread sand shall be carefully maintained in a loose dry condition and protected
against pre-compaction both prior to and following screeding. Any pre-compacted sand
or screeded sand left overnight shall be loosened before further laying of paving blocks
take place.

- Sand shall be slightly screeded in a loose condition to the predetermined depth only
slightly ahead of the laying of paving unit.

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11.7. SOFTSCAPE WORKS
The scope of services covers all horticultural operations and services including,
labour, equipment, services and transport for all plant materials, Good earth, top soil
conservation, manures, pesticides etc. completing the entire work within the
scheduled time, maintaining the entire Softscaping work for one year after virtual
completion of the work.
The Contractor shall refer to Specifications provided in this document for relating to
formation levels, sub-bases, concrete footings, foundations and all associated works.
The specifications are to be read along with necessary specifications from other
consultants.
Vendors‟ shop drawings shall be submitted for all such items where the Contractor
will procure and install items from/by a reputed vendor. Execution of all such items
shall be done after such drawings are approved by the Employer/ Employer‟s
representative.
Contractor shall prepare and issue all required working drawings and get them
approved by Employer/ Employer‟s representative with required number of revisions
till the details provided do not satisfy the Employer/ Employer‟s representative.
The scope includes maintenance of all above for 5 Years from the date of end Defects
Liability Period (DLP). DLP shall be of one year after completion of Landscape
Execution. The Contractor will maintain the entire landscape development area free
of cost for a period of one year after completion of all above works as certified by the
Employer/ Employer‟s Representative's in consultation with the Landscape Architect

11.8. SPECIAL CONDITION

The Contractor will have to provide the following items at no extra cost to Employer:
a. The Contractor will supply and install 3.0 metres high barricades for safeguarding
landscape development area and works, as indicated in the drawing. He may also
install the barricades in the landscape development area according to his own
understanding if he feels that any part of the landscape area is bound to be damaged
for any reason, after taking prior permission from the Employer/ Employer‟s
Representative.
b. The Contractor will supply, install and maintain at his own cost, the most modern,
automated watering system for the landscape, which will take care of the requirement
for particular plants, save water and does not waste water, including any requirements
specified by the Landscape Architect appointed by contractor. He will give full details
of the layout, size of the pipe, size of the sprinklers, bubblers, etc and their warranty
period. All equipment must conform to international standards and / or Indian
Standards if available. The design of the irrigation system has to be approved by
Employer/ Employer‟s representative.
c. All equipment required for development shall be made available by Contractor, and
its maintenance shall be his responsibility. This includes Tagara, Phawdas, Hose
Pipes, Ground Roller, Manual and/or Electric lawn Mowers, Sprinklers, etc.
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d. Contractor will ensure that all plants remain free of diseases, pests, etc during
development and maintenance periods. The contractor shall, without any additional
charge renew any dead or defective plant material and shall fully maintain including
watering, de-weeding etc. of the whole landscape as mentioned above.
e. The Contractor shall maintain Nursery at his own cost at designated locations as
shown in the drawing or at a suitable location within the plot as directed by
Employer/ Employer‟s Representative. The Nursery will be fenced with gates for
protection from cattle. The area of Nursery will be approximately 5000sqm. The item
would include construction and maintenance of Green Houses if required.
f. Contractor shall follow pre construction and during construction soil erosion control
measures as per the NBC Part 10, section 1, Chapter 4 – Protection of Landscape
during Construction.
g. The contractor in co-ordination with the Employer as applicable shall ensure
conservation and storage of top soil: Topsoil shall be stripped to a depth of 200 mm
from areas proposed to be occupied by buildings, roads, paved areas and external
services. It shall be stockpiled to a height of 400 mm in designated areas and shall be
re-applied to site during plantation of the proposed vegetation. Topsoil shall be
separated from sub-soil debris and stones larger than 50 mm diameter. The stored
topsoil may be used as finished grade for planting areas. It is the landscape
contractor‟s responsibility to conserve top soil that is not disturbed by the civil
contractor.
h. The Contractor shall:
I. Furnish the source of top soil to Employer/ Employer‟s Representative.
II. Study the soil report provided with the tender document, providing soil details
such as pH, alkalinity, total soluble salts, porosity, sodium content and organic matter.
Ref. Soil Test Report
III. Use the restored soil at site for landscape purpose, manure mixture, Neemcake,
weedicide shall be added if required.
IV. Not consider any external soil source unless the existing soil conserved from site
is lacking in quality and/or quantity.
Soil Analysis for Top Soil fertility determination

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 To determine the fertility of top soil for conservation, soil investigation shall be
carried out by an NABL accredited laboratory.
Adequate number of test samples of soil from a depth of 10-200mm below ground
level shall be collected from at least 5 representative locations from site, preserved
and transported (as per standard procedures specified by the laboratory) carefully to
the laboratory for carrying out necessary tests.
All relevant Indian Standards for sampling and conducting laboratory tests shall be
followed.
This soil samples shall be analyzed to determine soil type, texture, total organic
content, pH, extractable nutrients such as nitrogen, phosphorus, potassium, salinity,
cation exchange capacity, % base saturation and extractable heavy metals.
The soil analysis report from the laboratory shall also include a statement on the
fertility and suitability of the soil for plant growth based on the analysis, in addition
to the test results.

Top Soil conservation

Topsoil shall be removed for conservation to a depth of 200 mm (not more than 400
mm) and shall be separated from subsoil debris and stones larger than 50 mm
diameter.
It shall be stockpiled to a height of 400 mm in designated areas. The stockpiled
topsoil shall be protected from erosion during storage by installing earthern
berms/solid walls, temporary seeding (using native grass), covering with mulch or
plastic, etc.
The topsoil shall be protected with sand bags/solid walled enclosures (2 feet high)
on all sides for containment.
Appropriate drainage channels shall be dug around the storage area to prevent
flooding of the top soil storage area.
The top soil shall be reapplied to site during plantation of the proposed vegetation as
finished grade for planting areas.
Seeding will take place immediately after respreading topsoil and decompacting,
unless timing is inappropriate (for e.g., not in mid-summer).
i. The contractor to identify erosion prone areas on site and protect them from
construction activities throughout the construction period. Prevent / mitigate the
disturbances caused to site due to construction activity.
j. The contractor shall execute a sedimentation and erosion control plan that conforms
to the best management practices highlighted in the National Building Codes of India
(NBC) Part 10, section 1, Chapter 4 – Protection of Landscape during Construction.
This standard describes two types of measures that can be used to control
sedimentation and erosion. Stabilization measures include temporary seeding,
permanent seeding and mulching. Structural control measures include earth dikes, silt
fence, sediment trap, and sediment basin. All of these measures are intended to
stabilize the soil to prevent erosion.
k. The erosion and sedimentation control plan must be approved by Employer/
Employer‟s Representative and the erosion sedimentation control plan must be
maintained throughout the execution period.
l. The contractor shall execute measures of protection and preservation of existing
landscape on site during entire construction time.

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m. Design, execute and maintain a temporary storm water management layout for the
duration of construction activity. The storm water management layout should
conform to National Building Codes of India (NBC) Part 10, section 1, chapter 4 –
Protection of Landscape during Construction.
n. Contractor should take measures to prevent entry of any soluble/ insoluble
construction waste to enter the water table/ water ways/ ravines on site.

11.9. GENERAL SPECIFICATIONS

11.8.1 Holding Nursery

i. A piece of land has been secured within the site for use as a holding nursery as
indicated on the Contract Drawing. (Ref. Dwg. No)
ii. As a holding nursery the Contractor shall provide all necessary plant and equipment
to store his plant material, machinery and equipment for the duration of the contract,
including the two-year maintenance period.
iii. The Contractor shall be required to install and establish all equipment that may be
required to run a major landscape contract and ensure plant materials remains in a
healthy and fit condition. The list of requirements includes, but is not limited to:
- Provision of a 3,000 high tensioned chain link fence (with at least 2 no. lockable
gates) around the extent of the holding nursery)
- Grading and laying of crusher together with associated storm water drainage to take
vehicular loading
- Provision of all site utilities including water, telephone, electricity
- Provision of any shade structures that may be required to maintain the plants in a
healthy condition prior to planting out
- Provision of any irrigation systems, pumps, sprinklers that may be required to
maintain the plants in a healthy condition prior to planting out
- Provision of a site office to include at least one conference/meeting room capable of
comfortably accommodating 15 persons
iv. The Contractor may wish to use the holding nursery for the purpose of propagation of
plant stock for the contract. This is not a mandatory requirement since it is assumed
that plant stock will need to be outsourced in order to meet the programme target
dates. The decision to use the holding nursery as a propagation area rests entirely with
the Contractor having taken into account the programme constraints, the nature of the
site location (relatively remote) and his own commercial considerations.

11.8.2 Provision of Site Utilities

i. The Contractor is to allow for the provision at his own cost of all site utilities for the
duration of the contract including but not limited to water, electricity and telephone.

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11.8.3 Landscape Development Technique
i. The contractor will not be allowed to use different techniques or quality criteria or
materials unless his alternative system has been confirmed in writing by the
Employer/Employers representative.
ii. No cost increases for alternative specifications will be entertained unless formally
submitted in writing as an improvement in the quality of a product and accepted in
writing, following Employer/Employer‟s Representative approval, by the
Employer/Employers representative.

11.8.4 Quality of Workmanship and Materials

i. All materials and workmanship shall be of the high standards and quality demanded
by this specification. Sub-standard work and materials identified by the
Employer/Employer‟s representative will be rejected and will be required to be rebuilt
or replaced at the Contractor‟s costs.
ii. All plant material shall be of the genus, species and variety specified and substitutions
will not be permitted unless authorized in writing by the Employer/Employer‟s
representative. The sizes and plant description set out in the section headed Plant
Material.
iii. All trees and shrubs supplied for the contract shall be free of pest, disease,
discolouration and damage. Plants shall be well branched with vigorous shoots. The
root system of each plant shall contain a good proportion of fibrous roots.
iv. All materials are to be approved by the Employer/Employer‟s representative prior to
use on site. Materials shall be obtained from approved sources/manufacturers and/or
suppliers. All guarantees and warranties shall be copied and submitted to the
Employer/Employer‟s representative prior to requests for approval.
v. Where particular products are specified, the Main contractor‟s specialists
subcontractors if he wishes to use similar products from other manufacturers must
seek prior confirmation from the Employer/Employer‟s representative.

11.8.5 Site Responsibilities

i. From the commencement of the works until the Certificate of virtual Completion has
been issued by the Employer/Employer‟s representative, the Main contractors
specialists subcontractors shall, in respect of all areas of soft landscape works,
adjacent areas and parts of the site used by him, be responsible as follows:
- For adequate protection to grassed areas, planted areas and trees and for making good
Softscape works on removal of any protective measures at completion.
- For any damage to existing works and features and any necessary rectification work
required to obtain approval from Employer/Employer‟s Representative.
- For keeping all paved surfaces used by him in a clean and tidy condition.
- For periodic removal of all surplus excavations and waste matter produced by his
operations to a Local Authority registered tip off site, to be found by the Main
contractors specialists subcontractors.
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 - For keeping all Softscape areas in a weed-free and tidy condition and adequately
watered.
ii. The Main contractor‟s specialist subcontractors shall make appropriate allowance for
these requirements in his rates.
iii. The Main contractor‟s specialist subcontractors shall, within 24 hours of notification
and as directed by the Employer/Employer‟s representative, undertake at his own
expense any remedial works arising from the stated requirements.
iv. Tree conservation:
- All trees to be conserved shall be protected with a 3-4 foot high enclosure constructed
using brick/fencing (with an access gate for tree maintenance) at a distance indicated
in the table below depending on the diameter of the tree trunk.
TRUNK DIAMETER DISTANCE FROM TRUNK ON
ALL SIDES
(measured at 4.5 feet above natural grade)

Up to 6 inches Past dripline

6-9 inches 5 feet

10-14 inches 10 feet

15-19 inches 12 feet

over 19 inches 15 feet

- This tree enclosure shall be erected before demolition, grading, or construction begins
and remain until final inspection of the project. A „Warning” sign of size 8.5“x 11”
shall be prominently displayed on each protective enclosure to state the following:
- The following activities are prohibited within and in the vicinity of the tree
protection zone throughout the entire duration of the construction project:
- Cutting of tree roots by utility trenching, foundation digging, placement of curbs and
trenches, or other miscellaneous excavations
- soil disturbance or grade change
- drainage changes
- storage of material, topsoil, vehicles, or equipment
- Activity including but not limited to compaction, grading, construction etc.
- dumping of any material including but not limited to paint, petroleum products,
concrete, mortar, dirty water, waste
- use of the tree trunks as a backstop, support or anchorage as
- a temporary power pole, signpost or other similar function
- The following activities are permitted or required within the Tree Protective Zone
with approval from Landscape Architect:

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 - Mulching with wood chips (unpainted/untreated) or approved material to a four to six
inch depth, leaving the trunk clear of mulch to prevent inadvertent soil compaction
and moisture loss.
- Irrigation, Aeration, fertilization indicated by Landscape Architect for the healthy
growth/maintenance of the tree
- if tree is adjacent to or in the immediate proximity to a grade slope of 8% or more, e
rosion control measures shall be installed outside the Tree Protection Zone to prevent
siltation and/or erosion within the zone

11.8.6 Plant Protection

i. All plant material is to be carefully protected and if necessary wrapped in the nursery
during lifting, awaiting transportation, during transportation, unloading and during
storage on site.
ii. Any evidence of unsatisfactory protection to roots, stems, branches and leaves will
result in plants being rejected.
iii. Unprotected plants must not be transported during very hot weather, and all plants
must be kept moist during transportation and storage. No plant material shall be left
on site unplanted for more than two days.

11.8.7 Work by Machine or Hand

i. All operations herein described shall be carried out by suitable approved machines or
by hand.
ii. Any work around the base of existing trees, in confined spaces or which is
impractical to carry out by machine for any reason shall executed by hand and the
contractor shall include for this in his rates.

11.8.8 Notice of Intentions

i. The contractor shall give forty-eight hours written notice to the Employer/Employer‟s
representative of his intention to commence any of the following operations:
- Setting out,
- Planting,
- Topsoiling,
- Turfing,
- Sprigging,
- Maintenance visits

11.8.9 Heavy Machinery

i. Heavy machinery, which would excessively consolidate the sub-soil, shall not be
used during any operations nor shall heavy machinery be taken over areas prepared
for planting or grassing.

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11.8.10 Substitutions
i. If the Main contractor‟s specialist subcontractor is unable to supply a particular
species of plant he is to notify the Employer/Employer‟s representative in advance of
his intention to make a substitution. No substitution will be allowed without prior
written agreement of the Employer/Employer‟s representative.
ii. Notices of substitutions are to be made sufficiently for in advance of installation to
ensure that the substituted material conforms to specifications. Substitutions
requested by the Main contractor‟s specialist subcontractor after work has started on
site will not be entertained.

11.8.11 Setting Out

i. The Contractor shall be responsible for accurately setting out all the works prior to
the commencement of the works and shall rectify errors in setting out at his own
expense.
ii. Any discrepancy in site area between that shown on the drawings by Landscape
Architect appointed by contractor and the actual area on the ground shall be notified
to the Employer/ Employer‟s representative.
iii. The Contractor shall supply all necessary materials, equipment and labour to enable
the Landscape Architect to check the setting out, levels and dimensions on the site
along with the Employer/ Employer‟s representative.

11.8.12 Tools and Equipment

i. The Contractor shall use proper tools and equipment for the carrying out of the works
and is to ensure that the work force is fully and properly equipped with the correct
equipment and experience for the job at hand.

11.8.13 Failures of Plants (Pre-practical completion)

i. Any trees, shrubs, grass or other plants (other than those found to be missing or not in
accordance with the Contract Documents as a result of theft or malicious damage and
which shall be replaced), which are dead, dying, missing or found not to be have been
in accordance with the Contract Documents at practical completion of the Works shall
be replaced by the Contractor entirely at his own cost unless the Contract
Administrator shall otherwise instruct.
ii. The Contract Administrator shall certify the dates when in his opinion the
Contractor‟s obligations under this clause have been discharged.

11.8.14 Plants Defects Liability and Post Practical Completion Care by Contractor
i. Any grass which is found to be defective within 24 months, any shrubs, ordinary
nursery stock trees or other plants found to be defective within 24 months and any
semi-mature, advanced or extra large nursery stock trees found to be defective within
24 months of the date of virtual completion due to materials or workmanship not in
accordance with the Contract Documents shall be replaced by the Contractor entirely
at his own cost unless the Contract Administrator shall otherwise instruct.

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 ii. The Contract Administrator shall certify the dates when in his opinion the
Contractor‟s obligations under this clause have been discharged.
iii. Malicious Damage or Theft (Before Practical Completion): All loss or damage arising
from any theft or malicious damage prior to practical completion shall be made good
by the Contractor at his own expense.

11.8.15 Submittals
i. The Contractor shall submit for review drawings by Landscape Architect appointed
by contractor completely dimensioned, indicating any pattern layouts, special
installation procedure, cutting, fitting, sinking and adjacent equipment materials for
coordination.
ii. The Contractor shall submit samples of all materials and samples of workmanship for
approval by Employer/Employer‟s representative.
iii. The Contractor shall be responsible for producing and submitting for comment and
approval to the Employer/Employer‟s representative the shop drawings and samples
of all elements indicated in this section. All should be based on the drawings provided
by Landscape Architect appointed by contractor. All submissions should be reviewed,
approved and endorsed by the Contractor.

11.8.16 Handling, Storage And Delivery

i. The Contractor shall:
- Coordinate delivery with suppliers, to minimize handling.
- Handle and store equipment and materials in such a manner that no damage will be
done to the materials or the work of other trades.
- Store packaged materials, undamaged in their original wrappings, or containers with
manufacturer‟s labels and seals intact.
- Stack equipment and materials on wooden platforms at least 150mm clear of the
ground and protect with weatherproof covers.
- Damaged equipment, material or works will be rejected by the Employer/Employer‟s
representative whether built-in or not.
- For equipment, materials and work, covering shall be of suitable material containing
nothing that may injure or stain the materials.

11.8.17 Protection of Work

i. The Contractor shall protect all equipment, materials and completed work from
damage until final completion of the work.
ii. The Contractor shall remove and replace damaged work at no extra cost.

11.8.18 Reference Standards

i. The Contractor shall comply with all relevant Indian Standards, ASTM, British
Standard Code of Practice, Draft BS or DIN Standard applicable to elements
indicated in this section, the recommendations and requirements of such documents
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 shall be considered a minimum standard of such work described and must be
complied with.
ii. Nothing shall relieve the Contractor of his responsibility for providing a higher
standard than the relevant Code or Standard where it is required to comply with other
sections of the Specification.

11.10. PLANT MATERIALS AND PLANTING OPERATIONS

The following plant descriptions cover the different categories of plant material to be
used on the site.
These descriptions and their accompanying drawings requirements must be studied
carefully and adhered to.
Plants that do not reach the specified dimension or quality, characteristics in this
section or in the sizes and descriptions set out in the Bill of Quantities will be rejected
and will have to be replaced at the Contractor‟s cost.
Trees and palms and large feature plants that are growing in open ground are to be
prepared for transplanting at least 2 months before moving, either to containers in the
nursery or direct to the site.
Preparation of in-ground trees and palms shall be by root pruning to the stated
rootball dimensions.
Trenching around the outer edge of the rootball using pruning and a sharp spade shall
be done in four separate stages trenching in quarters, with one quarter of the tree roots
being cut and backfilled each week, the next quarter the following week, with all of
the ball being cut in one month.
If roots over 25mm are encountered these are to be cleanly cut with large secateurs or
pruning saw.
The trench which shall be at least 200mm wide shall be dug to the full specified depth
of the rootball and undercut at the end of the root-pruning exercise to sever base
roots.
The whole trench shall by this time be backfilled with sand. The tree is then to be
allowed to settle for one month before final wrapping with protection and lifting. The
rootball is to be well watered during this period.
For trees and palms that are to be containerised or root wrapped, the lifting and
placing in containers or being wrapped is to be done immediately after the root
trenching operation is complete.
Plants to be transported or moved are to be thoroughly wrapped and protected prior to
transporting.
Rootballs are to be wrapped and tied with Gunny sack or hessian sacking if not
containerised.
Exposed trunks are to be wrapped in rice straw including the lower parts of the
branch system.
The upper branch system, especially if well furnished with leaves and twigs during
transportation is to be completely wrapped in Lightweight netting or cloth tied and
palms are to be laid at an angle to prevent damage from overhead structures and from
buffeting and shall be covered by canvas as protection from wind.
Damaged trees will automatically be rejected on arrival at site.
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 All trees and palms are to be purchased, stored and grown on in suitable nursery
conditions within one month of the contract and made ready for direction by the
Landscape Architect appointed by Contractor.
Failure to procure within this time and to reveal the source of supply and location will
result in the Employer/Employer‟s representative sourcing the plant materials for the
Contractor, and the cost of this sourcing operation will be deducted from the
Contractor‟s payments.
All dimensions shown with tolerances (that is 120 - 150mm) refer to maximum and
minimum dimensions that will be accepted. Measurement of all plants of one species
shall, as a minimum, average between the upper and lower figures (that is in the
above case 135mm).
All trees and palms specified for containerising or root wrapping after root pruning
operations are to be well furnished with leaves over the crown of the tree. Thinning
of leaves to reduce transpiration to give a 50% cover is permissible providing due
notification is given that thinning is required to ensure that the trees can be inspected
before thinning work is done. Bare crowned trees will not be permitted.
Leave cover: Any trees or palms which shed their leaves within 2 weeks of
transplanting are to be replaced by the Contractor at no extra charge.

11.9.1 Trees
a. Instant Trees
These are semi-mature trees especially prepared in advance for transplanting.
Root pruning to cleanly cut roots to the diameter of the rootball shall be carried out 3
months in advance of transplanting.
Trees shall be 300 - 450mm (12” - 18”) circumference of stem when measured 1.0m
(3‟) from ground level and shall have a clear stem of minimum 1.8 metres.
The head shall be well balanced and contain at least four main branches 500-1000mm
long giving an overall height of 3 - 4m after pruning.
All saw cuts are to be painted with an approved insecticide/fungicide solution.

b. Extra Heavy Standard Trees (EHS)

These are large size nursery grown trees pruned during growth to produce a tight well
rounded head and a straight stem clear of leaves or twigs.
Trees shall be 140 - 180mm circumference of stem when measured 1m above ground
level and shall have a clear straight stem of minimum 2m.
The head shall be well balanced and rounded and contain at least four main branches,
and a well developed secondary branch system giving an overall height of 4.5 -
4.8mm at the time of planting.
Trees shall have a defined central leader. Pruning at the time of removal from the
nursery will not be permitted.
In dry weather conditions trees are to be sprayed with approved Anti-transpirant.
Rootball dimensions: diameter 750mm x 600 deep minimum. Branching/leaf spread
shall be of 2.2 - 2.4m diameter.

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c. Heavy Standard Trees
These are large size nursery grown trees pruned during growth to produce a tight well
rounded head, and a straight stem clear of leafs or twigs.
Trees shall be 120 - 150mm (5” - 6”) circumference of stem when measured 1.0m
(3‟) from ground level and shall have a clear straight stem of minimum 1.8 metres.
The head shall be well balanced and rounded and contain at least four main branches
with a well developed secondary branch system and a central leader, giving an overall
height of 3.5 - 4.0cm (10‟ - 13‟) at the time of planting.
Pruning at the time of removal from the nursery will not be permitted.
In dry weather conditions, trees are to be sprayed with approved Anti-transpirant.
Rootball dimensions: diameter 600mm (2‟) x 450mm (1‟6”) deep minimum.
Branching/leaf spread to be of 1.8 - 2.0m diameter.
d. Standard Trees
These are medium size nursery grown trees pruned during growth to produce a tight
well rounded head, and a straight stem clear of leaves or twigs.
Trees shall be 100 - 120mm circumference stem when measured 0.9m from ground
level and shall have a clear straight stem of minimum 1.5mm.
The head shall be well balanced and rounded and contain at least four main branches
with a well developed secondary branch system and a defined central leader that has
not been pruned, giving an overall height of 2.5 -3.0m at the time of planting.
Pruning at the time of removal from the nursery will not be permitted.
In dry weather conditions, trees are to be sprayed with approved Anti-transpirant.
Rootball dimensions: diameter 500mm (1.6”) x 300mm (1‟) deep minimum.
Branching/leaf spread shall be of 1.5 - 1.8m diameter.
e. Standard Feathered Whips
These are medium sized nursery grown trees having a single straight stem and
unbroken leader giving an overall height of 2.5 - 3m.
The stem shall be fully furnished with evenly spread and balanced lateral branches
down to ground level and shall be 80 - 100 mm circumference of stem when
measured 1m from ground level.
The tree shall have a strongly developed fibrous root system and shall be container
grown. Leaves or branches shall not be cut off before planting.
Rootball dimensions 450 x 300mm minimum. Branching/leaf spread shall be of 1.5 -
1.8m diameter.
f. Ships/Saplings
These are young tree grown from seed or cuttings which are trimmed or pruned,
furnished with branches down to ground level.
Trees shall have a single straight stem and unbroken leader between 900 - 1500mm
overall height.
Stem thickness will vary between species, but a strong stem which does not bend over
is required.

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 The tree shall have a strongly developed fibrous root system and shall be container
grown. Leaves shall not be cut before planting.
Container dimensions: 250mm diameter x 250mm deep minimum.

11.9.2 Palms
All palms shall be single stem. Single Stem Palms shall have clear straight trunks of
heights as stated in the Bill of Quantities as measured from the root collar to the base
of the lowest leaf sheath. The stem girth shall be of dimension normally found for
palms for the stem height and species specified.
Acceptable tolerances to variations in stem height shall be +200mm or -200mm from
the height specified in the Bills of Quantities.
The heads of palms shall be well balanced with at least 7 leaves and a healthy
growing apical shoot all free from pest and disease.
a. Rootball dimensions shall be in proportion to stem heights as follows:
Stem height Rootball diameter Depth

1m 400mm 400mm
2m 750mm 600mm
3m 900mm 600mm
4m 1200mm 750mm

1.1. Shrubs, Herbaceous Plants and Ground Covers

a. Shrubs
These are woody perennials of generally multi stemmed and bushy habit ranging
from 3 - 4.5m down to 500mm height.
Shrubs shall have no less than three main stems and shall be well balanced and bushy,
with strongly developed fibrous root systems, and shall be pruned in advance as
required to achieve the specified height tolerances.
Branches shall break from the base of the plant just above the root collar, and shall be
well furnished with leaves right down to ground level.
All plants are to be container grown in containers of suitable dimensions for the
species.
b. Herbaceous Plants
These are non-woody perennials usually of a clump forming habit.
Plants shall have a well developed main stem or stems with good symmetry, a healthy
root system, free from pest or disease.
Clumps of herbaceous plants shall include rhizomes, corns, tubers or roots and soil
undisturbed by lifting with evidence of growing shoots emerging above soil level.
All herbaceous plants are to be grown in containers unless specified as being
produced by alternative method.
c. Groundcover plants
These are low growing, 500mm or less, or prostrate shrubs or herbaceous plants
whose habit is to totally cover the soil.

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 All groundcover species shall be evenly balanced to allow equal growth in all
directions.
Plants shall have fully developed roots and leaves.
Rooted cuttings will not be accepted. All plants to be container grown.
Rooted shoots of certain spreading ground cover plants shall be used only where
specified, planted as „sprigs‟ as opposed to established plants in soil.
Plants shall be rooted shoots and shall have at least one and evidence of vigorous root
growth.
Recent cuttings with no root development shall not be acceptable.
d. Climbers
Climbers are plants whose growth habit is to climb upwards by means of twinning
stems, tendrils or clinging roots.
Plants shall be grown to reach the recommended size using stocks no less than one
year old, and no more than five years old at the time of the start of the contract.
Plants shall have at least two leader shoots up to the recommended height and a
vigorous root system.
All plants to be container grown.

11.9.3 Hedging Plants

Hedging Plants shall be shrubs such as Lawsonia, Ixoras, etc as per design
requirements of Landscape Architect appointed by contractor as suited to regular
clipping, previously prepared to establish a uniform height and complete foliage
cover to the stem from ground level upwards.
Plants shall be a minimum overall height of 500mm with a minimum of 4 branches
arising from ground level and a strongly developed fibrous root system.
Branches shall be well clothed in leaves down to ground level.
All plants to be container grown in suitably sized containers.
Hedging plants shall be prepared by root and branch pruning to achieve the „box‟
shape shown, at least 3 months before transplanting.

11.9.4 Container Grown Plants

Container grown plants shall mean trees and shrubs which have been grown in
containers sufficiently large to hold the developing root system from seed or cutting
and shall be filled with suitable nutrient rich, free draining compost as per design
requirements of Landscape Architect appointed by contractor.
Container grown stock shall be well watered prior to dispatch from the nursery and
shall remain in the container until planted on site, whereupon the container shall be
carefully removed to avoid soil disturbance.
Empty containers are to be removed from site.

11.9.5 Cultivation of Plant Beds

Cultivation of the completed soil mix beds shall take place only when the seeding or
planting operations can begin immediately after cultivation. No cultivation shall be

661
 undertaken in weather or ground conditions in which operations may destroy soil
structure or where soil mix has not been approved by the Landscape Architect.
Cultivation shall be by approved mechanical or manual means to a depth of 250mm
for Ground Cover and 450mm for Shrubs to provide an even, weed free texture.
After cultivation, stone picking from the surface of soil areas shall be carried out such
that all stones and lumps exceeding 50mm in diameter are collected. All stones,
weeds and rubbish brought up shall be removed from the site to a tip to be found by
the Contractor.
Ground cover, rooted shoot and herbaceous beds are to have 25mm solid conditioner
spread over the entire area and well forked in to the top 250mm of soil during
cultivation. This operation is separate from the mulching specified.

11.11. PLANTING TECHNIQUES AND ACCESSORIES

All plants shall be planted to accommodate the spreading root system of the plant to
the same soil depth as in the nursery and shall be well watered before removing them
from containers. Plants are to be positioned upright and the soil firmed around the
roots.
Planting shall be carried out in accordance with the schedule of plants and drawings
supplied by Landscape Architect appointed by contractor. The number of each
species and variety shall be evenly distributed over the area as indicated on the
drawings by Landscape Architect appointed by contractor.
For large areas the outer rows are to be set out first to ensure the correct shape to the
bed is established. The remaining plants are then to be evenly distributed to cover the
planting area. The Landscape Architect is to be notified in advance if there are too
many or too few plants to fill the area required and an assessment of setting out
adjustments will be directed accordingly.
Setting out of plants is to be completed and approved by Landscape Architect
appointed by contractor before planting into the soil bed can commence.

11.10.1 Small Shrubs, Herbaceous, Ground Cover and Root Planting in Beds
Small shrubs, ground cover and herbaceous plants shall be planted in pockets formed
by a trowel or spade.
The pocket shall be deep enough and wide enough to accommodate the root of the
plant.
The sides and base of the pocket shall be loosened and the plant roots lightly loosened
from the rootball.
The plant shall be placed upright in the pocket and firmed into the ground by
backfilling and treading or hand pressure.
The topsoil in areas to receive rooted shoots shall be brought to a fine layer 75mm
deep by approved mechanical means or hand raking.
Approved slow release fertiliser shall be applied evenly over the area at a rate of
40gms per square metre and shall be lightly raked into the surface.
Rooted shoots shall be firmly bedded into the soil at 75mm centres with each shoot
spread on the topsoil surface, separated from adjacent shoots.

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 The area shall be top-dressed with finely sifted topsoil/compost mix as approved by
the Landscape Architect appointed by Contractor to lightly cover the rooted shoots
after laying.
The ground shall then be firmed by lightly treading or hand pressure around the roots,
taking care not to damage the shoots, to ensure good contact with the soil.
Watering shall take place immediately after planting, using a fine spray.
The firmed up area is to be tightly cultivated after completion of this operation to
leave an even layer before mulching.

11.10.2 Shrub Pits

Shrub pits for large and medium shrubs, feature plants and climbers shall be
excavated to 150mm wider on either side than the root spread, and to a depth of
150mm deeper than the root depth and shall not be less than 300mm x 300mm x
450mm deep.
The bottom 150mm of the pit is to be forked loose prior to backfilling.
Backfill material shall be topsoil Mix A for backfilling purposes. (Ref. Section 11.4.3
Soil Mixes)
The Contractor shall note that for planting into turf areas, where topsoil has not been
spread topsoil mix will be required for backfilling purposes.
Climber pits shall be 150 - 200mm away from the supporting structure with the roots
spread away from the wall or adjacent supporting structure.
The climbing plants shall be trained through the wire mesh with leading shoots
directed upwards and tied.
Pits for shrubs and feature plants in planters shall be excavated to 150mm wider on
either side than the root spread and to a total depth of the rootball.
The bottom of the pit shall be lightly formed, prior to planting taking care not to
damage the terrain layer below.
After planting shrubs the area is to be watered immediately to bed the shrubs in.
Once the water has percolated away and left the surface relatively dry the soil area is
to be lightly forked to loosen the surface and leave an even soil layer.

11.10.3 Tree Pits

Tree pits shall be excavated to the dimensions and the location shown on the drawing
by Landscape Architect appointed by Contractor.
Tree pits shall be dug a minimum of 3 weeks period prior to back filling.
The bottom of the pit shall be forked to loosen the soil. In case the soil is clayey, a
layer of broken bricks and stones shall be spread on the bottom of the hole and this
layer shall be covered with dried leaves or straw.
No tree pit shall be less than 300mm wider on either side than the root spread, and to
a depth of 150mm deeper than the root depth, and shall not be less than 1m x 1m x
1m.
The trees shall be planted to the same depth in the nursery or as in their containers.

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 In case the site is infested with white ants the sides of the pits shall be brushed with a
mixture of BHC (10% concentration) and water in a proportion of 200 gms of BHC
mixed in 5 litres of water. BHC is the common name for the insecticide.

11.10.4 Backfilling of Pits (trees, shrubs and climbers)

Before backfilling, imported topsoil and sand is to be thoroughly mixed with soil
conditioner and organic fertiliser as specified for Topsoil Mix A. (Ref. Section
Section 11.4.3 Soil Mixes)
The tree pit shall be backfilled with the Soil Mix A to a depth which will allow soil,
after settlement to match surrounding ground level.
The filled pit shall be watered and allowed to settle. After settlement soil levels shall
be topped up as required.
The centre of the backfilled tree pit shall be excavated large enough to allow placing
of the rootball, and to allow even compaction all round during backfilling.
After careful removal of the container or wrapping, the rootball of trees shall be
placed carefully in the pit, and soil replaced gradually into the pit.
The soil is to be consolidated during backfilling in layers to ensure that the plant is
firmly held in the ground and that voids are not left around the roots.
Care shall be taken during planting to avoid damage to the root system, branches or
leaves.
After careful removal of the container or wrapping, the rootball of the roots of shrubs
and climbers shall be placed carefully and the soil replaced gradually in the pit.
The soil is to be consolidated during backfilling in layers to ensure that the plant is
firmly held in the ground and that voids are not left around the roots.
Care should be taken during planting to avoid damage to the root system, branches or
leaves.

11.10.5 Staking and Supports

Stakes shall always be used when planting instant trees, standards and single stem
palms and for tall shrubs when directed by the Landscape Architect appointed by
Contractor.
Stakes shall be in sawn timber of an approved type and be carried out according to the
size of plant to be supported. The types of approved staking methods are:
a. Tripod or Quadropod staking for large trees or palms (extra heavy standard and
above)
Three or four stakes each 50 x 50mm section shall be positioned equidistantly around
the tree and firmly driven into the ground at angles of between 30 - 40 degrees.
The inner ends of the stakes shall extend beyond the tree stem by not more than
150mm and shall not be higher than 300mm below the lowest branch.
The tree stem shall be wrapped in hessian or gunny sacking at the point where the tree
stakes are to be fastened in order to prevent bark damage.
The stakes shall be neatly and firmly fastened to the tree stem using rubber hose or
cord; String are not be used.

664
 The stakes are to be adjusted and the position of the protective wrapping is to be
altered up or down every month.
The hessian wrapping is to be sprayed with an approved horticultural pesticide.
b. Multiple guying - for large trees or palms (heavy standard and above)
A minimum of three wire guys are to be used per tree.
Each guy wire is to be fastened by a loop around the lowest branches of the tree at the
junction with the main trunk or branches of the tree at the junction with the main
trunk or stem.
Loops are to have protective rubber or plastic hose to prevent chafing and are to be
fastened back to the guy wire by means of U-clamps or bolts.
Guy wires are to be fastened at ground level to short stakes firmly driven at an angle
into the ground.
Stakes shall be minimum length of 600mm and are to be driven deep enough to resist
movement.
A notch is to be made near the top of each stake for the fastening of the guy wire.
Stakes shall be positioned equidistantly and equally around the tree and shall be at
least 300mm beyond the extent to the tree pit.
Distance away from the tree shall be gauged on site to provide firm and secure
guying.
Each guy wire is to have one turnbuckle located near the fastening to the stake.
Guy wires are to be kept in a proper tension and adjusted to maintain the tree in a
vertical position without guy wires being rigid.
c. Double Staking - for trees and palms (heavy standard and smaller)
Two stakes each 50mm x 50mm cross section shall be driven into the ground in a
vertical position on either side of and outside the rootball of the tree so as to form a
straight line outside the rootball of the tree so as to form a straight line with the stem
at the centre.
Stakes shall be driven in to penetrate the bottom of the tree pit and be deep enough to
resist lateral movement when tested.
Stakes shall not extend beyond the lowest branch of the tree and if necessary are to be
sawn off at the top.
Fastening or securing of the tree may be carried out by using either:
i. Cross bar
A wooden cross bar of same section as the stakes is fastened in a horizontal position
to the outside of the stakes by nails or tying securely at a level below the lowest
branch.
The tree is fastened to the cross bar with a single adjustable tie of an approved
rubberised or plastic type with a spacer and shall be fastened to prevent any chafing
or abrasion of the bark.
No nails or fixings are to be driven into the tree trunk.
ii. Wire/Hose loops

665
 Two separate wire or rope loops are made about the stem just below the lowest
branch with each being fastened back to one of the vertical stakes.
Each loop is to have a protective outer covering or sheath of rubber hose to prevent
chafing or abrasion of the bark.
The wire or rope is to be fastened to the stakes in a manner that allows adjustment of
the tension to be made easily.
Tension on each wire is to be equal to maintain the tree in a vertical position.
Where directed by the Landscape Architect appointed by Contractor the tree may be
secured with a second set of loops at a lower level.
d. Single Staking - for trees and palms of sapling size only
A single stake of cross section 50mm x 50mm is driven vertically into the ground
150mm - 250mm away from the tree.
The stake is driven down beyond the base of the tree pit and shall be firm when
tested.
The top of the stake shall be 100mm below the lowest branch.
Two ties of an approved rubberised or plastic type are to be used.
The top tie is to be located 100mm below the top of the stake; the lower tie 300mm
from the base.
Ties are to have spacers to maintain the 150mm - 250mm distance between the stake
and the tree.
Ties are to be fastened to avoid rubbing, chafing or abrasion of the bark.

e. Climber wires
Wires for training climbing plants against walls shall be approved lightweight PVC
mesh, fixed at 600mm intervals to screw eyes supplied under the sub contract.
Maximum mesh coverage shall be 180mm high x 240mm wide.
The climbing plants shall be trained through the wire mesh with the shoots directed
upwards and tied.

11.10.6 Turfing
a. Close Turfing
Close Turf shall be a live grass sod or mat at least 300mm square with a well
developed root system growing in a minimum of 25mm soil bed, free from stones or
extraneous roots, cut mechanically or by hand to give an extra thickness and texture.
A sample of one square metre of Turf shall be submitted to the Employer/Employer‟s
representative for approval before Turf is brought in for use on site.
The source of the material shall be stated by the Contractor.
Turf shall be free from weeds, fungus, pest or disease and contamination or
pollutants.
Turf sods shall be kept moist and in shade and shall be planted within 24 hours after
lifting.
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 In exceptionally dry weather, the turf must be kept well watered at the nursery or turf
farm in order to keep full green leave structure.
Dry, brown or wilting grass turf will be rejected and growth or recovery on site will
not be permitted.
i. Close Turfing: Ground Preparation
Rake the topsoil mix area to a smooth and uniform grade free of any slight mounds or
depressions to achieve a uniformly flat surface.
Re-grade any depressions or humps that may occur until a satisfactory grade is
achieved.
The area to be turfed is to be brought to a fine tilth by approved mechanical means or
by hand raking.
Any stones over 25mm in diameter shall be removed from the site of turfing.
Watering of the area shall be carried out to produce a moist condition of the soil and
to consolidate the soil.
If consolidation occurs to produce any areas with topsoil depths less than 100mm
these areas shall have extra topsoil spread to produce finished levels.
Fertiliser shall be applied to all areas to be turfed prior to turfing at the rate of 40gm
per square meter, evenly spread over the whole area and lightly worked into the soil.

ii. Close Turfing: Operations

Close turf sods shall be laid onto the surface of the prepared ground with leaf turfs
upwards, butt jointed as closely as possible to achieve a uniform cover.
The turf shall be laid off planks working over turves previously laid.
The whole area is then to be top dressed with finely sifted topsoil mix to give an
evenly smooth surface. The finished close turfing shall be lightly compacted by
treading or with a wooden beater to ensure even coverage and compaction.
Watering shall take place over the area that has been turfed immediately after
planting. Watering shall be undertaken by use of a fine spray to avoid disturbance of
soil particles.
Turfing shall be only accepted as complete after the growth of an even grass cover is
evident. Any areas not covered by green healthy grass to the satisfaction of the
Employer/Employer‟s representative within 28 days after turfing shall be re-laid as
specified at the Contractor‟s own expense.
For the period of 28 days after turfing the vegetative cover shall:
I. Evenly cover at least 90% of the areas with leaves and spreading shoots of
specified grass variety
II. be free of perennial weeds or disease
III. be healthy and vigorous and showing a strongly developed root system
Should there be any settlement due to lack of even compaction this will be corrected
by application of topdressing of finely sifted soil to maximum depth of 25mm.
If the depression is greater than 25mm the grass in the affected area shall be lifted, the
depression filled with sifted topsoil, lightly compacted and the affected area re-turfed

667
 as specified. These operations shall be done as often as necessary to produce an even
and smooth surface free from bumps and hollows.
All turfing operations shall be carried out from wooden planks or plywood boards,
with the workers moving away from completed turfed areas, raking any compressed
soil or footprints before laying of sods.
All access onto soil areas shall be on wooden boards or plywood sheets. Areas
compacted by working are to be re-cultivated and re-laid.
iii. Maintenance of Close Turfing Before Completion
The following operations are to be carried out as often as required to achieve the
specified quality of turf:
I. Cutting before Completion shall be carried out as necessary to keep the grass to a
maximum height of 30mm.
II. Watering shall be carried out as often as necessary before Completion to allow a
satisfactory green sward to develop over the whole close turfed area.
III. One fertiliser application per month is to be carried out for before Completion.

IV. Topdressing as specified as often as required to establish smooth even grades and
levels free of hollows.
V. If compaction or consolidation takes place or hard passing or baking of the soil
occurs, the soil areas are to be well watered first and lightly loosened by
mechanical means such as spiking, slitting or hollow tinning using approved
equipment.
VI. Completed close turfed areas are to be kept in a weed free insect free, fungus free
and tidy condition until Completion (that is start of maintenance period).
iv. Sourcing of Turf Types
Close turfing materials are to be obtained from a bona-fide horticultural source or
private landowner.
No turf is to be removed from unauthorised locations, roadside, riverbanks or private
property without permission of the Employer.
The Contractor is to inform source of all turf delivered to the Employer/Employer‟s
representative before any turf is laid at site.
b. Fine Turf
Fine Turf shall consist of fine bladed rhizomatous grass such as Bermuda grass or
cultivar specified by Landscape Architects appointed by the Contractor.
Fine Turf shall be a live grass sod or mat at least 300mm square with a well
developed root system growing in a minimum of 25mm soil bed, free from stones or
extraneous roots, cut mechanically or by hand to give an even thickness and texture.
A sample of one square metre of Fine Turf or both types shall be submitted to the
Employer/Employer‟s representative for approval before fine Turf is brought in for
use on site.
The source of the material shall be stated by the Contractor.
Fine Turf shall be free from weeds, fungus, pest or disease and contaminants or
pollutants.

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 Fine Turf sods shall be kept moist and in shade and shall be planted within 24 hours
after lifting.
i. Fine Turfing Operations
Subsoil mix shall be hand raked to provide an even and fine tilth to an even and
accurate level matching kerb edge levels.
Any lumps or stones over 25mm in diameter brought up in this operation shall be
removed from site.
Soil areas shall be lightly sprinkled with water to moisten surface in dry weather
before laying turf.
Pre-Turfing fertiliser shall be applied to all areas to be turfed prior to turfing at the
rate of 40gm per square metre evenly spread over the whole area and lightly worked
into the soil.
The turves shall be laid on the prepared soil bed and firmed into position in
consecutive rows with broken joints, closely butted and to the correct levels.
The turf shall be laid off planks working over turves previously laid.
Where necessary, the turves shall be lightly and evenly firmed with wooden beaters,
the bottom of the beaters being frequently scraped clean of accumulated soil and mud.
A dressing of finely sifted topsoil/sand/compost mix shall be applied and well
brushed into the joints to give an overall even surface.
Watering shall take place over the area that has been turfed immediately after
planting. Watering shall be undertaken by use of a fine spray to avoid disturbance of
soil particles.
Fine turfing shall only be accepted as complete when new growth has caused turves
to knit together and adhere by rooting to the soil bed.
Any areas not covered by green healthy grass to the satisfaction of the Landscape
Architect within 28 days after fine turfing shall be re-laid as specified at the
Contractor‟s own expense.
If shrinkage occurs or the joints open, finely sifted topsoil/ sand/ compost mix shall
be brushed into the gaps and shall be watered in.
Any inequalities in finished levels owing to variation in turf thickness or uneven
consolidation of soil shall be adjusted by lifting turves and by re-spreading fine soil
mix to correct levels and relaying turves as specified.
The finished level of the Fine Turf shall be 25mm above adjoining paved surfaces or
other hard edges after allowing for final settlement.
Turf edges and margins shall be laid with whole turves and uneven edges trimmed to
give an even line.

ii. Maintenance of Fine Turfing before Completion

Watering shall be carried out as often as necessary before completion to allow a
satisfactory green sward to develop over the whole fine turfed area.
Cutting before completion shall be carried out as necessary to keep the grass to a
maximum height of 25mm.

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 One extra fertiliser application is to be allowed for before completion, to be used if
directed by the Landscape Architect appointed by Contractor.
Completed fine turfed areas are to be kept in a weed free inset free, fungus free and
tidy condition until completion (that is start of maintenance period).
Edge cutting shall be carried out as required along edges of paths, plant beds or other
junctions with other materials. Only sharp edge cutting tools are to be used for this
operation.
Over cutting or ragged edges will require the relaying of the turf edge strip as
specified (that is 300mm wide).
iii. Specification for Sourcing of Turf Types
Fine Turf is to be specially prepared horticultural turf, re-lawn or turf-carpet,
mechanically cut to specified tolerances.
c. Slope retention work with Coir Mat Turfing
i. Site Preparation
Sub-grade shall be excavated to proper lines and grades based on construction plans.
The sub-grade shall be fairly smooth and free of sharp objects and debris that may
damage the Coir Mat.
The soils should be proof rolled prior to Coir Mat and backfill placement.
The soils should be compacted to 95 Percent of the relative density based on the Site
Engineer‟s recommendations.
Above the compacted soil, Top soil mix „A‟ to be laid upto 150 mm thick layer for
planting turf.
Coir mat to be laid first and then planting operation should take place.
ii. Laying of Coir Mat
Coir Mat should be placed in correct orientation as shown on the construction plans
and approved by the Engineer.
The Contractor should verify the orientation. The orientation of the Coir Mat should
be such that it is rolled in the direction of the slope – not perpendicular to it.
The Coir Mat should be cut to length based on construction plans using an Engineer
approved cutting tool.
Each sheet of Coir Mat should be pulled taut by hand to get rid of any wrinkles.
Adjacent sheets should be overlapped for minimum width of 0.30 M.
Each sheet may be secured in place using staples, pins, sandbags, backfill, or by other
Engineer approved methods to help prevent disruption during the installation of
adjacent sheets
iii. Turfing
Turfing should be done as per procedures mentioned above once Coir mat is installed.

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11.10.7 Watering of all Plants
After planting all plants are to be thoroughly watered to soak the ground all around
the rootball.
After watering and the water has percolated away leaving e surface relatively dry the
soil is to be lightly cultivated to give an even soil tilth.

11.10.8 Mulching
After completion of planting and watering and light cultivation operations a 50mm
deep layer of approved mulch shall be spread and forked in over all cultivated
planting areas.
Around each tree and palm and around the base of each climber, additional mulch is
to be applied to a 50mm depth to a diameter of 600mm.
Mulching is to be done within 2 days of completing planting and watering in.

11.10.9 Fertilising
After a period of settling in of at least one month, all pit planted materials shall be
fertilised with an approved slow release fertiliser at the rate of:
Trees : 250gm per tree
Shrubs/climbers : 50gm per plant
Ground Cover/Herbaceous : 100gm per square meter spread
Rooted Shoots : around the base of the plants - 40gm per square meter
All fertilised areas are to be watered immediately after fertiliser application.

11.10.10 Disease Control

The Contractor shall take all necessary precautions to prevent or eradicate any
outbreak of disease or insect attack.

11.10.11 Planting into Turf Areas

Where planting is to be carried out in areas of turf, the turf shall be carefully cut to
the size of the tree or shrub pit, rolled and stored for re-use, being kept moist and in
shade.
After planting is complete stored turf shall be re-laid around the base of the plant.
The Contractor shall replace at his own expense, any turf which is damaged during
planting operations.

11.10.12 Protection of Planted Areas

The contractor shall be responsible for protecting all planted areas.
If it is necessary for the Contractor to erect protective fencing, the Contractor shall be
responsible for keeping the fencing in position and in good repair until the end of the
maintenance period.
Fencing proposals shall be submitted to the Employer/Employer‟s representative for
approval.
Post and string fences shall not be acceptable.

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11.10.13 Maintenance prior to Completion
After planting and prior to the onset of the maintenance period, the Contractor shall
be responsible for carrying out all necessary measures to ensure that the plant
material thrives and becomes established and that the landscape areas are kept in a
clean and tidy condition.
The Contractor shall allow for carrying out the following maintenance operations
when necessary prior to the onset maintenance period, all as specified in section
11.11 of this specification:
- Replacement of dead/missing plants
- Grass cutting around trees
- Watering
- Cultivation and loosening of soil
- Weeding
- Pruning and clipping
- Firming up and adjusting stakes and ties
- Eradication of pest or insect attack
- Topdressing and mulching
- Fertilising
The Contractor shall be responsible for replacing any plants which fail to survive as a
result of inadequate maintenance operations, poor workmanship or poor quality of
plant material prior to completion.
The Virtual Completion Certificate will not be issued until all plants scheduled on the
Drawings and Schedule of Works are installed in a healthy condition in the manner
specified.

11.12. MAINTENANCE WORKS

11.11.1 General
i. The Contractor shall maintain the landscape for a two-year period after the date
certified by the Landscape Architect that the work has been satisfactorily completed
(issue of Certificate of Completion).
ii. The extent of the landscape to be maintained by the Contractor shall be deemed to
cover and include all soft landscape areas within the overall project boundaries as
shown on the drawings including all existing soft landscape not affected by the
contract works and retained intact or nearly so through the end of the contract period
as well as all the landscape works covered in the contract scope of works. No
additional maintenance charges will be allowed unless specifically agreed to by the
Landscape Architect in writing.
iii. The Contractor shall ensure that a senior qualified supervisor is made available for
organising and running the maintenance programme. The Contractor shall also have

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 available an experience foreman who can supervise the workers on a day-to-day
basis. An adequate trained labour force of at least 3 workers must be available for
routine work and they must be on site for at least half a working day, 5 days per week
during the maintenance period. Additional grass cutting operators will be needed to
ensure adequate cutting and cleaning.
iv. The Contractor‟s Supervisor shall inspect the site once per week during the
maintenance period and shall prepare a brief schedule of operations required for the
coming week. The format for the schedule of operations will cover each distinct
areas of the site such as frontage, rear, courtyard, roof, interior, etc. The schedule
shall describe the operations the Contractor intends to carry out in the coming week to
cover the items listed in the specification and to ensure that the current weather
conditions and growing performances, insect attack, etc is taken into account.
v. A copy of this schedule is to be submitted to the Landscape Architect and Employer
every week so that a running record of proposed operations can be checked at the
maintenance inspections each month. If in the opinion of the Landscape Architect the
maintenance works have not been satisfactorily carried out according to site
conditions and the specifications, part of the monthly payment will be withheld until
the works have been satisfactorily carried out.
vi. The contractor shall carry out all necessary measures to ensure that all pot plants,
trees and shrubs and other plants shall thrive and become established within this
period. All landscape areas will be inspected monthly and lists of remedial works
issued after each inspection. All items on the remedial lists are to be carried out by
the time of the next inspection, ie within one month.
vii. The Contractor shall keep the landscape areas clean and tidy at all times and dispose
of all waste materials arising from the cleaning.

11.11.2 Maintenance of Planted Areas

i. The Contractor shall water all trees, palms, shrubs, ground cover, rooted shoots,
herbaceous plants and other planting areas as often as necessary to keep the ground
moist all around and to the full depth of the roots of the plants to a minimum depth of
saturation of:
- 100mm for groundcover
- 300mm for shrubs
- 750mm for trees
ii. Fresh water only shall be used for the Works. Water shall be supplied to the
Contractor from agreed points on the site. However, it will be only to necessary for
the Contractor to supply his own means of transport from the watering points to the
plant beds.
iii. An inspection of watering requirements is to be made by the Contractor at least two
times a week in dry weather.
iv. Water shall be supplied using an approved hose or sprinkler so as not to cause
compaction or wash-outs of the soil or loosening of plants. The Contractor shall
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 immediately make good any such damage, soil erosion or outwash and plants
loosened by erosion are to replanted or if damaged, replaced.
v. All plant beds are to be kept in a weed free condition with a weeding operation once a
month. All weeds, stones and rubbish collected from this operation shall be removed
from the site to a tip to be found by the Contractor. Herbicides may not be used on
this site unless a specific application in writing is made by the Contractor with full
back up data on the performance of the chemicals and the particular need for the
chemicals use. Approval will in all cases be subject to the Landscape Architect‟s
decision.
vi. After weeding, at least once per month the soil surface is to be lightly broken up
between plants using a pronged fork upto maximum depth of 100mm. Contractor
shall Take care not to disturb the root systems of plants. After forking the soil loose,
the mulch and loosened soil are to be raked to give an even re-distribution of the
mulching materials
vii. Firming up and adjusting of stakes/ties shall be carried out monthly to ensure that the
trees and shrubs are firmly held in the ground. If required guy ropes or tree pits shall
be adjusted, tightened or loosened. If tree ties or ropes are rubbing the bark of the
trees, the ties are to be taken off and retied. Any damaged branches are to be carefully
pruned and the wounds sealed.
viii. All protective fencing is to be maintained and kept in good condition and in position
until the end of the maintenance period.
ix.Trees shall be pruned if dead, rotten or crossed branches are present or to maintain a
clear stem up to the specified height using the methods described below. Tree pruning
is to be reviewed monthly.
x. All shrubs and ground covers are to be reviewed monthly and pruned as and when
required during the Maintenance Period to promote bushy growth and good flowering
characteristics. The shrubs shall be checked and all dead wood, broken, damaged or
crossed branches shall be cut back, depending on species. Pruning and removal of
branches is to be carried out using sharp clean implements to give a clean sloping cut
with one flat face. Ragged edges of bark or wood are to be trimmed with a sharp
knife.
xi.Pruning for all plants shall be carried out as follows:
- Pruning is to be done with the cut just above and sloping away from an outward
facing health bud.
- Removal of branches is to be done by cutting flush with the adjoining stem and in
such a way that no part of the stem is damaged or torn.
- Ragged edges of bark are to be trimmed with a sharp knife.
- Any cuts or wounds over 25mm diameter are to be painted with an approved sealant
after trimmed.
- All pruning to be cleared up and removed from site after pruning.

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 xii.All hedges, mat forming herbaceous plants and ground cover plants shall be clipped
with shears as often as necessary (at least monthly) to maintain a tidy appearance.
Tall hedges are to be cut to forms shown on the drawings. Fertiliser is to be applied
to clipped areas around 1-2 weeks after clipping.
xiii. Selective pruning of flowering plants shall be done where special flowering
characteristics are required such as for Ixoras, Hibiscus, Allamanda where flowering
takes places on twig ends. Heavy clipping must not be used for these species since
this will remove future flower buds. Selective pruning by clipping non flowering
twigs and leaving flowering twigs is necessary for these plants, and this operation
must be done by experienced workers.
xiv.The Contractor shall allow for monthly fertiliser operations during the Maintenance
Period. An approved slow release fertiliser shall be applied to each plant at the rate of
50gm per shrub and 200gm per tree, one month after planting and thereafter monthly.
After spreading the fertiliser around the base of the plant the granules shall be lightly
forked into the soil, and the plant well watered. Herbaceous and ground cover areas
shall receive 25mm of approved soil conditioner, evenly spread and mixed with
50gm/m2 of approved slow release fertiliser, evenly spread over entire area and
lightly forked into the soil to break up the top layer, and the area well watered on a
month by month basis.
xv. The horticultural requirements of different plants or areas may involve variations to
those techniques (such as the use of organic liquid fertilisers for sensitive plants) and
variations in method will be authorised as required.
xvi.Heavy feeding plants such as Canna, Heliconia and Lantana shall be dressed with a
25mm mulch of approved organic compost or similar approved compost every 2
months, lightly forked in around the base of the plants.
xvii.Additional mulching layer, 25mm deep to be spread and forked in over all planted
areas at 3 monthly intervals.
xviii. The Contractor shall make regular weekly checks to ensure that the plant material is
insect and pest and fungus free. No pesticides may be used unless approval from the
Landscape Architect is given from the Contractor stating the chemical intended for
use; concentration, spraying programme and including full technical details of the
product.
11.11.3 Maintenance of Lawn Areas
i. The Contractor shall mow all lawn areas using approved cutting equipment to
maintain a close sward to a height of not less than 20mm and not more than 30mm for
all grass types.
ii. Mowing shall be carried out generally weekly, except in dry weather and grass shall
not be allowed to flower between cuts.
iii. Weekly inspections are to be made to ensure adequate planning of grass cuts to suit
growth and weather conditions. All clippings to be gathered up and removed from
site.

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 iv. All grass areas are to be watered by means of sprinklers during dry weather as often
as is required to keep the grass green and the soil moist.
v. The Contractor shall provide hoses and sprinklers for use from water points provided.
Weekly inspections are to be made to determine the need for water and, in dry
weather watering must be done to moisten the soil to a depth of 100mm.
vi. Fertiliser of NPK value 10-15-15 or similar approved be spread at a rate of 40gm/sq
m over all grass areas at monthly intervals, using approved spreading equipment to
give an overall even spread. Grass areas that have been fertilised shall be watered if
no rain falls within 24 hours.
vii. The Contractor shall apply top-dressing of not more than 15mm depth fine sand and
granulated compost raked and spread evenly over the lawn areas. The next top-
dressing shall be applied only after the grass has grown through to a mowable height.
viii. There shall be at least two applications of topdressing during the maintenance period,
to be directed by the Landscape Architect appointed by Contractor.
ix.If depressions or bumps over 25mm deep or high in turf areas during the maintenance
period these are to be levelled out by lifting the turf and raising the soil level with
sand/compost mix or trimming to level grades, followed by re-turfing.
x. Grass areas are to be kept free of weeds, annual grasses, fungus and insect attack and
free of stones or other debris throughout the maintenance period as often as is
required.
xi.All chemicals used shall be to the approval of the Employer/Employer‟s
representative. Assessment of these operations is to be prepared on the basis of the
weekly maintenance inspection chart.
xii.If compaction or consolidation takes place or hard passing or baking of the soil
occurs, the soil areas are to be well watered first and lightly loosened by mechanical
means such as spiking, slitting or hollow tinning using equipment approved by the
Employer/Employer‟s representative.

11.11.4 Replacement Planting

i. If during the course of the Maintenance Period trees or shrubs or other plants die
because of a fault by the Contractor, the Contractor shall replace the plant at no cost
to the Employer.
ii. All questions related to responsibility for the replacement planting will be subject to
site inspection and agreement of the appointment of responsibility.
iii. This will be done very month at the monthly maintenance inspections.

11.11.5 Final Handover

i. Two weeks before the end of the Maintenance Period a joint inspection shall be held
with the Maintenance Agency, Contractor and the Employer/Employer‟s

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 representative review the requirements for alteration or replacement in order to gain
approval for Final Handover.
ii. In order to ensure satisfactory handover procedures, the site meetings held each
month between the Contractor and Employer/Employer‟s Representative will be used
to inspect and approve the maintenance works which will be reviewed to ensure
adequate work has been done.
iii. At the time of the final inspection, all areas under this contract shall be free of weeds,
neatly cultivated and raked, and all plant boxes in good order.
iv. Grass shall be neatly cut and all clippings removed. No bare patches of earth shall be
visible in turf or planting areas unless specified (that is rings around tree trunks).
v. If, after this inspection, the Employer/Employer‟s representative is of the opinion that
all work has been performed in accordance with the drawings and specifications, the
Employer/Employer‟s representative will give written letter of acceptance and
completion of the project.
vi. If, all or certain portions of the work are not acceptable under the terms and intent of
the drawings and specifications, the formal maintenance period for all the work shall
be extended at no cost to the Employer/Employer‟s representative until the defects in
the work have been corrected and the work is accepted by the Employer/Employer‟s
representative.

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