BHEL SPEC Section D2 PDF

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SPEC NO. TCE CONSULTING ENGINEERS LIMITED SECTION: D36
TCE-5178A-405-01 SHEET 1 OF 20
SUPPLY AND FABRICATION OF STRUCTURAL

STEEL
1.0 SCOPE
1.1 This specification covers the general requirements for supply, fabrication,
preparation of and delivery at site of structural and miscellaneous steel.
1.2 This specification also covers design of all connections and substituted
members, preperation of all shop fabrication drawings and inspection of
structures.
2.0 APPLICABLE CODES AND SPECIFICATIONS
The following specifications, standards and codes are made a part of this
specification. All standards, specifications, codes of practice referred to
herein shall be the latest editions including all applicable official
amendments and revisions.
In case of discrepancy between this specification and those referred to

herein, this specification shall govern.
(a) MATERIALS
1. IS : 808 - Dimensions for Hot Rolled Steel Sections.
2. IS : 814 - Covered Electrodes for Metal Arc welding of

Structural Steels.
3. IS : 1363 - Black Hexagonal Bolts, Nuts and Lock Nuts

(diameter 6 to 39 mm) and Black Hexagonal
Screws (diameter 6 to 24 mm).
4. IS : 1367 - Technical Supply Conditions for Threaded

Fasteners.
5. IS : 1852 - Rolling and cutting tolerance for Hot Rolled

Steel products.
6. IS : 1977 - Structural Steel (Ordinary Quality)
7. IS : 2016 - Plain Washers.
8. IS : 2062 - Weldable Structural Steel.
9. IS : 2074 - Ready mixed paint, Air drying, Red Oxide Zinc

Chrome and Priming.
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10. IS : 3757 - High strength friction grip bolts.
11. IS : 5372 - Taper washers for channels.
12. IS : 5374 - Taper washer for I beams.
13. IS : 6610 - Heavy washers for steel structures.
14. IS : 6639 - Hexagon bolts for steel structures.
(b) CODES OF PRACTICE
1. IS : 800 - Code of practice for general construction in

steel.
2. IS : 816 - Code of practice for use of metal arc welding for

general construction in mild steel.
3. IS : 817 - Code of practice for training and testing of

metal arc welders.
4. IS : 818 - Code of practice for safety and health

requirements in electric and gas welding and
cutting operations.
5. IS : 822 - Code of procedure for inspection of welds.
6. IS : 1182 - Recommended practice for radiographic

examination of fusion-welded butt joints in steel
plates.
7. IS : 1200 - Method of measurement in building and civil

works.
8. IS : 1204 - Code of practice for use of welding in bridges

and structures subject to dynamic loading.
9. IS : 1477 - Code of practice for painting of ferrous metals

in building.
10. IS : 2595 - Code of practice for radiographic testing.
11. IS : 2598 - Safety code for industrial radiographic practice.
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12. IS : 3016 - Code of practices for fire protection in welding

and cutting operations.
13. IS : 3600 - Code of practice for testing fusion welded joints

and weld metal in steel.
14. IS : 3657 - Radiographic image quality indicators.
15. IS : 3658 - Code of practice for liquid penetrant flaw

detection.
16. IS : 3664 - Code of practice for ultrasonic testing by pulse

echo method.
17. IS : 4000 - Code of practice for assembly of structural

joints using high tensile friction grip fasteners.
18. IS : 4225 - Recommended practice for ultrasonic testing of

steel plates.
19. IS : 4260 - Recommended practice for ultrasonic testing of

welds in ferritic steel.
20. IS : 5334 - Code of practice for magnetic particle flaw

detection of welds.
21. IS : 7215 - Tolerances for fabrication of steel structures.
22. IS : 7310 - Approval test for welders working to approved

(part-I) welding procedures.
23. IS : 7318 - Approval tests for welders when welding

(part-I) procedure approval is not required.
24. IS : 9595 - Recommendations for metal arc welding of

carbon and carbon manganese steel.
25. IS : 823 - Code of procedure for manual arc welding of

mild steel.
26. IS : 1181 - Qualifying tests for metal arc welders (engaged

in welding structures other than pipes).
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3.0 STEEL MATERIALS
Steel materials shall comply with IS:2062 or IS:1977. Usage of steel

conforming to IS:1977 shall be restricted as indicated below.
All materials to be supplied by the Contractor shall be new, unused and free
from defects.
Steel conforming to IS:1977 shall be used only for the following :
Fe310-0(St 32-0) : For general purposes such as door/window

frames, grilles, steel gates, handrails, fence
posts, tee bars and other non-structural use.
Fe410-0(St 42-0) : For structures not subjected to dynamic

loading other than wind loads such as :
Platform roofs, foot over bridges, office

building, factory sheds etc.
Fe410-0(St 42-0) : Grade steel shall not be used :
(a) If welding is to be employed for

fabrication.
(b) If site is in severe earthquake zone.
(c) If plastic theory of design is used.
4.0 CONSULTANTs Scope of review of Design / Drawings Prepared by The

Vendor / Contractor
The CONSULTANT shall review design calculations / Drawings Prepared

by the Vendor / Contractor
5.0 FABRICATION
5.1 GENERAL
All workmanship and finish shall be of the best quality and shall conform to
the best approved method of fabrication. All materials shall be finished
straight and shall be machined /ground smooth true and square where so
specified. All holes and edges shall be free of burrs. Shearing and chipping
shall be neatly and accurately done and all portions of work exposed to
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view shall be neatly finished. Unless otherwise directed/approved reference

may be made to relevant IS codes for providing standard fabrication
tolerance. Material at the shops shall be kept clean and protected from
weather.
5.2 CONNECTIONS
5.2.1 Shop/field connections shall be welded unless otherwise specified on

OWNERS design drawings and shall be executed as per approved
fabrication drawings.
5.2.2 In case of bolted connections, taper washers or flat washers or spring

washers shall be used with bolts as necessary. In case of high strength
friction grip bolts, hardened washers shall be used under the nuts or the
bolt heads whichever are turned to tighten the bolts. The length of the
bolt shall be such that at least one thread of the bolt projects beyond the
nut, except in case of high strength friction grip bolts where this
projection shall be atleast three times the pitch of the thread.
5.2.3 In all cases where bearing is critical , the unthreaded portion of bolt shall
bear on the members assembled. A washer of adequate thickness may be
provided to exclude the threads from the bearing thickness, if a longer
grip bolt has to be used for this purpose.
5.2.4 All connections and splices shall be designed for full strength of members
or load indicated on Engineers design drawings. Column splices shall be
designed for the full tensile strength of the minimum cross section at the
splice.
5.2.5 All bolts, nuts, washers, electrodes, screws etc. shall be supplied/brought to
site 10% in excess of the requirement in each category and size. Rates shall
cover the cost of this extra quantity.
5.2.6 All members likely to collect rain water shall have drain holes provided.
5.3 STRAIGHTENING
All material, if necessary, before being worked shall be straightened and /or
flattened by pressure and shall be made free from twists by the
CONTRACTOR at his own cost. Heating or forging shall not be resorted
to without the prior approval of the ENGINEER in writing.
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5.4 Cutting, punching, drilling, welding and fabrication tolerances shall be

generally as per relevant IS codes.
5.5 ROLLING AND FORMING
Plates, channels R.S.J etc., for circular bins, bunkers hoppers, gantry
girders etc., shall be accurately laid off and rolled or formed to required
profile/shape as called for on the drawings. Adjacent sections shall be
match-marked to facilitate accurate assembly, welding and erection in the
field.
5.6 HIGH STRENGTH FRICTION GRIP BOLTING
5.6.1 Inspection after tightening of bolts shall be carried out as stipulated in the
appropriate standards depending upon the method of tightening and the
type of bolt used.
5.7 WELDING
5.7.1 Welding procedure shall be submitted to ENGINEER for approval. Welding

shall be entrusted to only qualified and experienced welders who shall be
periodically tested and graded as per IS: 817, IS: 7310 (Part I) and IS:
7318 (Part I) .
5.7.2 While fabricating plated beams and built up members, all shop splices in
each component part shall be made before such component part is welded
to other parts of the members. Wherever weld reinforcement interferes with
proper fit-up between components to be assembled for welding, these
welds shall be ground flush prior to assembly.
5.7.3 Approval of the welding procedure by the ENGINEER shall not relieve the
CONTRACTOR of his responsibility for correct and sound welding
without undue distortion in the finished structures.
5.7.4 No welding shall be done when the surface of the members is wet nor
during periods of high wind.
5.7.5 Each layer of a multiple layer weld except root and surfaces runs may be
moderately peened with light blows from a blunt tool. Care shall be
excercised to prevent scaling or flaking of weld and base metal from
overpeening.
5.7.6 No welding shall be done on base metal at a temperature below 0 Deg C.
Base metal shall be preheated to the temperature as per relevant IS
codes.
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5.7.7 Electrodes other than low-hydrogen electrodes shall not be permitted for
thickness of 20 mm and above.
5.7.8 Welding shall be done as per approved fabrication drawing as to type of

weld, length and size of weld, whether shop weld or site weld. Efforts shall
be made to reduce site welding so as to avoid improper welding due to
constructional difficulties.
5.7.9 Welding of structural steel shall be done by an electric are process. The
procedure to be followed, materials, plant and equipment to be used and
testing and inspection procedures to be applied shall be to the satisfaction
of the Engineer-in-Charge and shall conform generally to relevant
acceptable standards viz. IS:823 and Indian Standard Hand Book for metal
arc welding and other standard codes of practice internationally accepted.
5.7.10 Submerged-Arc-Welding shall be employed for assembling the components

of column, crane girders and for main frame beams. The CONTRACTOR
shall employ automatic welding machine of the approved make and type
for the welding, wherever feasible.
5.7.11 Open Arc Welding process using shielded arc electrodes shall be employed
for assembling the components of trusses, welding of stiffeners, brackets
etc. and for field welding. In other cases open arc welding shall be
restricted to the minimum and shall be used with the specific approval of
Engineer-in-Charge.
5.7.12 Whenever open arc manual welding is done for assembling the components
of structures, the job shall be so positioned that downhand welding is
possible. In cases where such positioning of job is not possible other
manual welding positions could be resorted to ; but it should be ensured
that the one chosen is the least strenuous for the welder.
5.7.13 Proper edge preparation shall be made for jointing of materials before
welding. Suitable edge preparation shall be done for all processes of
welding except for square-butt welds.
5.7.14 Type of edge preparation shall depend on the thickness of parent materials
that are to be joined. The edge forms shall be chosen to suit the design,
technology and production conditions and shall be subject to the approval
of Engineer- in Charge.
5.7.15 The edge form of weldments shall be prepared either by machines or by

automatic gas cutting with surface roughness of the welding area not
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exceeding Ra = 50. All edges cut by flame shall be ground before they are
welded.
5.7.16 The electrodes used for welding shall be of suitable type and size
depending upon specifications of the parent material, the method of
welding, the position of welding and the quality of welds desired e.g.
normal penetration weld or deep penetration welds.
5.7.17 Where covered electrodes are used, they shall be heavy coated shielded arc
electrodes and shall conform to requirements of IS:814. Covering shall be
heavy to withstand normal conditions of handling and storage. They shall
be free from all defects which would interfere with performance of
electrodes.
5.7.18 Only those electrodes which give radiographic quality welds shall be used.
5.7.19 Where bare electrodes are used these shall correspond in specification to
the parent material. The flux used for submerged arc welding should be
specially manufactured for the purpose and should have such a
composition which does not evolve any appreciable quantity of gases.
5.7.20 Specific approval of the Engineer-in-Charge shall be taken by the

CONTRACTOR for the various electrodes proposed to be used on the
work before any welding is started.
5.7.21 Electrodes of classification AWS-E-60 xx & E-70 xx shall be used for

welding steel conforming to IS::2062.
5.7.22 All electrodes to be used on work shall be fully dry and shall be heated
atleast for 4 hours upto a temperature of 110 deg.C or above in electric
oven, prior to use for welding. During welding the electrodes shall be kept
covered inside the thermally insulated flasks to avoid ingress of
moisture.
5.7.23 The sequence of welding shall be carefully chosen to ensure that the
components assembled by welding are free from distortion and large
residual stresses are not developed. The distortion should be effectively
controlled either by a counter effect or by a counter distortion. The direction
of the welding should be away from the point of restraint and towards
the point of maximum freedom.
5.7.24 The beam and column stiffeners shall preferably be welded to the webs
before the webs and flanges are assembled, unless the web and flanges of
the beam or column are assembled by automatic welding process.
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5.7.25 All welds shall be finished full and made with correct number of runs, the
welds being kept free from slag and other inclusions, all adhering slag
being removed from exposed faces immediately after such runs.
5.7.26 Current shall be appropriate for the type of electrode used. To ensure
complete fusion the weaving procedure should go proper and rate of arc
advancement should not be so rapid as to leave the edges unmelted.
5.7.27 Puddling shall be sufficient to enable the gases to escape from the molten
metal before it solidifies.
5.7.28 Non-uniform heating and cooling should be avoided to ensure that

excessive stresses are not lockedup resulting ultimately in cracks.
5.7.29 The welding shrinkage shall be minimised by adopting the correct

welding procedure and method. In long and slender members extra length
should be provided, at the time of fabrication, for shrinkage.
5.7.30 The ends of welds shall have full throat thickness. This shall be obtained on
all main welds by the use of run off and run on pieces adequately secured on
either side of main plates. Additional metal remaining after the removal of
extension pieces shall be removed by grinding or by other approved means
and the ends and surface of the welds shall be smoothly finished.
5.7.31 All main butt welds shall have complete penetration and except where it is
impracticable they shall be welded from both sides, back surface of the
weld being gouged out clean before first run of the weld is given from the
back.
5.7.32 All butt joints in flange plates of columns and other plate girders shall be
skew joints at an angle of 45 deg to the axis of the flange for the flanges
having width less or equal to 300mm, and at an angle of 60 deg for flanges
having width more than 300mm. No extra payment on account of skew joint
in place of straight joint shall be made.
5.7.33 All welds shall be inspected for flaws by any of the methods described
under clause 10.0 Inspection. The choice of the method adopted shall be
determined by the PURCHASER/ENGINEER.
5.7.34 The correction of defective welds like improper penetration, blowholes,

undercuts, cracking, slag inclusion etc. shall be carried out by removing the
defective weld portion by gouging by using gouging electrodes, cleaning
burrs etc. and rewelding or as directed by the ENGINEER without
damaging the parent metal. When a crack in the weld is removed. magnetic
particle inspection or any other equally positive means as prescribed by
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the ENGINEER shall be used to ensure that the whole of the crack and
material upto 25 mm beyond each end of the crack has been removed. Cost
of all such operations incidental to correction shall be to the
VENDOR/CONTRACTORs account.
5.8 WELDERS
5.8.1 Only welders who satisfy the appropriate tests and requirements as per
IS:817, IS:1181, IS: 7310 and IS:7318 shall be employed on welding
work. Should the welder fail in the first test, two further tests shall be
undertaken immediately and the welder, to qualify, must satisfactorily pass
both these tests.
5.8.2 Routine tests of all welders shall be required every six months.
ENGINEER/OWNER reserves the right to have any welder re-tested at any
time.
5.8.3 Structural joints shall be welded by only those welders who are qualified
for that particular type and position of welding. The welding of a butt joint
shall be completely done by the welder who starts the welding on that joint
i.e. welding by more than one welder on a particular joint shall not be
allowed. The welder shall punch his identification mark allotted to him
after testing, on the joints he welds.
5.9 INSPECTION AND TESTING OF WELDS
5.9.1 Visual Inspection
100 percent of the welds shall be inspected visually for external defects.
Dimension of weld shall be checked. Weld gauges shall be used to measure
the size of welds. The length and size of weld shall be designed for the
design forces. It may be slightly oversized but should not be under sized.
The profile of weld is affected by the position of the joint but it should be
uniform. In case of butt and corner welds the profile shall be convex and in
case of submerged arc fillet weld it shall be slightly concave. The welds
should have regular height and width of heads. The height and spacing of
ripples shall be uniform. The joints in the weld run where welding has been
recommended shall as far as possible be smooth and should not show any
hump or craters in the weld surface. Welds shall be free from unfilled
craters on the surface, under-cuts, lags on the surface and visible cracks.
Intermittent welds shall not be permitted without approval of ENGINEER.
Such inspection shall be done after cleaning the weld surface with
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steel wire brushes and chisel to remove the spatter metal, scales slag etc. If
external defects mentioned above are noticed there is every possibility of
internal defects and further radiographic/ultrasonic examination shall be
undertaken as per clause 5.9.5
5.9.2 Mechanical Testing
The following mechanical tests shall be carried out as per IS: 3600
(i) Transverse Tensile Test

(ii) Reduced Section Tensile Test
(iii) Free Bend Test
(iv) Transverse and Longitudinal Bend Test
5.9.3 Test plates shall be incorporated on either side of at least 10% of main butt
welds and the weld shall be continuous over the test plate. The test plates
shall be cut from extensions of the main plates and shall be fixed so that the
metal lies in the same direction as that of the main plate.
5.9.4 Test plates shall be prepared and tested in accordance with the accepted
standards, in the presence of the Engineer-in-Charge or his authorised
representative. All testing equipment and facilities for carrying out these
tests shall be provided by the Contractor within his unit rates. Should any
of these tests fail, further radiographic examination of the welds in
question on the main members, shall be undertaken in accordance with
clause 5.9.5.
5.9.5 Non-destructive and special testing
In addition to the contractors normal supervision and testing procedure,

radiographic/ultrasonic, liquid penetrant test, dry powder magnetic particle
test and wet magnetic particle test shall be carried out as and when required
by the Engineer-in-charge, on butt or fillet welded joints/and/or on test
specimens. These tests of welds except radiographic/ultrasonic tests shall
be carried out at the cost of the contractor wherever and whenever required
by the Engineer in Charge. Radiographic/ultrasonic tests shall, however,
be carried out by Engineer at department cost through separate independent
agency. In case of failure of any of the radiographic/ultrasonic tests, the
cost of that portion of the test shall be recovered from the contractor.
Rectification of such components shall be carried out by the contractor at
his cost.
Not withstanding any other stipulation contained elsewhere in these

specification, radiographic/ultrasonic testing shall be done as follows:-
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i) 1% radiographic testing at random for all Butt joints excluding the

butt joints of tension flanges at Crane girder.
ii) 100% radiographic testing for butt joints for tension flanges of crane
girders.
iii) Spot radiographic test in any one butt welds per flange of flanges of
main framing beams and columns.
iv) 100% ultrasonic tests on butt welds of flanges of main framing
beams and columns not covered by radiography.
5.9.6 Acceptance Of Welded Structures
The acceptance of the welded work shall depend upon correct dimensions
and alignment, absence of distortion in the structure, satisfactory results
from the examination and testing of the joints and the test specimens as per
IS, soundness of the welds and upon general workmanship being good.
ENGINEERs decision shall be final and binding on contractor in this
regard.
5.10 SAFETY PRECAUTIONS
5.10.1 CONTRACTOR shall take all necessary precautions for the safety of his
own personnel as well as that of other contractors working in the area.
5.10.2 Welders shall be provided with safety goggles and gloves, etc. All the
personnel working in the construction site shall be provided with safety
helmets. Personnel working at higher elevations shall be provided with
safety belts. Adequate first aid facilities shall be provided by the contractor
at his own cost. Any negligence in terms of safety measure and
consequences arising out of such negligence will be the sole responsibility
of the CONTRACTOR.
5.10.3 CONTRACTOR shall take precautionary measures such as providing

sheets/covers below the welding area to provide protection against falling
liquid metal and sparks. Area where welding is being done shall be suitably
barricaded to prevent movement of personnel underneath and sign boards
shall be put in such areas where erection/welding is being done.
5.11 END MILLING
Where compression joints are specified to be designed for bearing, the

bearing surfaces shall be milled true and square to ensure proper bearing
and alignment.
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5.12 FABRICATION TOLERANCES
The dimensional and weight tolerance for rolled shapes shall be in

accordance with IS : 1852 for indigenous steel and equivalent applicable
codes for imported steel. The acceptance limits for straightness (sweep and
camber) for rolled or fabricated members are :-
Struts and columns - L/1000 or 10 mm whichever is smaller
For all other members - L/500 or 15 mm whichever is smaller

Not primarily in
compression such as purlins,
girts, bracings and the web
members of trusses and
Latticed girders
Where L is the length of finished member or such lesser length as the

Engineer may specify.
A limit for twist prior to erection in
Box girders & Heavy columns - L/1500

Other members - L/1000
The twist of the member between any two sections shall be measured with
the web vertical at one of the sections.
Tolerance in specified camber of structural members shall be 3mm
Tolerance in specified length shall be as follows:
Type of member Tolerance
A column finished for contact 1 mm
Other members (e.g. beams) under 10 m + 0 & -3 mm
Other members (e.g. beams) 10 M long & over + 0 & -5 mm
End of Members
Beam to beam and beam to column connections. Where the abutting parts
are to be jointed by butt welds, permissible deviation from the squareness of
the end is :
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Beams upto 600 mm in depth 1.5 mm
Beams over 600 mm in depth 1.5 mm every 600 mm

upto maximum of 3 mm
Where abutting parts are to be jointed by bolting through cleats or end

plates, the connections require closer tolerance. Permissible deviation from
the squareness of the end is :
Beams upto 600 mm in 1 mm per 600 mm of depth to a max. of 1.5 mm.
Butt Joints
For full bearing, two abutting ends of columns shall first be aligned to
within 1 in 1000 of their combined length and then the following conditions
shall be met.
a) Over atleast 80% of the bearing surface the clearance between the
surfaces does not exceed 0.1 mm.
b) Over the remainder of the surfaces the clearance between the
surfaces does not exceed 0.3 mm.
Where web stiffeners are designed for full bearing on either the top flange
or bottom flange or both, at least half the stiffener shall be in positive
contact with the flange. The remainder of the contact face could have a
max. gap of 0.25 mm.
Depth of Members
Acceptable deviation from the specified overall depth is:
For depths of 900 mm and under - 3 mm
For depths over 900 mm and under 1800 mm - 5 mm
For depths of 1800 mm and over - + 8 mm

- 5 mm
Web Plates
An acceptable deviation from flatness in girder webs in the length between

the stiffeners or in a length equal to the girder depth shall be 1/150th of the
total web depth.
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Flanges Plates
A reasonable limit for combined warpage and tilt on the flanges of a built
up member is 1/200 of the total width of flange or 3 mm whichever is
smaller measured with respect to centreline of flanges.
Lateral deviation between centreline of web plates and centreline of flange

plate at contact surfaces, in the case of built up sections shall not exceed 3
mm.
6.0 STEEL GRATINGS, STAIRS, HANDRAILS, LADDERS AND

FLOOR PLATE COVERS
6.10 STEEL GRATING
6.1.1 All grating units shall be rectangular and diamond in pattern and welded
assembly. The grating are to be designed to sustain the maximum safe load
of 500kg/m2 of the plan area. The maximum width of opening for grating
shall not exceed 300mm. The minimum thickness of main bars shall be
5mm. The grating bar shall not be less than 38mm deep and span shall not
exceed 1500mm.
6.1.2 The gratings shall be made up in panel units designed to coincide with the
span of the structural framing as indicated in the drawings or as directed by
the Engineer-in-Charge.
6.1.3 The grating units shall be accurately fabricated and finished free from warps,
twists or any defects that would impair their strength, serviceability and
appearance.
6.1.4 Grating work shall include cut outs and clearance openings for all cols.,
pipes, ducts, conduits or any other installation penetrating through the
grating work. Such cut-outs and clearances shall be treated as follows:
6.1.5 The gratings shall be notched, trimmed and neatly finished around flanges
and webs of the columns, moment connections, cap plates and such other
components of the steel structures encountered during the placement of the
gratings. In all such cases, the trimming shall be done to follow the profile
of the component countered. After trimming, the binding strip shall be
provided on the grating to suit the profile so obtained.
6.1.6 Openings in gratings for pipes or ducts that are 150 mm in size or diameter
or larger shall be provided with steel bar toe plates of not less than 5 mm
thickness and 100 mm width, set flush with the bottom of the bearing bars.
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6.1.7 Penetrations in gratings that are more than 50 mm but less than 150 mm in
size or diameter shall be banded with plates of the size shown in the
detailed drgs. set flush with the bottom of the grating panel.
6.1.8 Penetrations, in grating that are less than 50 mm in size or diameter shall be
cut in field by others.
6.1.9 Unless otherwise indicated in the drgs. grating units at all penetrations shall
be made up in split section, accurately fitted and neatly finished to provide
for proper assembly and erection at the job site.
6.1.10 Grating units shall be provided with all necessary clips, bolts, nuts and lock
washers required for proper assembly and rigid installation and fastening to
abutting units and supporting structural steel framing members.
6.1.11 All fabricated grating section and accessories shall be primed in the shop
prior to erection at site.
6.1.12 Prior to painting all surfaces shall be cleaned, free from rust, mill-scale,
grease, oil or any other foreign matter that might affect the adherence of the
paint by sand blasting. While the primer shall be applied by Spray guns or
by brushes, the final coat of finished paint shall necessarily be applied by
means of spray guns only.
6.1.13 The applied coatings shall be uniform, free from voids and streaks. Drilled
or punched holes shall be touched up prior to erection or assembly.
6.1.14 In case, the fabrication of gratings is done by him at his own workshop
outside the project, then the unit rate quoted by him for this item shall be
inclusive of transport of the fabricated materials form his shop to the project
site. He shall also in such a case provide all facilities and access to the
Engineer-in-charge or his representative to carry out inspection of the
components being fabricated at his workshop during all stages of fabrication.
Maximum deviation in linear dimensions from the approved dimension shall
not exceed 5mm.
6.2 STAIRS
6.2.1 All the stairs and intermediate landings shall be constructed to size,
dimensions and design, as indicated in the detailed drawings. Each stairway
shall be fabricated as a complete unit which shall include struts, hangers,
posts, cross bracings, cleats and accessories, as required for connection to
structural steel framing and concrete.
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STEEL
6.2.2 Gratings for stair treads and landings shall be constructed to size, dimensions
and design as specified and shall match with floor grating pattern.
6.2.3 Stair treads shall be furnished complete with punched and slotted carrier
plates attached ready to bolt to stair stringers. Treads shall be provided with
an approved type anti-slip nosing set flush with the stair tread.
6.2.4 Grating treads and gratings for landings of interior stairs shall be paint
finished as specified for floor gratings.
6.3 HAND RAILS
Pipe hand rails, as specified in detailed drawings shall be assembled with

flush-type fittings and welded joints, ground and polished smooth. Railings
shall be provided with all necessary fittings, posts, brackets, bolts, kick
plates and similar accessories as shown on the approved drawings, and as
required for proper installation. Hand rails shall be provided on open sided
of chequered plates and steel grating platforms, steel stairways and around
all openings in chequered plate and steel grating floors as shown in
drawings.
6.4 LADDERS
Vertical ladders shall be called for on the approved drawings. The ladders
shall be provided with support arms formed of bent steel plate or clip
angles. Where shown on the drgs. the ladders shall have loose neck
supports, designed to form hand grabs and end brackets for fastening to
abutting construction. Maximum deviation in the linear dimensions of
railings, stairs and ladders, from the approved dimensions, shall not exceed
12mm.
6.5 FLOOR PLATES COVERS
Floor plates for platforms, trench covers, pit covers, etc., shall be formed of
raised pattern chequered steel plates of shape and size as shown on the
drgs., compete with stiffener ribs, top bars, anchors and necessary
accessories. Maximum deviation in the linear dimensions of floor plate
covers from approved dimensions shall not exceed 5mm.
7.0 INSPECTION
7.1.1 The VENDOR/CONTRACTOR shall give due notice to the PURCHASER/

ENGINEER in advance of the works getting ready for inspection. All
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STEEL
rejected material shall be promptly removed from the shop and replaced
with new material for the PURCHASER/ENGINEERs approval/
inspection. The fact that certain material has been accepted at the
VENDOR/CONTRACTORs shop shall not invalidate final rejection at site
by the PURCHASER/ENGINEER if it fails to conform to the requirements
of these specifications, to be in proper condition or has fabrication
inaccuracies which prevents proper assembly nor shall invalidate any claim
which the PURCHASER may make because of defective or unsatisfactory
materials and/or workmanship.
7.1.2 No materials shall be painted or despatched to site without inspection and

approval by the PURCHASER/ENGINEER unless such inspection is
waived in writing by the ENGINEER.
7.1.3 The VENDOR/CONTRACTOR shall provide all the testing and inspection
services and facilities for shop work except where otherwise specified.
7.1.4 For fabrication work carried out in the field the same standard of
supervision and quality control shall be maintained as in shop fabricated
work. Inspection and testing shall be conducted in a manner satisfactory to
the ENGINEER.
7.2 Inspection and tests on structural steel members shall be as set forth below :
7.2.1 Materials Testing
If mill test reports are not available for any steel materials the same shall be
got tested by the VENDOR/CONTRACTOR to the ENGINEERs
satisfaction to demonstrate conformity with the relevant specification at no
extra cost to OWNER.
7.3 TESTS ON WELDS
7.3.1 Magnetic Particle Test
Where welds are examined by magnetic particle testing, such testing shall
be carried out in accordance with relevant IS codes. If heat treatment is
performed, the completed weld shall be examined after the heat treatment.
All defects shall be repaired and retested. Magnetic particle tests shall be
carried out using alternating current. Direct current may be used with the
permission of the ENGINEER.
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STEEL
7.3.2 Liquid Penetrant Inspection

In the case of welds examined by Liquid Penetrant Inspection, such tests
shall be carried out in accordance with relevant IS Codes. All defects
shown shall be repaired and rechecked.
7.3.3 Radiographic Inspection
All full strength butt welds shall be subjected to radiographic/ultrasonic test

as per clause 5.9.5 in accordance with the recommended practice for
radiographic testing as per relevant IS code.
7.4 DIMENSIONS, WORKMANSHIP & CLEANLINESS
Members shall be inspected at all stages of fabrication and assembly to

verify that dimensions, tolerances, alignment, surface finish and painting
are in accordance with the requirements shown in the
VENDOR/CONTRACTORS approved fabrication drawing and
ENGINEERS drawings.
7.5 TEST FAILURE
In the event of failure of any members to satisfy inspection or test

requirement, the VENDOR/CONTRACTOR shall notify the ENGINEER
or his authorised representative. The VENDOR/CONTRACTOR must
obtain permission from the ENGINEER before repair is undertaken. The
quality control procedures to be followed to ensure satisfactory repair shall
be subject to approval by the ENGINEER.
7.6 The VENDOR/CONTRACTOR shall maintain records of all inspection and

testing which shall be made available to the ENGINEER or his authorised
representative.
8.0 SHOP MATCHING
Steel work, such as columns along with the tie beams/bracings/trusses etc,
may have to be shop assembled to ensure satisfactory fabrication, obtaining
of adequate bearing areas etc. if so desired by the ENGINEER. All these
shop assemblies shall be carried out by VENDOR/CONTRACTOR
9.0 DRILLING HOLES FOR OTHER WORKS
As a part of this Contract, holes in members required for installing

equipment or steel furnished by other manufacturers or other contractors
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STEEL
shall be drilled by the VENDOR/CONTRACTOR at no extra cost to the

OWNER.
10.0 MARKING OF MEMBERS
10.1 After checking and inspection, all members shall be marked for
identification during erection. This mark shall correspond to distinguishing
marks on erection drawings and shall be legibly painted and stamped on it.
The erection mark shall be stamped with a metal dye with figures at least
20mm high and to such optimum depth as to be clearly visible.
10.2 All erection marks shall be on the outer surface of all sections and near one
end, but clear of bolt holes. The marking shall be so stamped that they are
easily discernible when sorting out members. The stamped marking shall
be encircled boldly by a distinguishable paint to facilitate easy location.
10.3 Erection marks on like pieces shall be in identical locations. Members

having length of 7.0m or more shall have the erection mark at both ends.
11.0 ERRORS
Any error in shop fabrication which prevents proper assembling and fitting
up of parts in the field by moderate use of drift pins or moderate amount of
reaming will be classified by the ENGINEER as defective workmanship.
In case ENGINEER rejects the material or defective workmanship, the
same shall be replaced by the materials and workmanship conforming to the
ENGINEERs requirements by VENDOR/CONTRACTOR at no extra cost
to the OWNER.
12.0 PAINTING
12.1 All fabricated steel material, shall receive protective paint coating as specified
in specification No. TCE. 5178A-405-04 (Section D38).
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SPEC NO. TCE CONSULTING ENGINEERS SECTION : D37
TCE-5178A-405-02 ERECTION OF STRUCTURAL STEEL

SH 1 OF 8
1.0 SCOPE
This specification covers the general requirements for erection of structural steel.
It covers the supply and delivery of all necessary materials, labour, scaffolding,
tools, tackles, equipment and everything that is necessary for the satisfactory
completion of the job on schedule.
2.0 APPLICABLE CODES & SPECIFICATIONS
2.1 The following specifications, standards and codes are made a part of this
specification. All standards, specifications and codes of practice referred to
herein shall be the latest editions, including all applicable official amendments
and revisions.
2.2 In case of discrepancy between this specification and other documents referred to
2.3 STRUCTURAL
(a) IS:800 Code of Practice for General Construction in Steel
(b) IS:801 Code of Practice for Use of Cold Formed Light Gauge Steel
Structural Members in General Building Construction
(c) IS:806 Code of Practice for Use of Steel Tubes in General Building
Construction
(d) IS:7205 Safety Code for Erection of Structural Steel Work
(e) IS:7215 Tolerances for Fabrication of Steel Structures
(f) IS:4000 Code of practice for assembly of structural joints using high
tensile friction grip fasteners.
(g) IS:822 Code of procedure for inspection of welds
3.0 ERECTION SCHEME
3.1 Each Bid shall be accompanied by a broad erection scheme with dates and
estimated completion time for various parts of the work prepared by BIDDER
after a thorough study of the Bid drawings and the site conditions. This erection
scheme shall describe the methods proposed to be employed by BIDDER for
transporting his equipment, tools, tackles, gas cylinders, electrodes and all that is
necessary to site, unloading, transporting within the site, handling, assembling,
hoisting and erecting of the structural steel components and the type, capacity and
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quantity of equipment that BIDDER proposes to bring to site for all these
operations. The scheme shall also indicate the strength and tradewise
composition of the work force and supervisory personnel that will be deployed by
BIDDER for the various operations.
4.0 ERECTION PROGRAMME
4.1 Within 15 days of the acceptance of his Bid, the successful BIDDER shall submit,
a detailed erection programme. This programme shall be accompanied by a layout
plan identifying the areas proposed for unloading, main storage, subsidiary
storage, assembly and the transportation of equipment and fabricated material
between the storage and work areas. The layout shall clearly indicate the points at
which proposed erection begins, direction in which it is proposed to progress, the
deployment of equipment, access route for cranes to reach work areas, etc. The
locations and extent of site offices and stores, labour quarters if any, layout of
electrical cables and water pipes from the tap-off points shall also be indicated in
detail on the above layout. Full details of the method of handling, transport,
hoisting and erection including false work/staging, temporary bracing, guying,
etc. shall be furnished by CONTRACTOR in this erection programme along with
complete details of the quantity and capacity of the various items of erection
equipment that will be used. A site organisation chart showing the number of
supervisory personnel, and the number and composition of the various gangs shall
also accompany the erection programme.
4.2 Any modifications to the erection programme directed by ENGINEER for the
reasons of inadequacy of the quantity and/or capacity of the erection equipment,
erection personnel and supervisors, temporary bracing, guying etc., or safety of
the erection methods, or stability of the erected portions of structures, or
unsuitability of the erection sequence due to interference with the work of other
agencies shall be incorporated by CONTRACTOR and the work shall be carried
out in accordance with the revised programme. Approval by ENGINEER shall
not relieve CONTRACTOR from the responsibility for the safe, sound, accurate
and timely erection of structural steel work as required by ENGINEER/OWNER.
CONTRACTOR shall also make no extra claims for bringing additional
equipment to site for erection, if so directed by ENGINEER. CONTRACTOR
shall be deemed to have visualised all erection problems while bidding for the
work and no additional compensation shall be claimed on this account.
5.0 SITE OPERATIONS
5.1 An experienced and qualified Superintendent shall be in full time charge of the
job.
5.2 CONTRACTOR shall complete all preliminary works at site well before the
arrival of structural steel, such as establishment of a well equipped and adequately
staffed site office, stores, unloading gantry, unloading and pre-assembly yard,
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labour quarters if any, electrical and water connections, electrical winches,

derricks, cranes, compressors, all tools and tackles, rivet guns, welding sets,
torque wrenches, spud wrenches, staging, etc. as well as experienced erection and
supervisory personnel as part of this contract and any other work that may be
necessary so as to start erection immediately after the arrival of the first batch of
steel at site.
5.3 CONTRACTOR shall furnish at his own expense, the necessary non-inflammable
staging and hoisting materials or equipment required for the erection work and
shall remove and take them away after completion of the job. CONTRACTOR
shall also provide necessary passageways, fences, safety belts, helmets, lights and
other fittings to the satisfaction of OWNER/ENGINEER and to meet the rules of
local authorities and for protection to his men and materials. A licensed
electrician shall be kept on the job for the entire duration of the work to maintain
CONTRACTOR's electrical equipment and connections.
5.4 CONTRACTOR shall protect all existing plant, structures, piping, conduits,
equipment and facilities against damage during erection. Any damage caused by
CONTRACTOR shall be rectified entirely at CONTRACTOR's cost,to the
satisfaction of OWNER/ENGINEER. If work has to be carried out adjacent to
existing switch yards or electrical installations which are live, CONTRACTOR
must ensure suitable safety precautions in consultation with ENGINEER.
5.5 If a portion of the work of the project area cannot be made available to
CONTRACTOR for his activities due to operations being carried out by other
agencies, he shall suitably modify his sequence of operations so as to continue
work without interruption. CONTRACTOR shall work in coordination with other
agencies working on the project site and plan his work suitably so as not to hinder
the progress of construction at site.
6.0 ACCEPTANCE OF STEEL, ITS HANDLING & STORAGE
6.1 CONTRACTOR shall carefully check the steel to be erected at the time of
acceptance. Any fabrication defects observed should be brought to the notice of
OWNER/ ENGINEER.
6.2 No dragging of steel shall be permitted. All shall be stored 300mm above ground
on suitable packing to avoid damage. It shall be stored in the order required for
erection, with erection marks visible. All storage areas shall be prepared and
maintained by CONTRACTOR. Steel shall not be stored in the vicinity of areas
where excavation or grading will be done and, if so stored temporarily, this shall
be removed by CONTRACTOR well before such excavation and/or grading
commences to a safe distance to avoid burial under debris.
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6.3 Scratched or abraded steel shall be given a coat of primer specified under Data
Sheet A for protection after unloading and handling prior to erection. All milled
and machined surfaces shall be properly protected from rust/corrosion by suitable
coating and also from getting damaged.
6.4 Point of delivery of fabricated steel shall be the location where it is to erected.
7.0 ANCHOR BOLTS & FOUNDATIONS
7.1 CONTRACTOR shall carefully check the location and layout of anchor bolts
embedded in foundations constructed , to ensure that the structures can be
properly erected as shown on the drawings, Any discrepancy in the anchor
bolts/foundation shall be reported to ENGINEER.
7.2 Levelling of column bases to the required elevation may be done either by
providing shims or three nuts on the upper threaded portion of the anchor bolt.
All shim stock required for keeping the specified thickness of grout and in
connection with erection of structures on foundations, crane brackets or at any
other locations shall be of good M.S. plates at no extra cost to the OWNER.
7.3 A certain amount of cleaning of foundations and preparing the area is considered
normal and shall be carried out by CONTRACTOR.
7.4 Where beams bear in pockets or on walls, bearing plates shall be set and levelled
as part of the work. All grouting under column base plates or beam bearing
plates will be carried out by CONTRACTOR, as a part of his scope of work.
8.0 ASSEMBLY & CONNECTIONS
8.1 Field connections may be effected by welding unless otherwise indicated in the
drawings. Connections for removable members shall be by means of bolting
8.2 All assembling shall be carried on a level platform.
8.3 Drifts shall be used only for drawing the work to proper position and must not be
used to such an extent as to damage the holes. Size of drifts larger than the
nominal diameter of hole shall not be used. Any damaged holes or burrs must be
rectified to the satisfaction of ENGINEER.
8.4 Corrections of minor misfits and reasonable amount of reaming and cutting of
excess stock from rivets shall be considered as a part of erection. Any error in the
shop, which prevents proper fit on a moderate amount of reaming and slight
chipping or cutting, shall be immediately reported to ENGINEER.
9.0 ERECTION
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9.1 All structural steel shall be erected as shown on the drawings. Proper size steel
cable slings, etc., shall be used for hoisting. Guys shall not be anchored to
existing structures, foundations, etc. unless so permitted by ENGINEER in
writing. Care shall be taken to see that ropes in use are always in good condition.
9.2 Steel columns in the basement, if any, are to be lowered and erected carefully
with the help of a crane and/or derrick without damaging the basement walls or
floor.
9.3 Structural steel frames shall be erected plumb and true. Frames shall be lifted at
such points that they are not liable to buckle and deform. Trusses shall be lifted
only at node points. In the case of trusses, roof girders, all of the purlins and wind
bracing shall be placed simultaneously and the columns shall be erected truly
plumb on screed bars over the pedestals. All steel columns and beams shall be
checked for plumb and level individually before and after connections are made.
Temporary bracings shall be introduced wherever necessary to take care of all
loads to which the structure may be subjected, including erection equipment and
the operation thereof. Such bracings shall be left in place as long as may be
required for safety and stability.
9.4 Chequered plates shall be fixed to supporting members by tack welding or by

countersunk bolts as shown/specified in relevant drawings and/or as directed by
ENGINEER. The edges shall be made smooth and no burrs or jagged ends shall
be left. While splicing, care should be taken so that there is continuity in pattern
between the two portions. Care should also be taken to avoid distortion of the
plate while welding. The erection of chequered plates shall include :
(a) Welding of stiffening angles/vertical stiffening ribs
(b) Cutting to size and making holes to required shape wherever necessary to
allow service piping and/or cables to pass through
(c) Splicing as shown in relevant drawings
(d) Smoothening of edges
(e) Fixing of chequered plates by tack welding or by countersunk bolts
(f) Providing lifting hooks for ease of lifting.
9.5 As erection progresses, the work shall be securely bolted to take care of all dead
load, wind, seismic and erection stresses.
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9.6 No riveting or welding or final bolting shall be done until the structure has been
properly aligned and approved by ENGINEER. No cutting, heating or enlarging
of the holes shall be carried out without the prior written approval of ENGINEER.
10.0 INSPECTION
10.1 ENGINEER/OWNER or their authorised representatives shall have free access

to all parts of the job during erection and all erection shall be subjected to their
approval. In case of faulty erection, all dismantling and re-erection required will
be at CONTRACTOR's cost. No paint shall be applied to rivet heads or field
welds or bolts until these have been approved by ENGINEER.
11.0 TOLERANCES
Tolerances mentioned below shall be achieved after the entire structure or part
thereof is in line, level and plumb. The tolerances specified below do not apply to
steel structures where the deviations from true position are intimately linked with
and directly influence technological process. In such cases, the tolerances on
erected steel structures shall be as per recommendations of process
technologists/suppliers which will be indicated in the drawings.
11.1 COLUMNS
11.1.1 Deviation of column axes at foundation top level with respect to true axes :
(a) In longitudinal direction : 5 mm
(b) In lateral direction : 5 mm
11.1.2 Deviation in the level of bearing

surface of columns at foundation
top with respect to true level : 5 mm
11.1.3 Out of plumbness (verticality) of column axis from true vertical axis, as measured
at column top :
(a) For columns upto and including : 1/1000 of column height in

15 metres in height mm or 15mm whichever is
less
(b) For columns exceeding 15 : 1/1000 of column height in

metres in height mm or 20 mm whichever
is less
11.1.4 Deviation in straightness in longitudinal : 1/1000 of column height in

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and transverse planes of column at any : mm or 10 mm whichever

point along the height is less
11.1.5 Difference in erected position of adjacent : 10 mm

pairs of columns along length or across
width of building prior to connecting
trusses/beams with respect to true distance
11.1.6 Deviation in any bearing or seating level : 5 mm

with respect to true level
11.1.7 Deviation in differences in bearing levels : 10 mm

of a member on adjacent pair of columns
both across and along the building
11.2 TRUSSES AND BEAMS
11.2.1 Shift at the centre of span of top chord : 1/250 of height of truss in
member with respect to the vertical plane mm or 15 mm whichever
passing through the centre of bottom chord is less
11.2.2 Lateral shift of top chord of truss at the : 1/1500 of span of truss in
centre of span from the vertical plane mm or 15 mm whichever
passing through the centre of supports is less
of the truss
11.2.3 Lateral shift in location of truss from its : 10 mm

true vertical position
11.2.4 Lateral shift in location of purlin true

position : 5 mm
11.2.5 Deviation in difference of bearing : i) 20 mm for trusses

levels of trusses or beams from ii) For beams :
the true difference Depth < 1800mm : 6mm
Depth > 1800mm : 10 mm
11.2.6 Deviation in sag in chords and diagonals : 1/1500 of length in mm or

of truss between node points 10mm whichever is smaller
11.2.7 Deviation in sweep of trusses, beams etc. : 1/1000 of span in mm subject
in the horizontal plane to a maximum of 10 mm
11.3 HIMNEY AND TOWRES
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11.3.1 Verticality from the true Vertical axis. 1/1000 of the height of the
chimney or tower in mm.
12.0 PAINTING
12.1 After steel has been erected, all bare and abraded spots, rivet heads, field welds,
bolt heads and nuts shall be spot painted with primer specified in Data Sheet A.
Before paint is applied, the surface shall be dry and free from dust, dirt, scale and
grease. All surfaces inaccessible after erection shall receive two coats of the
approved paint before erection.
13.0 COMPLETED OR PARTLY COMPLETED WORK
13.1 Owner shall have the right to take possession of or use any completed or partly
completed part of work. Such possession or use shall not be deemed to be an
acceptance of any work not in accordance with the contact
14.0 CLEAN UP OF WORK SITE
14.1 During erection, the CONTRACTOR shall without any additional payment, at all
times keep the working and storage areas used by him, free from accumulation of
waste materials or rubbish. Before completion of erection, he shall remove or
dispose of in a satisfactory manner all temporary structures, waste and debris and
leave the premises in a condition satisfactory to OWNER/ENGINEER.
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SPEC. .NO. TCE CONSULTING ENGINEERS LIMITED SECTION: -D38
TCE-5178A-405-04 SHEET 1 OF 3
PAINTING OF STRUCTURAL STEEL
1.0 SCOPE
1.1 This specification covers the general requirements for painting structural
steel work. It covers the supply and delivery of all necessary materials,
labour, scaffolding, tools, equipment and everything that is necessary for
the job completion on schedule. The specific requirements of the project
are indicated in Cl. 4.0.
1.2 Shop painting shall be understood to mean painting prior to erection

whether such materials are fabricated in shop or at site. In case the
contract covers shop painting only, the contractor shall ensure that the
painted surfaces are not abraded / scratched etc. as they leave his works /
shops, in case of ex-works delivery contract and in case of FOR site
contracts, the materials as received at site should be in good condition.
Otherwise all damaged, abraded and scratched surfaces shall be touched
up on receipt of materials at site as specified. If the contract covers both
shop painting and painting after erection, the responsibility would be
total. In case of routine maintenance painting of erected steel work, the
surface preparation, primer application and painting shall be as per Cl.4.0.
2.0 APPLICABLE CODES
The following specifications, Standards and Codes are made a part of this
Specification. All standards and codes of practice referred to herein shall
be the latest editions including all applicable official amendments and
revisions.
In case of discrepancy between this specification and those referred to

(a) IS : 101 : Methods of test for ready mixed paints

and enamels
(b) ASTM : American standard test methods for paints

and coatings
(c) ASA A 13.1-1981 : Scheme for identification of piping systems

American National Standards Institution.
(d) SIS-05 5900-1967 : Surface preparations standards for Painting

(Swedish Standard) Steel Surfaces,
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TCE FORM 329 R3

TCE-5178A-405-04 SHEET 2 OF 3
3.1 All paint delivered to the fabrication shop / site shall be ready mixed,
in original sealed containers, as packed by the paint manufacturers and no
thinners shall be permitted.
3.2 Paint shall be stirred frequently to keep the pigment in suspension.
4.0 SPECIFIC TECHNICAL REQUIREMENTS
4.1 Following specific technical requirements in addition to those specified

above shall be complied with.
4.2 Scope of painting shall be as follows :
a) One shop coat of primer after fabrication.
b) One touch up coat of primer on abraded surfaces after erection
c) Two coats of primer after erection.
d) Two final protective colour coats of chlorinated rubber finish paint
4.3 Surfaces of steel work to be painted shall be thoroughly cleaned by means

of mechanical and power tool cleaning.
4.4 First, one Shop coat of Inorganic Zinc Silicate primer (65 microns) after
fabrication but before erection shall be applied. After erection apply one
coat of Inorganic Zinc Silicate primer as touchup paint at all damaged
surfaces (1 x 65 microns) plus two coats of Chlorinated Rubber Zinc
Phosphate Primer (2 x 40 microns). Finish paint shall be two coats of
Chlorinated Rubber finish paint (2 x 40 microns)
4.5 Surfaces inaccessible after assembly and after erection shall receive 2
coats of the primer paint prior to assembly.
4.6 Colour code shall be as desired by the OWNER and will be indicated
during execution.
4.7 Separate colour code or identification mark shall be adopted in the

fabrication shop for members fabricated from steel supplied by the
OWNER and the VENDOR / CONTRACTOR.
4.8 Welds and adjacent parent metals shall not be applied with primer and /
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TCE FORM 329 R3

TCE-5178A-405-04 SHEET 3 OF 3
4.9 Surfaces coming in contact with concrete, and such other areas should not
be painted, if so specified or directed by Engineer.
4.10 All machine finished surfaces shall be provided with a coat of white lead
or tallow before despatch to site to prevent rust formation.
4.11 No painting shall be done in frosty / foggy weather or when the humidity
is high enough to cause condensation on the surface to be painted. Paint
shall not be applied when the temperature of the surface to be painted is
50 C or lower.
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TCE FORM 329 R3

TCE CONSULTING ENGINEERS LTD
SPEC. NO. SECTION: D39
TITLE
TCE.5178A-418-01 SHEET 1 OF 8
EARTHWORK IN GRADING,
EXCAVATION AND BACK FILLING
1. SCOPE
This specification covers the general requirements of earthwork in
excavation in different materials, site grading, filling in areas as shown
in drawing, back filling around the foundations and in plinths,
conveyance and disposal of surplus soils or stacking them to the
stockyard or pit with a lead of 3000m with in plant area or outside as
directed by the Engineer and all operations covered within the intent
and purpose of this specification.
2. APPLICABLE CODES
The following Indian Standard Codes, unless otherwise specified
herein, shall be applicable. In all cases, the latest revision of the codes
shall be referred to.
1. IS 783 - Code of practice for laying of concrete pipes.

2. IS 1200 - Method of measurement of building and civil
engineering works.
Part 1 Earthwork
(Part 1)
Part 27 Earthwork done by mechanical appliances.
(Part 27)
3. IS 3764 - Excavation work-code of safety.
4. IS 2720 - Methods of test for soils:
(Part 1) - Part 1 Preparation of dry soil samples for various
tests.
(Part 2) - Part 2 Determination of water content.
(Part 4)- - Part 4 Grain size analysis.
(Part 5) - Part 5 Determination of liquid and plastic limit.
(Part 7) - Part 7 Determination of water content-dry density
relation using light compaction.
Part (8) - Part 8 Determination of water content-dry density
relation using heavy compaction
Part (9) - Part 9 Determination of dry density - moisture
content relation by constant weight of soil method.
(Part 14) - Part 14 Determination of density index (relative
density) of cohesionless soils.
(Part 28) - Part 28 Determination of dry density of soils in
place, by the sand replacement method.
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TCE.5178A-418-01 SHEET 2 OF 8
(Part 29) - Part 29 Determination of dry density of soils in

place, by the core cutter method.
(Part 33) - Part 33 Determination of the density in place by the
ring and water replacement method.
(Part 34) - Part 34 Determination of density of soil in place by
rubber balloon method.
(Part 38) - Part 38 Compaction control test (Hilf Method).
3. DRAWINGS
3.1 The Engineer will furnish drawings wherever, in his opinion, such
drawings are required to show areas to be excavated/ filled grade level,
sequence of priorities etc. The Contractor shall follow strictly such
drawings.
4. GENERAL
4.1 The Contractor shall furnish all tools, plants, instruments, qualified
supervisory personnel, labour, materials any temporary works,
consumables, any and everything necessary, whether or not such items
are specifically stated herein for completion of the job in accordance
with the specification requirements.
4.2 The Contractor shall carry out the survey of the site before excavation
and set properly all lines and establish levels for various works such as
earthwork in excavation for grading, basement, foundations, plinth
filling, roads, drains, cable trenches, pipelines etc. Such survey shall
be carried out by taking accurate cross sections of the area
perpendicular to established reference/ grid lines at 8 m. intervals or
nearer as determined by the Engineer based on ground profile. These
shall be checked by the Engineer and thereafter properly recorded.
4.3 The excavation shall be done to correct lines and levels. This shall
also include, where required, proper shoring to maintain excavations
and also the furnishing, erecting and maintaining of substantial
barricades around excavated areas and warning lamps at night for
ensuring safety.
4.4 The rates quoted shall also include for dumping of excavated materials
in regular heaps, bunds, riprap with regular slopes as directed by the
Engineer, within the lead specified and levelling the same so as to
provide natural drainage. Rock/ soil excavated shall be stacked
properly as directed by the Engineer. As a rule, all softer material
shall be laid along the centre of heaps, the harder and more weather
resisting materials forming the casing on the sides and the top. Rock
shall be stacked separately.
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TITLE
TCE.5178A-418-01 SHEET 3 OF 8
5. CLEARING
5.1 The area to be excavated filled shall be cleared of fences, trees, plants,
logs, stumps, bush, vegetation, rubbish, slush, etc. and other
objectionable matter. If any roots or stumps of trees are met during
excavation, they shall also be removed. The material so removed shall
be burnt or disposed off as directed by the Engineer. Where earthfill is
intended, the area shall be stripped of all loose/ soft patches, top soil
containing objectionable matter/ materials before fill commences.
6. PRECIOUS OBJECTS, RELICS, OBJECTS OF ANTIQUITY, etc.

6.1 All gold, silver, oil, minerals, archaeological and other findings of
importance, trees cut or other materials of any description and all
precious stones, coins, treasures, relics, antiquities and other similar
things which may be found in or upon the site shall be the property of
the Owner and the Contractor shall duly preserve the same to the
satisfaction of the Owner and from time to time deliver the same to
such person or persons as the Owner may from time to time authorise
or appoint to receive the same.
7. EXCAVATION
7.1 All excavation work shall be carried out by mechanical equipment
unless, in the opinion of the Engineer, the work involved and time
schedule permit manual work.
7.2 Excavation for permanent work shall be taken out to such widths,
lengths, depths and profiles as are shown on the drawings or such other
lines and grades as may be specified by the Engineer. Rough
excavation shall be carried out to a depth 150 mm above the final
level. The balance shall be excavated with special care. Soft pockets
shall be removed even below the final level and extra excavation filled
up as directed by the Engineer. The final excavation if so instructed by
the Engineer, should be carried out just prior to laying the mud-mat.
7.3 The Contractor may, for facility of work or similar other reasons
excavate, and also backfill later, if so approved by the Engineer, at his
own cost outside the lines shown on the drawings or directed by the
Engineer. Should any excavation be taken below the specified
elevations, the Contractor shall fill it up, with concrete of the same
class as in the foundation resting thereon, upto the required elevation.
No extra shall be claimed by the Contractor on this account.
7.4 All excavation shall be done to the minimum dimensions as required
for safety and working facility. Prior approval of the Engineer shall be
obtained by the Contractor in each individual case, for the method he
proposes to adopt for the excavation, including dimensions, side
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slopes, dewatering, disposal, etc. This approval, however, shall not in

any way relieve the Contractor of his responsibility for any consequent
loss or damage. The excavation must be carried out in the most
expeditious and efficient manner. Side slopes shall be as steep as will
stand safely for the actual soil conditions encountered. Every
precaution shall be taken to prevent slips. Should slips occur, the
slipped material shall be removed and the slope dressed to a modified
stable slope. Removal of slipped earth will not be paid for, if the slip is
due to negligence of CONTRACTOR.
7.5 Excavation shall be carried out with such tools, tackles and equipment
as described hereinbefore. Blasting or other methods may be resorted
to in the case of hard rock; however not without the specific
permission of the Engineer.
7.6 The Engineer may also direct that in some extreme case, the rock may
be excavated by heating and sudden quenching for splitting the rock..
8. STRIPPING LOOSE ROCK

8.1 All loose boulders, semi detached rocks (along with earthy stuff which
might move therewith) not directly in the excavation but so close to the
area to be excavated as to be liable, in the opinion of the Engineer, to
fall or otherwise endanger the workmen, equipment, or the work, etc.,
shall be stripped off and removed away from the area of the
excavation. The method used shall be such as not to shatter, or render
unstable or unsafe the portion which was originally sound and safe.
8.2 Any material not requiring removal as contemplated in the work, but
which, in the opinion of the Engineer, is likely to become loose or
unstable later, shall also be promptly and satisfactorily removed as
directed by the Engineer.
9. FILL, BACK FILLING AND SITE GRADING
9.1 GENERAL
All fill material will be subject to the Engineer's approval. If any
material is rejected by the Engineer, the Contractor shall remove the
same forthwith from the site at no extra cost to the Owner. Surplus fill
material shall be deposited/ disposed off as directed by the Engineer
after the fill work is completed.
No earthfill shall commence until surface water discharges and streams
have been properly intercepted or otherwise dealt with as directed by
the Engineer.
9.2 MATERIAL
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To the extent available, selected surplus soils from excavated materials

shall be used as backfill. Fill material shall be free from clods, salts,
sulphates, organic or other foreign material. All clods of earth shall be
broken or removed. Where excavated material is mostly rock, the
boulders shall be broken into pieces not larger than 150 mm size,
mixed with properly graded fine material consisting of murrum or
earth to fill up the voids and the mixture used for filling.
9.3 If any selected fill material is required to be borrowed, the Contractor
shall make arrangements for bringing such material from outside
borrow pits. The material and source shall be subject to prior approval
of the Engineer. The approved borrow pit area shall be cleared of all
bushed, roots of trees, plants, rubbish etc. top soil containing salts/
sulphate and other foreign material shall be removed. The materials so
removed shall be burnt or disposed off as directed by the Engineer.
The Contractor shall make necessary access roads to borrow areas and
maintain the same, if such access road does not exist, at his cost.
9.4 FILLING IN PITS AND TRENCHES AROUND FOUNDATIONS
OF STRUCTURES, WALLS ETC.
As soon as the work in foundations has been accepted and measured,
the spaces around the foundations, structures, pits, trenches etc. shall
be cleared of all debris, and filled with earth in layers not exceeding
15 cm., each layer being watered, rammed and properly consolidated,
before the succeeding one is laid. Each layer shall be consolidated to
achieve 90% proctor density to the satisfaction of the Engineer. Earth
shall be rammed with approved mechanical compaction machines.
Usually no manual compaction shall be allowed unless the Engineer is
satisfied that in some cases manual compaction by tampers cannot be
avoided. The final backfill surface shall be trimmed and levelled to
proper profile as directed by the Engineer or indicated on the drawings.
9.5 PLINTH FILLING
Plinth filling shall be carried out with approved material as described
hereinbefore in layers not exceeding 15 cm, watered and compacted
with mechanical compaction machines. The Engineer may however
permit manual compaction by hand tampers in case he is satisfied that
mechanical compaction is not possible. When filling reaches the
finished level, the surface shall be flooded with water, unless otherwise
directed, for at least 24 hours allowed to dry and then the surface again
compacted as specified above to avoid settlements at a later stage. The
finished level of the filling shall be trimmed to the level/ slope
specified.
Where specified in the schedule of works, compaction of the plinth fill
shall be carried out by means of 12 tonne rollers smooth wheeled,
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sheep-foot or wobbly wheeled rollers. In case of compaction of

granular material such as sands and gravel, vibratory rollers shall be
used. A smaller weight roller may be used only if permitted by the
Engineer. As rolling proceeds water sprinkling shall be done to assist
consolidation. Water shall not be sprinkled in case of sandy fill.
The thickness of each unconsolidated fill layer can in this case be upto
a maximum of 300 mm. The Engineer will determine the thickness of
the layers in which fill has to be consolidated depending on the fill
material and equipment used.
Rolling shall commence from the outer edge and progress towards the
centre and continue until compaction is to the satisfaction of the
Engineer, but in no case less than 10 passes of the roller will be
accepted for each layer.
The compacted surface shall be properly shaped, trimmed and
consolidated to an even and uniform gradient. All soft spots shall be
excavated and filled and consolidated.
At some locations/ areas it may not be possible to use rollers because
of space restrictions etc. The Contractor shall then be permitted to use
pneumatic tampers, rammers etc. and he shall ensure proper
compaction.
9.6 SAND FILLING IN PLINTH AND OTHER PLACES
At places backfilling shall be carried out with local sand if directed by
the Engineer. The sand used shall be clean, medium grained and free
from impurities. The filled-in-sand shall be kept flooded with water
for 24 hours to ensure maximum consolidation. Any temporary work
required to contain sand under flooded condition shall be to the
Contractor's account. The surface of the consolidated sand shall be
dressed to required level or slope. Construction of floors or other
structures on sand fill shall not be started until the Engineer has
inspected and approved the fill.
9.7 FILLING IN TRENCHES
Filling in trenches for pipes and drains shall be commenced as soon as
the joints of pipes and drains have been tested and passed. The
backfilling material shall be properly consolidated by watering and
ramming, taking due care that no damage is caused to the pipes.
Where the trenches are excavated in soil, the filling from the bottom of
the trench to the level of the centreline of the pipe shall be done by
hand compaction with selected approved earth in layers not exceeding
8 cm; backfilling above the level of the centreline of the pipe shall be
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done with selected earth by hand compaction or other approved means

in layers not exceeding 15 cm.
In case of excavation of trenches in rock, the filling upto a level 30 cm.
above the top of the pipe shall be done with fine materials, such as
earth, murrum etc. The filling up of the level of the centreline of the
pipe shall be done by hand compaction in layers not exceeding 8 cm.
whereas the filling above the centreline of the pipe shall be done by
hand compaction or approved means in layers not exceeding 15 cm.
The filling from a level 30 cm. above the top of the pipe to the top of
the trench shall be done by hand or other approved mechanical
methods with broken rock filling of size not exceeding 15 cm mixed
with fine material as available to fill up the voids.
Filling of the trenches shall be carried simultaneously on both sides of
the pipe to avoid unequal pressure on the pipe.
10. GENERAL SITE GRADING

10.1 Site grading shall be carried out as indicated in the drawings and as
directed by the Engineer. Excavation shall be carried out as specified
in the specification. Filling and compaction shall be carried out as
specified under Clause 9.0 and elsewhere unless otherwise indicated
below.
10.2 If no compaction is called for, the fill may be deposited to the full
height in one operation and levelled. If the fill has to be compacted, it
shall be placed in layers not exceeding 225 mm and levelled uniformly
and compacted as indicated in Clause 9.4 before the next layer is
deposited.
10.3 To ensure that the fill has been compacted as specified, field and
laboratory tests shall be carried out by the Contractor at his cost.
10.4 Field compaction test shall be carried out at different stages of filling
and also after the fill to the entire height has been completed. This
shall hold good for embankments as well.
10.5 The Contractor shall protect the earthfill from being washed away by
rain damaged in any other way. Should any slip occur, the Contractor
shall remove the affected material and make good the slip at his cost.
10.6 The fill shall be carried out to such dimensions and levels as indicated
on the drawings after the stipulated compaction. The fill will be
considered as incomplete if the desired compaction has not been
obtained.
10.7 If specifically permitted by the Engineer, compaction can be obtained
by allowing loaded trucks conveying fill or other material to ply over
the fill area. Even if such a method is permitted, it will be for the
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Contractor to demonstrate that the desired/ specified compaction has

been obtained. In order that the fill may be reasonably uniform
throughout, the material should be dumped in place in approximately
uniform layers. Traffic over the fill shall then be so routed to compact
the area uniformly throughout.
10.8 If so specified, the rock as obtained from excavation may be used for
filling and levelling to indicated grades without further breaking. In
such an event, filling shall be done in layers not exceeding 50 cms
approximately. After rock filling to the approximate level, indicated
above has been carried out, the void in the rocks shall be filled with
finer materials such as earth, broken stone, etc. and the area flooded so
that the finer materials fill up the voids. Care shall be taken to ensure
that the finer fill material does not get washed out. Over the layer so
filled, a 100 mm thick mixed layer of broken material and earth shall
be laid and consolidation carried out by a 12 tonne roller. No less than
twelve passes of the roller shall be accepted before subsequent similar
operations are taken up.
11. FILL DENSITY

11.1 The compaction, only where so called for, in the schedule of
quantities/ items shall comply with the specified (Standard Proctor/
Modified Proctor) density at moisture content differing not more than
4 percent from the optimum moisture content. The Contractor shall
demonstrate adequately at his cost, by field and laboratory tests that
the specified density has been obtained.
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SPEC. NO. TCE CONSULTING ENGINEER'S LTD SECTION : D40
TCE.5178A-418-02 TITLE
SPECIFICATION FOR SHEET 1 OF 1
TIMBER SHORING
1.0 SCOPE
This specification covers the general requirements of timber shoring for excavation of
trenches, pits, open excavations etc.
2.0 Close timbering shall be done by completely covering the sides of the trenches and pits
generally with short, upright members called 'polling boards'. These shall be of minimum
25 cm x 4 cm sections or as directed by Engineer. The boards shall generally be placed in
position vertically side by side without any gap on each side of the excavation and shall be
secured by horizontal walings of strong wood at maximum 1.2 metres spacings, strutted
with ballies or as directed by Engineer. The length of the ballie struts shall depend on the
width of the trench or pit. If the soil is very soft and loose, the boards shall be placed
horizontally against each side of the excavation and supported by vertical walings, which
in turn shall be suitably strutted. The lowest boards supporting the sides shall be taken into
the ground and no portion of the vertical side of the trench or pit shall remain exposed, so
as to render the earth liable to slip out.
2.1 Timber shoring shall be 'close' or 'open' type, depending on the nature of soil and the depth
of pit or trench. The type of timbering shall be as approved by Engineer. It shall be the
responsibility of Contractor to take all necessary steps to prevent the sides of excavations,
trenches, pits, etc., from collapsing.
2.2 Timber shoring may be required to keep the sides of excavations vertical to ensure safety
of adjoining structures or to limit the slope of excavations, or due to space restrictions or
for other reasons. Such shoring shall be carried out, except in an emergency, only under
instructions from Engineer.
2.3 The withdrawal of the timber shall be done very carefully to prevent the collapse of the pit
or trench. It shall be started at one end and proceeded with systematically to the other end.
Concrete or masonry shall not be damaged during the removal of the timber. No claim
shall be entertained for any timber which cannot be withdrawn and is lost or buried.
2.4 In the case of open timbering, the entire surface of the side of trench or pit is not required
to be covered. The vertical boards of minimum 25 cm x 4 cm sections shall be spaced
sufficiently apart to leave unsupported strips of maximum 50 cm average width. The
detailed arrangement, sizes of the timber and the spacings shall be subject to the approval
of Engineer. In all other respects, specification for close timbering shall apply to open
timbering.
2.5 In case of large pits and open excavations, where shoring is required for securing safety of
adjoining structures or for any other reasons and where the planking for sides of
excavations/pits cannot be strutted against, suitable inclined struts supported on the
excavated bed shall be provided. Load from such struts shall be suitably distributed on the
bed to ensure no yielding of the strut
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SPEC.NO. TCE CONSULTING ENGINEERS LTD SECTION: D41
TCE.5178A-418-03 TITLE
SHEET 1 OF 1
DEWATERING
1. SCOPE
This specification covers the general requirements of dewatering excavations

in general.
2.1. All excavations shall be kept free of water. Grading in the vicinity of
excavation shall be properly closed to prevent surface water running into
excavated areas. Contractor shall remove by pumping or other means
approved by Engineer any water inclusive of rain water and subsoil water
accumulated in excavation and keep all excavations dewatered until the
foundation work is completed and backfilled. Sumps made for dewatering
must be kept clear of the excavations / trenches required for further work.
Method of pumping shall be approved by Engineer; but in any case, the
pumping arrangement shall be such that there shall be no movement of
subsoil or blowing in due to differential head of water during pumping.
Pumping arrangements shall be adequate to ensure no delays in construction.
2.2. When there is a continuous inflow of water and quantum of water to be

handled is considered in the opinion of Engineer, as large, well point system
- Single stage or multi stage, shall be adopted. Contractor shall submit to
Engineer his scheme of well point system including the stages, the spacing,
number and diameter of well points, headers etc., and the numbers, capacity
and location of pumps of approvals.
2.3. The coal handling system includes construction of deep under ground
structure which will involve heavy dewatering during the construction. The
coal handling system being turnkey job, shall include the cost of dewatering
maintaining the level of water 1.0 m below the bottom of foundation level
during the construction and disposal of water at the location to be decided by
the ENGINEER.
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SPEC.NO. TCE CONSULTING ENGINEERS SECTION: D42
TITLE
TCE. 5178A-418-04 SHEET 1 OF 1
RAIN AND SURFACE WATER DRAINAGE
1. SCOPE
This section covers the drainage of rain and surface water in excavated areas.
2. Grading in the vicinity of excavation shall be such as to exclude rain /

surface water draining into excavated areas. Excavation shall be kept clean of
rain and such water as the Contractor may be using for his work by suitably
pumping out the same at no extra cost to the owner. The scheme for pumping
and discharge of such water shall be approved by the Engineer.
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TCE FORM 329 R3

.
TCE.5178A-403-01 TITLE SHEET 1 OF 26
CONCRETE AND ALLIED WORKS
1.0 SCOPE
1.1 This specification covers the general requirements for concrete using on-site
production facilities including requirements in regard to the quality, handling,
storage of ingredients, proportioning, batching, mixing, transporting, placing,
curing, protecting, repairing, finishing and testing of concrete; formwork;
requirements in regard to the quality, storage, bending and fixing of
reinforcement; grouting as well as mode of measurement and payment for
completed works
1.2 It shall be very clearly understood that the specifications given herein are brief
and do not cover minute details. However, all works shall have to be carried
out in accordance with the relevant standards and codes of practices or in their
absence in accordance with the best accepted current engineering practices or
as directed by ENGINEER from time to time. The decision of ENGINEER as
regards the specification to be adopted and their interpretation and the mode of
execution of work shall be final and binding on CONTRACTOR and no claim
whatsoever will be entertained on this account.
2.0 APPLICABLE CODES AND SPECIFICATIONS
2.1 The following specifications, standards and codes, including all official
amendments/revisions and other specifications & codes referred to therein,
should be considered a part of this specification. In all cases the latest
issue/edition/revision shall apply. In case of discrepancy between this
specification and those referred to herein below or other specifications
forming a part of this bid document, this specification shall govern.
2.2 MATERIALS
1 IS.269 Specification for 33 grade ordinary portland cement.
2 IS.455 Specification for portland slag cement.
3 IS.1489 (Part 1&2) Specification for portland-pozzolana cement.
4 IS: 8112 Specification for 43 grade ordinary portland cement.
5 IS:12269 Specification for 53 grade ordinary Portland Cement.
6 IS:12330 Specification for sulphate resisting Portland Cement.
7 IS:383 Specification for coarse and fine aggregates from natural sources
for concrete.
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8 IS:432 (Parts 1 & 2) Specification for mild steel and medium tensile steel
bars and hard-drawn steel wires for concrete reinforcement.
9 IS:1786 Specification for high strength deformed steel bars and wires for
concrete reinforcement.
10 IS:1566 Specification for hard-drawn steel wire fabric for concrete

reinforcement.
11 IS:9103 Specification for admixtures for concrete.
12 IS:2645 Specification for integral cement waterproofing compounds.
13 IS:4990 Specification for plywood for concrete shuttering work.
2.3 MATERIAL TESTING
1 IS:4031 (Parts 1 to 15) Methods of physical tests for hydraulic cement.
2 IS:4032 Method chemical analysis of hydraulic cement.
3 IS:650 Specification for standard sand for testing of cement.
4 IS:2430 Methods for sampling of aggregates for concrete.
5 IS.2386 (Parts 1 to 8) Methods of test for aggregates for concrete.
6 IS:3025 Methods of sampling and test (physical and chemical) water used
in industry.
7 IS:6925 Methods of test for determination of water soluble chlorides in

concrete admixtures.
2.4 MATERIAL STORAGE
1 IS:4082 Recommendations on stacking and storing of construction

materials at site.
2.5 CONCRETE MIX DESIGN
1 IS:10262 Recommended guidelines for concrete mix design.
2 SP:23 (S&T) Handbook on Concrete Mixes.
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2.6 CONCRETE TESTING
1 IS.1199 Method of sampling and analysis of concrete.
2 IS:516 Method of test for strength of concrete.
3 IS:9013 Method of making, curing and determining compressive strength

of accelerated cured concrete test specimens.
4 IS:8142 Method of test for determining setting time of concrete by

penetration resistance.
5 IS:9284 Method of test for abrasion resistance of concrete.
6 IS:2770 Methods of testing bond in reinforced concrete.
2.7 EQUIPMENT
1 IS:1791 Specification for batch type concrete mixers.
2 IS:2438 Specification for roller pan mixer.
3 IS:4925 Specification for concrete batching and mixing plant.
4 IS:5892 Specification for concrete transit mixers and agitator.
5 IS:7242 Specification for concrete spreaders.
6 IS:2505 General Requirements for concrete vibrators: Immersion type.
7 IS:2506 General Requirements for screed board concrete vibrators.
8 IS:2514 Specification for concrete vibrating tables.
9 IS:3366 Specification for pan vibrators.
10 IS:4656 Specification for form vibrators for concrete.
11 IS:11993 Code of practice for use of screed board concrete vibrators.
12 IS:7251 Specification for concrete finishers.
13 IS:2722 Specification for portable swing weigh batchers for concrete

(single and double bucket type).
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14 IS:2750 Specification for steel scaffoldings.
2.8 CODES OF PRACTICE
1 IS:456 Code of practice for plain and reinforced concrete.
2 IS:457 Code of practice for general construction of plain and reinforced

concrete for dams and other massive structures.
3 IS:3370 (Parts 1 to 4) Code of practice for concrete structures for storage
of liquids.
4 IS:3935 Code of practice for composite construction.
5 IS:2204 Code of practice for construction of reinforced concrete shell roof.
6 IS:2210 Criteria for the design of reinforced concrete shell structures and
folded plates.
7 IS:2502 Code of practice for bending and fixing of bars for concrete
reinforcement.
8 IS:5525 Recommendation for detailing of reinforcement in reinforced

concrete works.
9 IS:2751 Code of practice for welding of mild steel plain and deformed bars
used for reinforced concrete construction.
10 IS:9417 Specification for welding cold worked bars for reinforced

concrete construction.
11 IS:3558 Code of practice for use of immersion vibrators for consolidating

concrete.
12 IS:3414 Code of practice for design and installation of joints in buildings.
13 IS:4326 Code of practice for earthquake resistant design and construction

of building.
14 IS:4014 (Parts 1 & 2) Code of practice for steel tubular, scaffolding.
15 IS:2571 Code of practice for laying insitu cement concrete flooring.

16 IS:7861 Code of practice for extreme weather concreting.
Part 1 Recommended practice for hot weather concreting.

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Part 2 Recommended practice for cold weather concreting.
2.9 CONSTRUCTION SAFETY
1 IS.3696 (Parts 1& 2) Safety code for scaffolds and ladders.
2 IS:7969 Safety code for handling and storage of building materials.
3 IS:8989 Safety code for erection of concrete framed structures.
3.0 GENERAL
3.1 ENGINEER shall have the right at all times to inspect all operations including
the sources of materials, procurement, layout and storage of materials, the
concrete batching and mixing equipment, and the quality control system. Such
an inspection shall be arranged and ENGINEER's approval obtained, prior to
starting of concrete work. This shall, however, not relieve CONTRACTOR of
any of his responsibilities. All materials, which do not conform to this
specification, shall be rejected.
3.2 Materials should be selected so that they can satisfy the design requirements of
strength, serviceability, safety, durability and finish with due regards to the
functional requirements and the environmental conditions to which the
structure will be subjected. Materials complying with codes/standards shall
generally be used. Other materials may be used after approval of the
ENGINEER and after establishing their performance suitability based on
previous data, experience or tests.
4.0 MATERIALS
4.1 CEMENT
Cement shall be supplied by the OWNER at the rate specified in SECTION-F.
4.1.1 Unless otherwise called for by ENGINEER/OWNER, cement shall be

ordinary portland cement conforming to IS:269, IS:8112 or IS:12269.
4.2 AGGREGATES (GENERAL)
4.2.1 Aggregates for use in concrete works confirming to grading as per IS:383 shall
be used.
Sand for lean concrete, plastering, brick masonry, flooring work shall confirm
to IS codes having FM 1.56.
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Sand for filling shall be from near by location/pits as approved by

ENGINEER.
4.2.2 Aggregates shall consist of naturally occurring stones (crushed or uncrushed),

gravel and sand. They shall be chemically inert, strong, hard, clean, durable
against weathering, of limited porosity, free from dust/silt/ organic
impurities/deleterious materials and conform to IS:383. Aggregates such as
slag, crushed over burnt bricks, bloated clay ash, sintered fly ash and tiles shall
not be used.
4.2.3 Aggregates for special purposes shall be as specified by ENGINEER/OWNER
4.2.4 Aggregates shall be washed and screened before use where necessary or if
directed by the ENGINEER.
4.2.5 Aggregates containing reactive materials shall be used only after tests
conclusively prove that there will be no adverse affect on strength, durability
and finish, including long term effects, on the concrete.
4.2.6 The fineness modulus of sand shall neither be less than 2.2 nor more than 3.2.
4.2.7 The maximum size of coarse aggregate shall be as stated on the drawings but
in no case greater than 1/4 of the minimum thickness of the member.
4.2.8 Plums 160 mm and above of a reasonable size may be used where directed.
Plums shall not constitute more than 20% by volume of the concrete.
4.3 WATER
4.3.1 Water used for both mixing and curing shall conform to IS:456. Potable
waters are generally satisfactory. Water containing any excess of acid, alkali,
sugar or salt shall not be used.
4.4 REINFORCEMENT
4.4.1 Reinforcement bars shall conform to IS:432 or IS:1786 and welded wire fabric
to IS:1566 as shown or specified on the drawing.
4.4.2 All reinforcement shall be clean, free from pitting, oil, grease, paint, loose mill
scales, rust, dirty, dust, or any other substance that will destroy or reduce
bond.
4.4.3 If permitted by ENGINEER, welding of reinforcement shall be done in
accordance with IS:2751 or IS:9417 as applicable.
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4.5 ADMIXTURES
4.5.1 Accelerating, retarding, water-reducing and air entraining admixtures shall

conform to IS:9103 and integral water proofing admixtures to IS:2645.
4.5.2 Admixtures may be used in concrete as per manufacturer's instructions only

with the approval of ENGINEER based upon evidence that with the passage of
time neither the compressive strength nor its durability is reduced. An
admixture's suitability and effectiveness shall be verified by trial mixes with
the other materials used in the works. If two or more admixtures are to be used
simultaneously in the same concrete mix, their interaction shall be checked
and trail mixes done to ensure their compatibility. There should also be no
increase in risk of corrosion of the reinforcement or other embedments.
4.5.3 Calcium chloride shall not be used for accelerating set of the cement for any
concrete containing reinforcement or embedded steel parts. When calcium
chloride is permitted such as in mass concrete works, it shall be dissolved in
water and added to the mixing water by an amount not exceeding 1.5 percent
of the weight of the cement in each batch of concrete. The designed concrete
mix shall be corrected accordingly.
5.0 SAMPLES AND TESTS
5.1 All materials used for the works shall be tested before use.
5.2 Manufacturer's test certificate shall be furnished, for each batch of

cement/steel and when directed by ENGINEER samples shall also be got
tested by the CONTRACTOR in a laboratory approved by ENGINEER at no
extra cost to OWNER. However, where material is supplied by OWNER, all
testing charges shall be borne by OWNER, but transportation of material
samples to the laboratory shall have to be done by CONTRACTOR at no extra
cost.
5.3 Sampling and testing shall be as per IS:2386 under the supervision of
ENGINEER. The cost of all tests, sampling etc. shall be borne by
CONTRACTOR.
5.4 Water to be used shall be tested to comply with requirements of IS:456.
5.5 CONTRACTOR shall furnish manufacturer's test certificates and technical

literature for the admixture proposed to used. If directed the admixture shall be
got tested at an approved laboratory at no extra cost.
6.0 STORING OF MATERIALS

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6.1 All material shall be stored in a manner so as to prevent its deterioration and
contamination, which would preclude its use in the works. Requirements of
IS:4082 shall be complied with.
6.2 CONTRACTOR will have to make his own arrangements for the storage of
adequate quantity of cement even if cement is supplied by OWNER. If such
cement is not stored properly and has deteriorated, the material shall be
rejected. Cost of such rejected cement, where cement is supplied by OWNER,
shall be recovered as specified in General Conditions of Contract. Cement
bags shall be stored in dry weatherproof shed with a raised floor, well away
from the outer walls and insulated from the floor to avoid moisture from
ground. Not more than 10 bags shall be stacked in any tier. Storage
arrangement shall be approved by ENGINEER. Storage under tarpaulins shall
not be permitted. Each consignment of cement shall be stored separately and
consumed in its order of receipt.
6.3 Each size of coarse and fine aggregates shall be stacked separately and shall
be protected from leaves and contamination with foreign material. The stacks
shall be on hard, clean, free draining bases, draining away from the concrete
mixing area.
6.4 CONTRACTOR shall make his own arrangements for storing water at site in
tanks to prevent contamination.
6.5 The reinforcement shall be stacked on top of timber sleepers to avoid contact
with ground/water. Each type and size shall be stacked separately.
7.0 CONCRETE
7.1 GENERAL
7.1.1 Concrete grade shall be as designated on drawings. In concrete grade M15,

M20 etc. the number represents the specified characteristics compressive
strength of 150 mm cube at 28 days, expressed in N/sq.mm as per IS:456.
Concrete in the works shall be "DESIGN MIX CONCRETE" or "NOMINAL
MIX CONCRETE". All concrete works of grade M5, M7.5 and M10 shall be
NOMINAL MIX CONCRETE whereas all other grades, M15 and above, shall
be DESIGN MIX CONCRETE.
7.2 DESIGN MIX CONCRETE
7.2.1 Mix Design & Testing

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7.2.1.1 For Design Mix Concrete, the mix shall be designed according to IS:10262
and SP:23 to provide the grade of concrete having the required workability
and characteristic strength not less than appropriate values given in IS:456.
The design mix shall in addition to such that it is cohesive and does not
segregate and should result in a dense and durable concrete and also capable
of giving the finish as specified. For liquid retaining structures, the mix shall
also result in water tight concrete. The CONTRACTOR shall exercise great
care while designing the concrete mix and executing the works to achieve the
desired result.
7.2.1.2 Unless otherwise specifically by ENGINEER/OWNER the minimum cement

content for Design Mix Concrete shall be as per Appendix-A of IS:456 or as
given below, whichever is higher.
Grade of Concrete Minimum Cement Content in Kg/Cu.m of

Concrete
M15 300
M20 340
M25 360
The minimum cement content stipulated above shall be adopted irrespective of

whether the CONTRACTOR achieves the desired strength with less quantity
of cement. The CONTRACTOR's quoted rates for concrete shall provide for
the above eventuality and nothing extra shall become payable to the
CONTRACTOR on this account. Even in the case where the quantity of
cement required is higher than that specified above to achieve desired strength
based on an approved mix design, nothing extra shall become payable to the
CONTRACTOR.
7.2.1.3 It shall be CONTRACTOR's sole responsibility to carry out the mix designs at
his own cost. He shall furnish to ENGINEER at least 30 days before
concreting operations, a statement of proportions proposed to be used for the
various concrete mixes and the strength results obtained. The strength
requirements of the concrete mixes ascertained on 150 mm cubes as per
IS:516 shall comply with the requirements of IS:456.
Minimum Compressive Specified Characteristic

Grade of concrete strength N/Sq.mm at compressive strength
7 days N/Sq.mm at 28 days
M 15 10.0 15.0
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M 20 13.5 20.0
M 25 17.0 25.0
M 30 20.0 30.0
M 35 23.5 35.0
M 40 27.0 40.0
7.2.1.4 A range of slumps which shall generally be used for various types of
construction unless otherwise instructed by the ENGINEER is given below
Slump in millimeters
Structure/Member
Maximum Minimum
Reinforced foundation walls and footings 75 25
Plain footings, caissons and substructure walls 75 25
T.G. and massive compressor foundations 50 25
Slabs, Beams and reinforced walls 100 25
Pump & miscellaneous Equipment Foundations 75 25
Building columns 100 25
Pavements 50 25
Heavy mass construction 50 25
7.2.2 Batching & Mixing of Concrete
7.2.2.1 Proportions of aggregates and cement, as decided by the concrete mix design,
shall be by weight. These proportions shall be maintained during subsequent
concrete batching by means of weigh batchers capable of controlling the
weights within one percent of the desired value.
7.2.2.2 Amount of water added shall be such as to produce dense concrete of required
consistency, specified strength and satisfactory workability and shall be so
adjusted to account for moisture content in the aggregates. Water- cement ratio
specified for use by ENGINEER shall be maintained. Each time the work
stops, the mixer shall be cleaned out, and while recommencing, the first batch
shall have 10% additional cement to allow for sticking in the drum.
7.2.2.3 Arrangement should be made by CONTRACTOR to have the cubes tested in

an approved laboratory or in field at his own expense, with prior consent of
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ENGINEER. Sampling and testing of strength and workability of concrete

shall be as per IS:1199, IS:516 and IS:456.
7.3 NOMINAL MIX CONCRETE
7.3.1 Mix Design & Testing
7.3.1.1 Mix design and preliminary tests are not necessary for Nominal Mix Concrete.
However works tests shall be carried out as per IS:456. Proportions for
Nominal Mix Concrete and w/c ratio may be adopted as per Table 3 of IS:456.
However it will be CONTRACTOR's sole responsibility to adopt appropriate
nominal mix proportions to yield the specified strength.
7.3.2 Batching & Mixing of Concrete
7.3.2.1 Based on the adopted nominal mixes, aggregates shall be measured by

volume. However cement shall be by weight only.
8.0 FORMWORK
8.1 Formwork shall be all inclusive and shall consist of but not limited to shores,
bracings, sides of footings, walls, beams and columns, bottom of slabs etc.
including ties, anchors, hangers, inserts, falsework, wedges etc.
8.2 The design and engineering of the formwork as well as its construction shall
be the responsibility of CONTRACTOR. However, if so desired by
ENGINEER the drawings and calculations for the design of the formwork
shall be submitted to ENGINEER for approval.
8.3 Formwork shall be designed to fulfill the following requirements :
a) Sufficiently rigid and tight to prevent loss of grout or mortar from the
concrete at all stages and appropriate to the methods of placing and
compacting.
b) Made of suitable materials.
c) Capable of providing concrete of the correct shape and surface finish

within the specified tolerance limit.
d) Capable of withstanding without deflection the worst combination of

selfweight, reinforcement and concrete weight, all loads and dynamic
effects arising from construction and compacting activities, wind and
weather forces.
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e) Capable of easily striking without shock, disturbance or damage to the

concrete.
f) Soffit forms capable of imparting a camber if required.
g) Soffit forms and supports capable of being left in position if required.
h) Capable of being cleaned and/or coated if necessary immediately prior to

casting the concrete; design temporary openings where necessary for
these purposes and to facilitate the preparation of construction joints.
8.4 The formwork may be of timber, plywood, steel, plastic or concrete depending
upon the type of finish specified. Sliding forms and slip form may be used
with the approval of ENGINEER. Timber for formwork shall be well
seasoned, free from sap, shakes, loose knots, worm holes, warps and other
surface defects. Joints between formwork and formwork and between
formwork and structures shall be sufficiently tight to prevent loss of slurry
from concrete, using seals if necessary.
8.5 The faces of formwork coming in contact with concrete shall be cleaned and
two coats of approved mould oil applied before fixing reinforcement. All
rubbish, particularly chippings, shavings, sawdust, wire pieces dust etc. shall
be removed from the interior of the forms before the concrete is placed. Where
directed, cleaning of forms shall be done by blasting with a jet of compressed
air at no extra cost.
8.6 Forms intended for reuse shall be treated with care. Forms that have
deteriorated shall not be used. Before reuse, all forms shall be thoroughly
scraped, cleaned, nails removed, holes suitably plugged, joints repaired and
warped lumber replaced to the satisfaction of ENGINEER. CONTRACTOR
shall equip himself with enough shuttering to allow for wastage so as to
complete the job in time.
8.7 Permanent formwork shall be checked for its durability and compatibility with
adjoining concrete before it is used in the structure. It shall be properly
anchored to the concrete.
8.8 Wire ties passing through beams, columns and walls shall not be allowed. In
their place bolts passing through sleeves shall be used. Formwork spacers left
in situ shall not impair the desired appearance or durability of the structure by
causing spalling, rust staining or allowing the passage of moisture.
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8.9 For liquid retaining structures sleeves shall not be provided for through bolts
nor shall through bolts be removed if provided. The bolts, in the latter case,
shall be cut at 25 mm depth from the surface and the hole made good by
cement mortar of the same proportion as the concrete just after striking the
formwork.
8.10 Where specified or shown on drawings all corners and angles exposed in the
finished structure shall have chamfers or fillets of 20 mm x 20 mm size.
8.11 Forms for substructure may be omitted when, in the opinion of ENGINEER,
the open excavation is firm enough (in hard non-porous soils) to act as a form.
Such excavations shall be slightly larger, as directed by ENGINEER, than that
required as per drawing to compensate for irregularities in excavation.
8.12 CONTRACTOR shall provide adequate props carried down to a firm bearing
without overloading any of the structures.
8.13 The shuttering for beams and slabs shall be so erected that the side shuttering
of beams can be removed without disturbing the bottom shuttering. If the
shuttering for a column is erected for the full height of the column, one side
shall be built up in sections as placing of concrete proceeds or windows left
for placing concrete from the side to limit the drop of concrete to 1.0m or as
directed by ENGINEER. CONTRACTOR shall temporarily and securely fix
items to be cast in (embedments/ inserts) in a manner that will not hinder the
striking of forms or permit loss of grout.
8.14 Formwork showing excessive distortion, during any stage of construction,

shall be repositioned and strengthened. Placed concrete affected by faulty
formwork, shall be entirely removed and formwork corrected prior to
placement of new concrete at CONTRACTOR's cost.
8.15 The striking time for formwork shall be determined based on the following
requirements :
a) Development of adequate concrete strength;
b) Permissible deflection at time of striking form work;
c) Curing procedure employed - its efficiency and effectiveness;
d) Subsequent surface treatment to be done;
e) Prevention of thermal cracking at re-entrant angles;
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f) Ambient temperatures; and
g) aggressiveness of the environment (unless immediate adequate steps are

taken to prevent damage to the concrete).
8.16 Under normal circumstances (generally where temperatures are above 20

Deg.C) forms may be struck after expiry of the time period given in IS:456
unless directed otherwise by ENGINEER. For Portland Pozzolana/slag
cement the stripping time shall be suitably modified as directed by the
ENGINEER. It is the CONTRACTOR'S responsibility to ensure that forms
are not struck until the concrete has developed sufficient strength to support
itself, does not undergo excessive deformation and resist surface damage and
any stresses arising during the construction period.
9.0 REINFORCEMENT WORKMANSHIP
9.1 Reinforcing bars supplied bent or in coils shall be straightened cold without
damage at no extra cost. No bending shall be done when ambient temperature
is below 5 Deg.C. Local warming may be permitted if steel is kept below 100
Deg.C.
9.2 All bars shall be accurately bent gradually and according to the sizes and
shapes shown on the drawings/ schedules or as directed by ENGINEER.
9.3 Re-bending or straightening incorrectly bent bars shall not be done without
approval of ENGINEER.
9.4 Reinforcement shall be accurately fixed and maintained firmly in the correct
position by the use of blocks, spacers, chairs, binding wire etc. to prevent
displacement during placing and compaction of concrete. The tied inplace
reinforcement shall be approved by ENGINEER prior to concrete placement.
Spacers shall be of such materials and designs as will be durable, not lead to
corrosion of the reinforcement and not cause spalling of the concrete cover.
9.5 Binding wire shall be 16 gauge soft annealed wire. Ends of the binding wire
shall be bent away from the concrete surface and in no case encroach into the
concrete cover. 9.6 Substitution of reinforcement, laps/splices not shown on
drawing shall be subject to ENGINEER's approval.
10.0 TOLERANCES
10.1 Tolerance for formed and concrete dimensions shall be as per IS:456 unless
specified otherwise.
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10.2 Tolerances specified for horizontal or vertical building lines or footings shall
not be constructed to permit encroachment beyond the legal boundaries.
11.0 PREPARATION PRIOR TO CONCRETE PLACEMENT
11.1 Before concrete is actually placed in position, the inside of the formwork shall
be cleaned and mould oil applied, inserts and reinforcement shall be correctly
positioned and securely held, necessary openings, pockets, etc. provided.
11.2 All arrangements-formwork, equipment and proposed procedure, shall be

approved by ENGINEER. CONTRACTOR shall maintain separate Pour Card
for each pour as per the format enclosed.
12.0 TRANSPORTING, PLACING AND COMPACTING CONCRETE
12.1 Concrete shall be transported from the mixing plant to the formwork with
minimum time lapse by methods that shall maintain the required workability
and will prevent segregation, loss of any ingredients or ingress of foreign
matter or water.
12.2 In all cases concrete shall be deposited as nearly as practicable directly in its
final position. To avoid segregation, concrete shall not be rehandled or caused
to flow. For locations where direct placement is not possible and in narrow
forms CONTRACTOR shall provide suitable drops and "Elephant Trunks".
Concrete shall not be dropped from a height of more than 1.0m as stipulated in
clause 8.13.
12.3 Concrete shall not be placed in flowing water. Under water, concrete shall be
placed in position by tremies or by pipeline from the mixer and shall never be
allowed to fall freely through the water.
12.4 While placing concrete the CONTRACTOR shall proceed as specified below
and also ensure the following :
a) Continuously between construction joints and predetermined abutments.
b) Without disturbance to forms or reinforcement.
c) Without disturbance to pipes, ducts, fixings and the like to be cast in; ensure
that such items are securely fixed. Ensure that concrete cannot enter open
ends of pipes and conduits etc.
d) Without dropping in a manner that could cause segregation or shock.
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e) In deep pours only when the concrete and formwork designed for this
purpose and by using suitable chutes or pipes.
f) Do not place if the workability is such that full compaction cannot be

achieved.
g) Without disturbing the unsupported sides of excavations; prevent

contamination of concrete with earth. Provide sheeting if necessary. In
supported excavations, withdraw the linings progressively as concrete is
placed.
h) If placed directly onto hardcore or any other porous material, dampen the
surface to reduce loss of water from the concrete.
i) Ensure that there is no damage or displacement to sheet membranes.
j) Record the time and location of placing structural concrete.
12.5 Concrete shall normally be compacted in its final position within thirty
minutes of leaving the mixer. Concrete shall be compacted during placing with
approved vibrating equipment without causing segregation until it forms a
solid mass free from voids thoroughly worked around reinforcement and
embedded fixtures and into all corners of the formwork. Immersion vibrators
shall be inserted vertically at points not more than 450 mm apart and
withdrawn slowly till air bubbles cease to come to the surface, leaving no
voids. When placing concrete in layers advancing horizontally, care shall be
taken to ensure adequate vibration, blending and melding of the concrete
between successive layers. Vibrators shall not be allowed to come in contact
with reinforcement, formwork and finished surfaces after start of initial set.
Over-vibration shall be avoided.
12.6 Concrete may be conveyed and placed by mechanically operated equipment

after getting the complete procedure approved by ENGINEER. The slump
shall be held to the minimum necessary for conveying concrete by this
method. When concrete is to be pumped, the concrete mix shall be specially
designed to suit pumping. Care shall be taken to avoid stoppages in work once
pumping has started.
12.7 Except when placing with slip forms, each placement of concrete in multiple
lift work, shall be allowed to set for at least 24 hours after the final set of
concrete before the start of subsequent placement. Placing shall stop when
concrete reaches the top of the opening in walls or bottom surface of slab, in
slab and beam construction, and it shall be resumed before concrete takes
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initial set but not until it has had time to settle as determined by ENGINEER.
Concrete shall be protected against damage until final acceptance.
13.0 MASS CONCRETE WORKS
13.1 Sequence of pouring for mass concrete works shall be as approved by

ENGINEER. CONTRACTOR shall exercise great care to prevent shrinkage
cracks and shall monitor the temperature of the placed concrete if directed.
14.0 CURING
14.1 Curing and protection shall start immediately after the compaction of the
concrete to protect it from :
a) Premature drying out, particularly by solar radiation and wind;
b) leaching out by rain and flowing water;
c) rapid cooling during the first few days after placing;
d) high internal thermal gradients;
e) low temperature or frost;
f) vibration and impact which may disrupt the concrete and interfere with its
bond to the reinforcement.
14.2 All concrete, unless directed otherwise by ENGINEER, shall be cured by use
of continuous sprays or ponded water or continuously saturated coverings of
sacking, canvas, hessain or other absorbent material for the period of complete
hydration with a minimum of 7 days. The quality of curing water shall be the
same as that used for mixing.
14.3 Where a curing membrane is directed to be used by the ENGINEER, the same
shall be of a non-wax base and shall not impair the concrete finish in any
manner. The curing compound to be used shall be got approved from the
ENGINEER before use and shall be applied with spraying equipment capable
of a smooth, even textured coat.
14.4 Curing may also be done by covering the surface with an impermeable
material such as polyethylene, which shall be well sealed and fastened.
14.5 Extra precautions shall be exercised in curing concrete during cold and hot
weather.
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15.0 CONSTRUCTION JOINTS AND KEYS
15.1 Construction joints will be as shown on the drawing or as approved by

ENGINEER. Concrete shall be placed without interruption until completion of
work between construction joints. If stopping of concreting becomes
unavoidable anywhere, a properly formed construction joint shall be made
with the approval of ENGINEER.
15.2 Dowels for concrete work, not likely to be taken up in the near future, shall be
coated with cement slurry and encased in lean concrete as indicated on the
drawings or as directed by ENGINEER.
15.3 Before resuming concreting on a surface which has hardened all laitance and
loose stone shall be thoroughly removed by wire brushing/hacking and surface
washed with high pressure water jet and treated with thin layer of cement
slurry for vertical joints and a 15mm thick layer of cement sand mortar for
horizontal layers, the ratio of cement and sand being the same as in the
concrete mix.
15.4 When concreting is to be resumed on a surface which has not fully hardened,
all laitance shall be removed by wire brushing, the surface wetted, free water
removed and a coat of cement slurry applied. On this a layer of concrete not
exceeding 150 mm thickness shall be placed and well rammed against the old
work. Thereafter work shall proceed in the normal way.
16.0 FOUNDATION BEDDING
16.1 All earth surfaces upon which or against which concrete is to be placed, shall
be well compacted and free from standing water, mud or debris. Soft or
spongy area shall be cleaned out and back filled with either soil-cement
mixture, lean concrete or clean sand compacted as directed by ENGINEER.
The surfaces of absorptive soils shall be moistened.
16.2 Concrete shall not be deposited on large sloping rock surfaces. The rock shall
be cut to form rough steps or benches by picking, barring or wedging. The
rock surface shall be kept wet for 2 to 4 hours before concreting.
17.0 FINISHES
17.1 GENERAL
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17.1.1 The formwork for concrete works shall be such as to give the finish as
specified. The CONTRACTOR shall make good any unavoidable defects as
directed consistent with the type of concrete and finish specified; defects due
to bad workmanship (e.g. damaged or misaligned forms, defective or poorly
compacted concrete) will not be accepted. CONTRACTOR shall construct the
formwork using the correct materials and to meet the requirements of the
design and to produce finished concrete to required dimensions, plumbs,
planes and finishes.
17.2 Surface Finish Type F1
17.2.1 This type of finish shall be for non-exposed concrete surfaces against which
back fill or concrete is to be placed. The main requirement is that of dense,
well compacted concrete. No treatment is required except repair of defective
areas, filling all form tie holes and cleaning up of loose or adhering debris. For
surfaces below grade which will receive waterproofing treatment the concrete
shall be free of surface irregularities which would interfere with proper and
effective application of waterproofing material specified for use.
17.3.1 This type of finish shall be for all concrete work which will be exposed to
view upon completion of the job. The appearance shall be that of a smooth
dense, well- compacted concrete showing the slight marks of well fitted
shuttering joints. The CONTRACTOR shall make good any blemishes.
17.4.1 This type of finish shall be for concrete work which will be exposed to view
but to give an appearance of smooth, dense, well-compacted concrete with no
shutter marks, stain free and with no discolouration, blemishes, arrises,
airholes etc. Only lined or coated plywood with very tight joints shall be used
to achieve this finish. The panel size shall be uniform and as large as
practicable. Any minor blemishes that might occur shall be made good by
CONTRACTOR.
17.5 INTEGRAL CEMENT FINISH ON CONCRETE FLOOR
17.5.1 In all cases where integral cement finish on a concrete floor has been
specified, the top layer of concrete shall be screeded off to proper level and
tamped with tamper having conical projections so that the aggregate shall be
forced below the surface. The surface shall be finished with a wooden float
and a trowel with pressure. The finish shall be continued till the concrete
reaches its initial set. No cement or cement mortar finish shall be provided on
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the surface. Where specified, a floor hardener as approved by the ENGINEER

shall be supplied and used as recommended by the manufacturer.
18.0 REPAIR AND REPLACEMENT OF UNSATISFACTORY CONCRETE
18.1 Immediately after the shuttering is removed, all the defective areas such as
honey-combed surfaces, rough patches, holes left by form bolts etc. shall be
brought to the notice of ENGINEER who may permit patching of the defective
areas or reject the concrete work.
18.2 All through holes for shuttering shall be filled for full depth and neatly
plugged flush with surface.
18.3 Rejected concrete shall be removed and replaced by CONTRACTOR at no

additional cost to OWNER.
18.4 For patching of defective areas all loose materials shall be removed and the
surface shall be prepared as directed by the ENGINEER.
18.5 Bonding between hardened and fresh concrete shall be done either by placing
cement mortar or by applying epoxy. The decision of the ENGINEER as to the
method of repairs to be adopted shall be final and binding on the
CONTRACTOR and no extra claim shall be entertained on this account. The
surface shall be saturated with water for 24 hours before patching is done with
1:5 cement sand mortar. The use of epoxy for bonding fresh concrete shall be
carried out as directed by ENGINEER.
19.0 VACUUM DEWATERING OF SLABS
19.1 Where specified floor slabs, either or grade or suspended, shall be finished by
vacuum dewatering including all operations such as poker vibration, surface
vibration, vacuum processing, floating and trowelling as per equipment
manufacturers recommendation. The equipment to be used shall be subject to
ENGINEER's approval.
20.0 HOT WEATHER REQUIREMENTS
20.1 Concreting during hot weather shall be carried out as per IS:7861 (Part I).
20.2 Adequate provisions like pre-cooling of aggregates, use of ice etc, shall be
made to lower concrete temperature which shall not exceed 40C at the time
of placement of fresh concrete.
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20.3 Where directed by ENGINEER, CONTRACTOR shall spray non- wax based
curing compound on unformed concrete surfaces at no extra costs.
21.0 COLD WEATHER REQUIREMENTS
21.1 Concreting during cold weather shall be carried out as per IS:7861 (Part 2)
21.2 The ambient temperature during placement and upto final set shall not fall
below 5 Deg C. Approved anti- freeze/accelerating additives shall be used
where directed.
21.3 For major and large scale concreting works the temperature of concrete at
times of mixing and placing, the thermal conductivity of the formwork and its
insulation and stripping period shall be closely monitored.
22.0 LIQUID RETAINING STRUCTURES
22.1 The CONTRACTOR shall take special care for concrete for liquid retaining
structures, underground structures and those others specifically called for to
guarantee the finish and water tightness.
22.2 The minimum level of surface finish for liquid retaining structures shall be
Type F2. All such structures shall be hydro-tested.
22.3 The CONTRACTOR shall include in his price of hydro- testing of structure,
all arrangements for testing such as temporary bulk heads, pressure gauges,
pumps, pipe lines etc.
22.4 Any temporary arrangements that may have to be made to ensure stability of
the structures shall also be considered to have been taken into account while
quoting the rates.
22.5 Any leakage that may occur during the hydro-test or subsequently during the
defects liability period or the period for which the structure is guaranteed shall
be effectively stopped either by cement/epoxy pressure grouting, guniting or
such other methods as may be approved by the ENGINEER. All such
rectification shall be done by the CONTRACTOR to the entire satisfaction of
the OWNER/ENGINEER at no extra cost to the OWNER.
22.6 All construction materials brought to the site shall be used only after getting
the approval of ENGINEER-IN-CHARGE of testing laboratory.
23.0 TESTING CONCRETE STRUCTURES FOR LEAKAGE
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23.1 Hydrostatic test for water tightness shall be done at full storage level or soffit
of cover slab, as may be directed by ENGINEER, as described below :
a) In case of structures whose external faces are exposed, such as elevated
tanks, the requirements of the test shall be deemed to be satisfied if the
external faces show no sign of leakage or sweating and remain completely dry
during the period of observation of seven days after allowing a seven day
period for absorption after filling with water.
b) In the case of structures whose external faces are submerged and are not
accessible for inspection, such as underground tanks, the structures shall be
filled with water and after the expiry of seven days after the filling, the level of
the surface of the water shall be recorded. The level of water shall be recorded
again at subsequent intervals of 24 hrs. over a period of seven days.
Backfilling shall be withheld till the tanks are tested. The total drop in surface
level over a period for seven days shall be taken as an indication of the
watertightness of the structure. The ENGINEER shall decide on the actual
permissible nature of this drop in the surface level, taking into account
whether the structures are open or closed and the corresponding effect it has
on evaporation losses. Unless specified otherwise, a structure whose top is
covered shall be deemed to be water tight if the total drop in the surface level
over a period of seven days does not exceed 40 mm.
c) Each compartment/segment of the structure shall be tested individually and

then all together.
23.2 For structures such as pipes, tunnels etc. the hydrostatic test shall be carried
out by filling with water, after curing as specified, and subjecting to the
specified test pressure for specified period. If during this period the loss of
water does not exceed the equivalent of the specified rate, the structure shall
be considered to have successfully passed the test.
24.0 OPTIONAL TESTS
24.1 If the ENGINEER feels that the materials i.e. cement, sand, coarse aggregates,
reinforcement and water are not in accordance with the specifications or if
specified concrete strengths are not obtained, he may order tests to be carried
out on these materials in laboratory, to be approved by the ENGINEER, as per
relevant IS Codes. OWNER shall pay only for the testing of material supplied
by the OWNER, otherwise CONTRACTOR shall have to pay for the tests.
Transporting of all material to the laboratory shall however be done by the
CONTRACTOR at no extra cost to OWNER.
24.2 In the event of any work being suspected of faulty material or workmanship
requiring its removal or if the works cubes do not give the stipulated strengths,
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ENGINEER reserves the right to order the CONTRACTOR to take out cores
and conduct tests on them or do ultrasonic testing or load testing of structure,
etc. All these tests shall be carried out by CONTRACTOR at no extra cost to
the OWNER. Alternately ENGINEER also reserves the right to ask the
CONTRACTOR to dismantle and re-do such unacceptable work at the cost of
CONTRACTOR.
24.3 If the structure is certified by ENGINEER as having failed, the cost of the test
and subsequent dismantling/ reconstruction shall be borne by
CONTRACTOR.
25.0 GROUTING
25.1 Grout shall be provided as specified on the drawings. The proportion of

Standard Grout shall be such as to produce a flowable mixture consistent with
minimum water content and shrinkage. Surfaces to be grouted shall be
thoroughly roughened and cleaned. All structural steel elements to be grouted
shall be cleaned of oil, grease, dirt etc. The use of hot, strong caustic solution
for this purpose will be permitted. Prior to grouting, the hardened concrete
shall be saturated with water and just before grouting water in all pockets shall
be removed. Grouting once started shall be done quickly and continuously.
Variation in grout mixes and procedures shall be permitted if approved by
ENGINEER. The grout proportions shall be limited as follows:
W/C
Use Grout Thickness Mix Proportions Ratio
(max)
One part Portland cement to
a) Fluid mix Under 25 mm 0.44
one part sand.
25 mm and over but One part Portland Cement to 2
b) General mix 0.53
less than 50 mm parts of sand.
One part Portland Cement to 3
c) Stiff mix 50 mm and over 0.53
parts of sand.
25.2 NON-SHRINK GROUT
25.2.1 Non-shrink grout where called for in the Schedule of Quantities or specified
on the drawings shall be provided in strict accordance with the manufacturer's
instructions/specifications on the drawings.
26.0 INSPECTION
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26.1 All materials, workmanship and finished construction shall be subject to

continuous inspection and approval of ENGINEER. Materials rejected by
ENGINEER shall be expressly removed from site and shall be replaced by
CONTRACTOR immediately at no extra cost to OWNER.
27.0 CLEAN-UP
27.1 Upon the completion of concrete work, all forms, equipment, construction
tools, protective coverings and any debris, scraps of wood, etc. resulting from
the work shall be removed and the premises left clean.
28.0 ACCEPTANCE CRITERIA
28.1 Any concrete work shall satisfy the requirements given below individually and
collectively for it to be acceptable.
a) properties of constituent materials;
b) characteristic compressive strength;
c) specified mix proportions;
d) minimum cement content;
e) maximum free-water/cement ratio;
f) workability;
g) temperature of fresh concrete;
h) density of fully compacted concrete;
i) cover to embedded steel;
j) curing;
k) tolerances in dimensions;
l) tolerances in levels;
m) durability;
n) surface finishes;
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o) special requirements such as;

i) water tightness;
ii) resistance to aggressive chemicals
iii) resistance to freezing and thawing
iv) very high strength
v) improved fire resistance
vi) wear resistance
vii) resistance to early thermal cracking
28.2 The ENGINEER's decision as to the acceptability or otherwise of any concrete

work shall be final and binding on the CONTRACTOR.
28.3 For work not accepted, the ENGINEER may review and decide whether
remedial measures are feasible so as to render the work acceptable. The
ENGINEER shall in that case direct the CONTRACTOR to undertake and
execute the remedial measures. These shall be expeditiously and effectively
implemented by the CONTRACTOR. Nothing extra shall become payable to
the CONTRACTOR by the OWNER for executing the remedial measures.
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CONCRETE POUR CARD
CLIENT: DATE: POUR NO

PROJECT: STRUCTURE:
CONTRACTOR: MAX AGGREGATE SIZE/SLUMP: MM/ MM
DRG. NO.: START/COMPLETION TIME: /
CONCRETE GRADE/QUANTITY: M / m3 MIXING TIME:
SL. CONTRACTORS ENGINEERS
ITEM REMARKS
NO. REP. SIGNATURE SIGNATURE
1 CENTERLINES CHECKED
FORMWORK AND STAGING CHECKED FOR
2
ACCURACY, STRENGTH & FINISH
BEFORE CONCRETING
3 REINFORCEMENT CHECKED
4 COVER TO REINFORCEMENT CHECKED
VERIFIED TEST CERTIFICATE FOR
5 YES/NO YES/NO
CEMENT/STEEL
ADEQUACY OF MATERIALS/EQUIPMENT
6 YES/NO YES./NO
FOR POUR
EMBEDDED
PARTS CIVIL
CHECKED
7 MECHANICAL
(LOCATION AND PLUMB)

ELECTRICAL
POUR AUTHORISED SITE ENGINEER

SOFFIT(S) AND POUR TOP(T) LEVELS S(B) T(B)
CHECKED BEFORE(B) AND AFTER(A) FORM
8
REMOVAL (ONLY OF OVER 10M SPAN AND
IMPORTANT STRUCTURES LIKE T.G. ETC.) S(A) T(A)
CONSTRUCTION JOINT LOCATION AND
9 TIME (IF NOT AS PER DRAWING)
CEMENT CONSUMPTION IN KGS
10
NUMBER OF CUBES AND IDENTIFICATION

11 BANKS
TEST CUBE RESULTS (7 DAYS / 28 DAYS)
12 /
CONCRETE CONDITION ON FORM

13 REMOVAL V. GOOD / GOOD / FAIR
SITE-IN-CHARGE
NOTES:
1. EACH ITEM TO BE CHECKED & SIGNED BY THE RESPECTIVE ENGINEER/SITE-IN-CHARGE.
2. ITEMS 8 TO 13 (BOTH INCLUSIVE) TO BE FILLED BY ONLY ENGINEER.
3. EACH POUR TO HAVE SEPARATE CARDS, IN TRIPLICATE ONE EACH FOR CLIENT, TCE & SITE
OFFICE.
4. UNDER REMARKS INDICATE DEVIATIONS FROM DWGS. & SPECIFICATIONS, CONGESTION IN
REINFORCEMENT.
IF ANY, UNUSUAL OCCURENCES, SUCH AS FAILURE OF EQUIPMENTS, SINKING OF

SUPPORTS/PROPS. HEAVY RAINS AFFECTING CONCRETING, POOR COMPACTION, IMPROPER
CURING, OTHER DEFFICIENCES, OBSERVATIONS ETC.
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TCE.5178A-419 SHEET 1 OF17

SPECIFICATION FOR WATER SUPPLY AND
SANITARY WORKS
1.0 SCOPE
1.1 This specification covers the general requirements for supplying and laying of
water supply pipe line with necessary fittings and fixtures for
buildings/structures tapping off from potable water supply
distribution system, supplying and laying sewage pipe line with disposal
works including provision of all fittings and fixtures of sanitary works and
such other related items of work forming a part of the 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, plants,
labour, materials, and any and everything necessary for satisfactorily
carrying out the work.
2.0 APPLICABLE CODES
2.1 The following standards and codes are made a part of this specification. All
standards, codes of practice referred to herein shall be the latest editions
including all official amendments and revisions.
1. IS.458 : Concrete Pipes (with and without

reinforcement).
2. IS.554 : Dimensions for pipe threads where

pressure tight joints are required on
the threads.
3. IS.651 : Salt glazed stoneware pipes and

fittings.
4. IS.774 : Flushing Cisterns for water closets and

urinals (valveless siphonic type)
5. IS.775 : Cast iron brackets and supports for wash

basins and sinks.
6. IS.781 : Sand-cast brass screw-down bib taps and

stop taps for water services.
7. IS.783 : Code of practice for laying of concrete pipes.
8. IS.1068 : Electroplated coatings of nickel and

chromium on iron and steel.
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9. IS.1239 : Mild steel tubes (Part I) and mild steel

tubulars and other wrought steel pipe
fittings (Part II).
10. IS.1536 : Centrifugally cast (spun) iron pressurepipes

for water, gas and sewage.
11. IS.1626 : Asbestos cement building pipes,

gutters and fittings (spigot and socket types).
12. IS.1703 : Ball valves (horizontal plunger type) including

floats for water supply purposes.
13. IS.1726 : Cast iron manhole covers and frames.
14. IS.1729 : Sand cast iron spigot and socket soil, waste
and ventilating pipes, fittings and accessories.
15. IS.1742 : Code of practice for buildings drainage.
16. IS.2326 : Automatic flushing cisterns for urinals.
17. IS.2470 : Code of practice for design and

construction of septic tanks.
18. IS.2556 : Vitreous sanitary appliances (Part I to

Part XV)
19. IS.2963 : Non-ferrous waster fittings for wash

basins and sinks.
20. IS.3311 : Waste plug and its accessories for sinks

and wash basins.
21. IS.5329 : Code of practice for sanitary pipe work

above ground for buildings.
22. IS.5434 : Non-ferrous alloy bottle traps for

marine use.
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3.0 DRAWINGS
3.1 Drawings released for construction showing locations of sanitary and water
supply fixtures will be furnished to the CONTRACTOR and drawings so
furnished shall form a part of this specification. Drawing will also furnish
the details of one or more supply points outside the building for the water
supply system and disposal point/ scheme for sanitary works. The
CONTRACTOR shall refer to these drawings for all information contained
therein which pertains to details as required for this work. CONTRACTOR
shall submit to OWNER/ENGINEER for his approval, detailed working
drawings showing layout of water supply and sanitary works with necessary
fittings and fixtures before the actual construction is undertaken.
3.2 All civil works will be measured and paid under respective items of work.
4.0 SANITARY INSTALLATION
4.1 The work shall be carried out complying in all respects with any specific
requirements of the local body in whose jurisdiction the work is situated,
and as approved by the Owner/ Engineer. No extra payment shall be made for
such work except when there is any item specifically included for such work in
schedule.
4.2 Any damage caused to the building, or to installations therein, either due to
negligence on the part of the Contractor, or due to actual requirements of the
work, shall be made good and the building or the installation shall be
restored to its original condition by the Contractor
4.3 All sanitary and plumbing work shall be carried out by licensed plumbers.
4.4 On completion of the work, the site shall be cleaned and disposed of all debris
as directed by the Engineer.
4.5 All sanitary appliances including sanitary fittings, fixtures, toilet requisites
shall be of size, and design as specified in the item of work and as per
sample approved by the Engineer.
4.6 All sanitary fittings and fixtures shall be acceptable to the Owner/Engineer
and if there are any variations, they shall satisfy the permissible tolerances
in dimensions/slope/ contour as specified in relevant IS codes/ standards.
4.7 All white glazed porcelain fixtures, such as wash basin, sink drain board,
water closet pan, urinal, `P' trap etc. shall have hard durable white glazed
finish. They shall be free from cracks, indentations, or other glazing
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defects. No chipped porcelain fixtures shall be used. Joints between iron and
earthenware pipes shall be made perfectly air and water tight by caulking with
neat cement mortar.
4.8 INDIAN TYPE WATER CLOSET (W.C.)
This shall be the long pan pattern with separate footrests made of white
glazed earthenware, white glazed vitreous china or of white glazed fire clayThe
general requirements shall conform to IS.2556 (Parts III and X). Each pan
shall have an integral flushing rim of suitable type. It shall also have an inlet
or supply horn for connecting the flush pipe. The flushing rim and inlet
shall be of the self draining type. It shall have a weephole at the flushing
inlet to the pan. The flushing inlet shall be in the front, unless otherwise
specified or ordered by the Engineer. The inside of the bottom of pan shall
have sufficient slope from the front towards the outlet and the surface shall be
uniform and smooth enable easy and quick disposal while flushing. The
exterior surface shall be unglazed and sufficiently rough or grooved at right
angles to the axis of the outlet. Pans shall be provided with a trap `P' or `S'
type with a minimum 50 mm water seal and 50 mm dia. vent horn. Pan shall be
laid at the correct location and level over a bed of lime concrete using brick
aggregates (1 part lime mortar to 2 parts brick bats with lime mortar of 1
part lime to 2 parts of sand) or cement-sand admixture as specified in the
drawings.
4.9 EUROPEAN TYPE WATER CLOSET (W.C)
Water closets shall be either of white glazed earthenware, white glazed

vitreous china or white glazed fire clay as specified and shall be of "Siphonic
Wash down type" conforming to IS.2556 (Part VIII). The closets shall be
of one piece construction with approved plastic/bakelite seat and cover. Each
water closet shall have 4 fixing holes having a minimum diameter of 6.5 mm
for fixing to floor and shall have an integral flushing rim of suitable type. It
shall also have an inlet of supply horn for connecting the flush pipe. The
flushing rim and inlet shall be of the self-draining type. The water closet
shall have a weephole at the flushing inlet. Each water closet shall have an
integral trap with either "S" or "P" outlet with at least 50 mm water seal. The
water closets shall have an antisiphonage 50 mm dia. vent horn on the outlet
side of the trap. The inside surface of water closets and traps shall be uniform
and smooth in order to ensure in efficient flush. The serrated part of the
outlet shall not be glazed externally. The water closet when sealed at the
bottom of the trap in line with the back plate, shall be capable of
holding not less than 10 litres of water between the normal water level and
the highest possible water level of the water closet installed.
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4.10 URINALS
Urinals shall be of the bowl pattern, either flat back or angle back type
lipped in front. They shall be of white glazed earthenware, white glazed
vitreous china or white glazed fire clay, and of size as specified
conforming to IS.2556 (Part VI). The urinals shall be of one piece
construction. Each urinal shall be provided with not less than two fixings
holes of a minimum dia. of 6.5 mm on each side. Each urinal shall have an
integral flushing box rim of suitable type and inlet or supply horn for
connecting the flush pipe. The flushing rim and inlet shall be of the self-
draining type. It shall have a weephole at the flushing inlet of the urinal.
At the bottom of the urinal, an outlet horn for connecting to an outlet pipe
shall be provided. The exterior of the outlet horn shall not be glazed and the
surface shall be provided with grooves at right angles to the axis of the
outlet to facilitate fixing to the outlet pipe. The inside surface of the urinal
shall be uniform and smooth throughout to ensure efficient flushing. The
bottom of pan shall have sufficient slope from the front, towards the outlet
such that there is efficient draining of the urinal. The waste fittings shall be
chromium plated.
4.11 WASH BASINS
a) Wash basins shall be of white glazed earthenware, white glazed vitreous

china or white glazed fire clay as specified and conforming to IS.2556
Type Size
Flat Back 630 x 450 mm
Flat Back 550 x 400 mm
b) Wash basins shall be of one piece construction, including a combined

overflow. All internal angles shall be designed so as to facilitate
cleaning. Each basin shall have a rim sloping inside towards the bowl
on all sides except sides on contact with the walls and shall have
skirting at the back. Basins shall be provided with single or double tap
holes as specified. The tap holes shall be square. A suitable tap hole
button shall be supplied if one tap hole is not required in installation.
Each basin shall have a circular waste hole to which the interior of basin
shall drain. The waste hole shall be either rebated or bevelled internally
with diameter of 65 mm at top and a depth of 10 mm to suit a waste plug
having 64 mm diameter. Each basin shall be provided with a non-
ferrous 32 mm waste fittings. Stud slots to receive the brackets on the
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under side of the wash basins shall be suitable for a bracket with stud
not exceeding 13 mm diameter, 5 mm high and 305 mm from the back
of basin to the centre of the stud. The stud slots shall be of depth
sufficient to take 5 mm stud. Every basin shall have an integral soap
holder recess or recesses which shall fully drain into the bowl. The
position of the chain stay-hole shall not be lower than the overflow slot.
A slot type of overflow having an area of not less than 5 sq.cm. shall
be provided and shall be so designed as to facilitate cleaning of the
overflow. The specifications for waste plug, chain and stay shall be the
same as given for sinks.
(c) All the waste fittings shall be chromium plated. Bottle trap shall
conform to IS. 5434. The chromium plating shall be of service grade
No. 2 conforming to IS.1068.
4.12 SINKS
a) The sinks shall be of white glazed earthenware, white glazed vitreous

china or white glazed fire clay as specified conforming to IS.2556 (Part
V) and shall be of the following sizes :
450 x 300 x 150 mm

600 x 450 x 200 mm
b) They shall be of one piece construction, including a combined overflow.

The floor of the sink shall gently slope towards the outlet. The outlet
shall in all cases be suitable for waste fittings having flange of 64 mm
diameter and the waste hole shall have a minimum diameter of 65 mm
at the bottom to suit the waste fittings. The waste hole shall be
either rebated or bevelled having a depth of 10 mm. Each sink shall be
provided with a non-ferrous 40 mm dia. waste fitting. The sink shall have
overflow of the weir type and the inverts shall be 30 mm below the top
edge. Each sink shall be provided with a waste plug, of suitable dia.
chain and stay. The plug shall be of rubber or other equally suitable
material and shall be water tight when fitted. Plug chains shall be of brass
wire chromium plated. It shall have an overall length from the collar to
the stay of not less than 300 mm. There shall be a triangular or D
shackle at each end, one of which shall be brazed to the plug and the
other securely fixed to the stay. The 150 mm long shank of the waste
shall be threaded conforming to the requirements of IS.2556 for
sinks only. The waste fittings and plug fittings shall be chromium plated.
The chromium plating shall be of service grade No.2 conforming to
IS.1068.
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4 13 FLUSHING CISTERNS
The flushing cisterns shall be automatic or manually operated, high level or

low level, as specified. For water closets and urinals high level cistern is
intended to operate with minimum height of 125 cm and a low level cistern a
maximum height of 30 cm between the top of the pan and the underside of the
cistern. They shall be of cast iron, glazed earthenware, or pressed steel
complying with the requirement of IS.774. Automatic flushing cistern for
urinals shall conform to IS.2326.
5.0 CAST IRON SOIL, WASTE AND VENT PIPES AND FITTINGS
5.1 All cast iron pipes and fittings shall be of uniform thickness with strong and
deep sockets, free from flaws, air holes, cracks, sand holes and other defects
and conform to IS.1536. The diameter specified shall be internal diameter
of pipe. The pipes and fittings shall be true to shape, smooth and cylindrical and
shall ring clearly when struck over with a light hand hammer. All pipes and
fittings shall be properly cleaned of all foreign material before being fixed.
5.2 All plug bends of drainage pipes shall be provided with inspection and
cleaning caps, covers, which shall be fixed with nuts and screws. Pipes shall
be fixed to the wall by W.I. or M.S. holder bat clamps, unless projecting
ears with fixing holes are provided at socket end of pipe. The pipes shall be
installed, truly vertical or to the lines and slopes as indicated. The clamps
shall be fixed to the walls by embedding their hooks in cement concrete
blocks (1:2:4) 10 cm x 10 cm making necessary holes in the walls at proper
places. All holes and breakages shall be made good. The clamps shall be
kept 25 mm clear of the finished face of the walls to facilitate cleaning and
painting of pipes.
5.3 The annular space between the socket and spigot shall be filled with a gasket of
hemp or spun yarn soaked in neat cement slurry. The joint shall then be filled
with stiff cement mortar 1:2 (1 cement : 2 fine sand) well pressed with
caulking tool and finished smooth on top at an angle of 45 . The joint
shall be kept wet for not less then 7 days by tying a piece of gunny bag kept
moist. Joints shall be perfectly air tight as well as water tight.
5.4 C.I. pipes and fittings which are exposed shall be first cleaned and then painted
with a coat of red lead primer. Two coats of zinc paint with white base and
mixed with pigment of required colour to get the approved shade shall be
given over the base primer coat.
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5.5 The thickness of fittings and their socket and spigot dimensions shall
conform to the thickness and dimensions specified for the corresponding sizes
of straight pipes.
5.6 The connection between the main pipe and branch pipes shall be made by
using branches and bends with access for cleaning. Floor traps shall be
provided with 25 mm dia. puff pipe where the length of the waste is more
than 1800 mm or the floor trap is connected to a waste stack through bends.
5.7 C.I. pipes shall be measured along the centre lines of pipes including fittings
such as branches, plug, bends, etc.
5.8 All cast iron pipes and fittings including joints shall be tested by a smoke
test to the satisfaction of the Engineer and left in working condition after
completion. The smoke test shall be carried out as stated under :
Smoke shall be pumped into the pipe at the lowest and from a smoke
machine which consists of a bellow and a burner. The material usually burnt
is greasy cotton waste which gives out a clear pungent smoke which is
easily detectable by sight as well as by smell if there is a leak at any point of
the pipeline.
5.9 Water test and air test shall be conducted as stipulated in IS.5329.
6.0 ASBESTOS CEMENT PIPES AND FITTINGS
6.1 All A.C. soil, waste, vent pipes, and fittings shall conform to IS.1626. The
pipes shall have spigot and socket ends. These shall be composed of an
inert aggregate consisting of clean asbestos fibre cemented together by
ordinary portland cement conforming to IS.269, or portland blast furnace
slag cement conforming to IS.455. No organic material shall be added to the
composition.
6.2 The pipes shall be straight and the ends of the pipes and fittings shall be
finished square to their axes. The finished pipes and fittings shall be true and
smooth, their inner and outer surfaces shall be concentric. They shall be in all
respects sound, homogenous and free from impurities or other imperfections.
6.3 The permissible tolerance on the thickness and external dimensions of pipes
and fittings including hydraulic test pressure of the pipes and fittings shall
conform to IS.1626.
6.4 All AC pipes and fittings shall be of approved make and with necessary
accessories, wherever required. The diameter wherever specified for pipes
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and fittings shall be clear internal diameter. All gaps between pipes and
fittings and walls shall be filled with cement mortar 1:3 neatly finished for
which no extra cost will be paid. All pipes and fittings shall be supported
with standard fixing brackets.
6.5 The annular space between the socket and spigot shall be filled with a gasket of
hemp of spun yarn soaked in tar. The joint shall then be filled with stiff
cement mortar 1:2 (1 cement : 2 fine sand ) well pressed with caulking
tools and finished smooth on top with neat cement paste at an angle of 450.
The joint shall be kept wet for not less than 7 days by tying a piece of gunny
bag kept moist. Joints shall perfectly air-tight as well as water-tight.
6.6 A.C. pipes shall be measured along the centre lines of pipes including fittings
such as junctions, bends, etc.
6.7 Pipes and fittings shall be tested with a smoke test as specified in Clause 5.8.
7.0 G.I. PIPES
7.1 The pipes shall be galvanised mild steel welded pipes and seamless screwed
and sockets tubes conforming to the requirements of IS.1239, for heavy grade.
They shall of the diameter (nominal bore) specified in the description of the
item. The sockets shall be designated by the respective nominal bores of the
pipes for which they are intended. The pipes and sockets shall be finished
neatly, well galvanised on both inner and outer surfaces, and shall be free
from cracks, surface flaws, laminations and other defects. All screws, threads
shall be clean and well cut. The ends shall be cut cleanly and square with the
axis of the tube.
7.2 All screwed tubes and sockets shall have pipe threads conforming to the
requirements of IS.554. Screwed tubes shall have taper threads while the
sockets shall have parallel threads.
7.3 The fittings shall be of malleable cast iron or mild steel tubes complying
with all the appropriate requirements as specified for pipes. The fittings
shall be designated by the respective nominal bores of the pipes for which
they are intended. The fittings shall have screw threads at the ends
conforming to the requirements of IS.554. Female threads on fittings shall
be parallel and male threads (except on running nipples and collars of unions)
shall be tapered.
7.4 a) The pipes and fittings shall be inspected at site before use to ascertain that
they conform to the specification. The defective pipes shall be rejected.
Where the pipes have to be cut or rethreaded the ends shall be carefully
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filled out so that no obstruction to bore is offered. The ends of the pipes shall
then be threaded conforming to the requirements of IS.554 with pipe dies and
taps carefully in such a manner as will not result in slackness of joints when
the two pieces are crewed together. The taps and dies shall be used only for
straightening bent and damaged screw threads and shall not be used for
turning of the threads so as the make them slack, water tight joint. The
screw-thread of pipes and fittings shall be protected from damage until they are
fitted.
b) The pipes shall be cleaned and cleared of all foreign matter before being
laid. In jointing the pipes, the inside of the socket and the screwed end of
the pipes shall be oiled and rubbed over with white lead and a few turns of
spun yarn wrapped around the screwed end of the pipe.The end shall then
be screwed in the socket, tee, etc., with the pipe wrench. Care should be
taken that all pipes and fittings are properly jointed so as to make the joints
completely water tight and pipes are kept at all times free from dust and dirt
during fixing. Burrs from the joint shall be removed after screwing.
After laying, the open ends of the pipes shall be temporarily plugged to
prevent access of soil or any other foreign matter.
c) Any threads exposed after jointing shall be painted or in the case of

underground piping thickly coated with approved anticorrosive paint to
prevent corrosion.
7.5 a) For internal work the galvanised iron pipes and fittings shall run on the
surface of the walls or ceiling (not in chase) unless otherwise specified. The
fixing shall be done by means of standard pattern holder bat clamps,
keeping the pipes about 1.5 cm clear of the wall. Pipes and fittings shall be
fixed truly vertical/horizontal. When it is found necessary to conceal the
pipes, chasing may be adopted or pipes fixed in the ducts of recesses etc.
provided there is sufficient space to work on the pipes with the usual tools.
The pipes shall not ordinarily be buried in walls or solid floors. Where
unavoidable, pipes may be buried for short distances provided adequate
protection is given against damage, but the joints in pipes shall not be buried.
Where directed by the Engineer, a M.S. pipe sleeve shall be fixed at a place
where a pipe is passing through a wall or floor for reception of the pipe and
to allow freedom for expansion/contraction and other
movements/maintenance. In case the pipe is embedded in walls or floors it
should be painted with anti-corrosive bitumastic paint of approved quality.
The pipe should not come in contract with lime mortar or lime concrete as the
pipe is affected by lime. Under the floors the pipes shall be laid in layer of
sand filling or as directed by the Engineer.
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b) G.I. pipes with socket and spigot ends shall be provided with lead caulked
joints wherever specified and the joints shall conform to the requirements of
IS.3114.
7.6 a) The work of excavation and backfilling shall be done true to line and gradient
in accordance with general specifications for earth work in trenches for pipes
laid underground.
b) The pipes shall be laid on a layer of 7.5 cm sand and filled upto 15 cm above
the pipes. The remaining portion of the trench shall then be filled with
excavated earth. The surplus earth shall be got rid of as directed. when
excavation is done in rock the bottom shall be cut deep enough to permit the
pipes to be laid on a cushion of sand 75 mm minimum.
7.7 The pipes and fittings after they are laid and jointed shall be subjected to
hydrostatic pressure test as specified by the Engineer and shall satisfactorily
pass the test. Pipe line system shall be tested in sections as the work
proceeds, keeping the joints exposed for inspection. Pipes shall be slowly
and carefully charged with water allowing all air to escape. All draw off taps
shall then be closed and water pressure gradually raised to test pressure. Care
shall be taken to ensure that pressure gauge is accurate and preferably
should have been recalibrated before the test. Pump used having been stopped,
the section of the pipeline shall maintain the test pressure for at least half an
hour. Any joints or pipes found leaking shall be removed and replaced by the
Contractor without extra cost.
7.8 The G.I. pipe line shall be cut to the required length at the position where
the meter and stop cock are required to be fixed. The ends of the pipes
shall be threaded. The meter and stop cock shall be fixed in position by
means of connecting pipe, G.I. nuts, sockets, etc. 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 meter installed exactly horizontally or
vertically and with the arrow cast on the body of the meter pointing in the
direction of flow. Care shall be taken that the factory seal of the meter is not
disturbed. Whenever the meter is to be fixed to a newly fitted pipe line, the
pipe line will have to be completely washed before fixing the meter. For this
purpose, a connecting piece of pipe equal to the length of the meter is to be
fixed on the new pipe line. The water shall be allowed to flow completely
to wash the pipe line and then the meter installed as described above by
replacing the connecting piece.
7.9 The G.I. pipes with fittings completely fixed in position shall be
measured and paid for based on the finished centre line lengths.
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8.0 STONEWARE PIPES AND FITTINGS
8.1 All pipes with spigot and socket ends shall conform to IS.651 and shall be of
grade À' as specified. These shall be sound, free from visible defects such as
fine cracks or hair cracks. The glaze of the pipes shall be free from crazing.
The pipes shall give a sharp clear note when struck with a light hammer.
There shall be no broken blisters. The pipe shall be handled with
sufficient care to avoid damage to them.
8.2 Pipes shall be laid to the correct grade and alignment shown in the
plan/sections with their sockets up the gradient. Laying and jointing shall
conform to the general requirements specified in IS.651.
8.3 Stoneware pipes used for sewers shall be subjected to a test pressure of 1.5 m
head of water at the highest point of the section under test. The test shall
be carried out suitably by plugging the low end of the drain and the ends of
the connection if any and filling the system with water. A buckle bend
shall be temporarily jointed in at the top end and a sufficient length of
vertical pipe jointed to it so as to provide the required test head or the top may
be plugged with a connection to a hose ending in a funnel which could be
raised or lowered till the required head is obtained and fixed suitably for
observation. Where leakage will be visible the defective part of the work shall
be removed and made good.
8.4 In measuring the length of sewer pipes, thick length between faces of
manholes shall only be measured omitting lengths of channels between
inside faces of walls of manholes or chambers.
9.0 STOP COCK AND BIB COCK
9.1 A bibcock (bibtap) is a draw off tap with a horizontal inlet and free outlet and
stopcock (stop tap) is a valve with a suitable means of connections for insertion
in a pipe line for controlling or stopping the flow. They shall be of
specified size and shall be of the screw down type. The closing device should
work by means of a disc carrying a renewable non-metallic washer, which
shuts against water pressure on a seating at right angles to the axis of the
threaded spindle which operates it. The handle shall be either crutch or
butterfly type securely fixed to the spindle. The cocks shall open in anti-
clockwise direction. When the bib cocks and stop cocks are required to be
chromium plated, the chromium plating shall be of service Grade No. 2
conforming to IS.1068. In finish and appearance, the plated articles shall be
free from plating defects such as blisters, pits, roughness and shall not be
stained or discoloured.
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9.2 These fittings shall be of brass heavy class, chromium plated (C.P) and of
approved manufacture and pattern with screwed of flanged ends as specified.
The fittings shall in all respects comply with the requirements of IS.781. The
standard size of brass fittings shall be designated by the nominal bore of the
pipe to which the fittings are attached. A sample of each kind of fitting shall
be got approved from the Engineer and all supplies made according to the
approved samples.
9.3 All cast fittings shall be sound and free from laps, blow holes and fittings,
both internal and external surfaces shall be clean, smooth and free from sand
etc. Burning, plugging stopping or patching of the casting shall not be
permitted. The bodies, bonnets, spindles and other parts shall be truly
machined and when assembled the parts shall be axial, parallel and
cylindrical with surfaces smoothly finished. The area of the waterway of the
fittings shall not be less than the area of the nominal bore.
9.4 The fittings shall be fully examined and cleared of all foreign matter before
being fixed. The fittings shall be fitted in the pipe line in a workmanlike
manner. The joints between fittings and pipes shall be made leak- proof. The
joints and fittings shall be leak proof when subjected to a pressure test
specified by the Engineer and the defective fittings and joints shall be
replaced or redone.
10.0 SOAK PIT
10.1 Soak pit shall be constructed as detailed in working drawings at the location
as directed by the Engineer. Earthwork excavation shall be carried out to the
exact dimensions. Brick masonry lining with open joints shall be constructed
in the pit upto 150 mm below the outlet pipeline. Brick masonry in cement
mortar 1:6 shall be constructed above this level upto ground. Well burnt
brick aggregates of nominal size 40 mm to 80 mm and coarse sand shall
be filled within the chamber. Construction of pit lining and filling of the
brick ballast shall progress simultaneously.
11.0 MANHOLES
11.1 Manholes of types and sizes as specified shall be constructed in the sewer
line at such places and to such levels and dimensions as shown in the
drawings or as directed by the Engineer. The size specified indicate the
inside dimensions of the manhole.
11.2 Excavation and backfilling shall be as per respective specifications.
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11.3 Manhole shall be built on a bed of cement concrete 1:4:8 (1 cement : 4 sand :
8 graded stone aggregate of 40 mm nominal size). The thickness of the bed
concrete shall be 23 cm unless otherwise specified or directed by the
Engineer. In bad ground special foundation as suitable shall be provided.
11.4 Brick work shall be with first class country bricks in cement mortar 1:4 (1
cement : 4 sand). The external joints of the brick masonry shall be finished
smooth. The joints of the pipes with the masonry shall be made perfectly
leak-proof.
11.5 The brick walls of manholes shall be plastered inside with 13 mm thick
cement plaster 1:2 (1 cement : 2 sand) finished smooth with a floating coat of
neat cement.
11.6 Channels and benching shall be in cement concrete 1:2:4 (1 cement : 2 sand : 4
graded stone aggregate).
11.7 The depth of channels and benching shall be as indicated in the table given
below :
Size of drain Top of channel at the centre Depth of benching at side

above bed concrete wall above bed concrete
mm
mm mm
100 150 200
150 200 300
200 250 350
250 300 400
300 350 450
350 400 500
400 450 550
450 500 600
11.8 All manholes deeper than 0.8 m shall be provided with staggered M.S. rungs
as specified in drawings. Rungs shall be painted with coal tar, the portion
embedded in cement concrete block being painted with thick cement slurry
before fixing.
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11.9 C.I. manhole covers and frames shall conform to IS 1726. The covers and
frames shall be neatly cast and they shall be free from air and sand holes and
from cold shuts. They shall be neatly dressed and carefully trimmed. All
casting shall be free from voids whether due to shrinkage or other causes.
Cover shall have a raised chequered design on the top surface to provide an
adequate non-slip grip. The cover shall be capable of easy opening and
closing and it shall be correctly fitted in the frame. The cover shall be gas
tight and water tight. The cover shall be coated with black bituminous
composition. It shall not flow when exposed to a temperature of 630C and
shall not be brittle as to chip off at temperature of 00C.
11.10 The frame of the manhole cover shall be firmly embedded to correct
alignment and levels in plain cement concrete 1:2:4 (1 cement : 2 sand : 4
graded stone aggregate) on top of the brick masonry. After completion of the
work, manhole covers shall be smeared with thick grease.
11.11 Manhole cover and frame shall conform to "Medium Duty", 500 mm internal
diameter and shall weigh not less than 116 kg. (weight of cover 58 kg. and
weight of frame 58 kg.).
11.12 The depth of the manholes shall be reckoned from top level of C.I cover to the
invert level of channel. The depth shall be measured correct to centimetres.
11.13 Inspection chambers shall be constructed similar to manholes as detailed in

working drawings.
11.14 Sewers of unequal sectional area shall not be jointed at the same invert
level in a manhole. The invert of the smaller sewer at its junction with main
shall be at least 2/3 the diameter of the main, above the invert of the main.
The branch sewer should deliver sewage in the manhole in the direction of
main flow and the junction must be made with care so that flow in the main is
not impeded. No drains from house fittings e.g. gully trap or soil pipe etc.
to manhole shall normally exceed a length of 6 meters unless it is
unavoidable.
12.0 DROP CONNECTION
12.1 In cases where branch sewer enters the manholes of main pipe sewer at a
higher level than the main sewer, a drop connection should be provided.
Pipes and specials conforming to IS 1729 shall be of the same size as the
branch pipe sewer.
12.2 For 150 mm and 250 mm main line, if the difference in level between the
water line (peak flow level) and the invert level of branch line is less than 600
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SANITARY WORKS
mm a drop connection may be provided within the manhole by giving a

suitable ramp. If the difference in level is more than 600 mm the drop should
be provided externally.
12.3 The excavation shall be done for the drop connection at the place where the
branch line meets the manhole. The excavation shall be carried up to the bed
concrete of the manholes and to the full width of the branch line.
Excavation and backfilling shall be done as per respective specifications.
12.4 At the end of branch sewer line C.I. tee shall be fixed to the line which shall
be extended through the wall of manhole by a horizontal piece of C.I. pipe to
form an inspection or cleaning eye. The C.I. drop pipe shall be connected
to the tee at the top and to the C.I. bend at the bottom. The bend shall be
extended through the wall of the manhole by a piece of pipe which shall
discharge into the channel. Necessary channel shall be made with cement
concrete of grade M15 and finished smooth to connect the main channel.
The joint between C.I. pipe and fittings shall be lead caulked. The joint
between C.I. tee and S.W. branch line shall be made with cement mortar 1:1
(1 cement : 1 fine sand). The exposed portion of the drop connection shall be
encased alround with minimum 150 mm. thick concrete 1:5:10 (1 cement :
5 coarse sand : 10 graded stone aggregate 40 mm nominal size) and cured.
For encasing the concrete around the drop connection, necessary centering
and shuttering shall be provided. The holes made in the walls of the
manhole shall be made good with brick work in cement mortar 1:4 (1
cement : 4 coarse sand) and plastered with cement mortar 1:2 (1 cement : 2
fine sand) on the inside of the manhole wall. The excavated earth shall be
back filled in the trench in level with the original ground level. Drop
connection shall be measured in numbers.
13.0 ROAD GULLY CHAMBERS
13.1 The chamber shall be of brick masonry/RCC and shall have a C.I. grating with
frame fixed in 150 mm thick cement concrete of grade M15 at the top. The
size of the chamber shall be taken as clear internal dimensions of the C.I.
frame. The chamber shall have a S.W. connection pipe, the length of which
between road gully chamber and the point of discharge to drain or to open
ground shall be measured separately. The chamber shall be built at the
locations indicated in drawings.
13.2 Bed concrete, brick work, plastering, RCC work, excavation, backfilling, etc.
shall be as per details given on the drawing and in compliance with the
requirements laid down in the specifications for the respective items.
13.3 The gully grating cover shall be hinged to the frame to facilitate its opening
for cleaning and repairs. The weight of grating shall be 75 kg. minimum.
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13.4 After completion of the work, the exposed surfaces of the grating and the
frame shall be painted with a thick coat of coal tar.
14.0 SEPTIC TANK
14.1 Hume pipe septic tank and accessories shall be horizontal type of
standard manufacture as approved by the Engineer. Septic tank shall be
installed exactly as per manufacturer's requirements and instructions at
locations indicated by the Engineer. 230 mm thick and 500 mm internal
diameter brick manhole shall be constructed upto grade level and covered
with 500 mm circular medium duty cast iron frame and cover. Internal face
of brick work shall be plastered with 13 mm thick cement mortar 1:3.
14.2 RCC/brick masonry septic tanks shall be constructed as per the drawings.
All other requirements shall conform to IS : 2470.
15.0 GUARANTEE FOR WATER SUPPLY, SOIL & VENT SYSTEMS
15.1 The Contractor shall deliver to the Owner/Engineer upon completion of his
work under this contract, a written guarantee that :
i) for a period of one (1) year after acceptance by the Engineer, plumbing
and drainage work shall be free from defective material and
workmanship;
ii) for a period of one (1) year after acceptance by the Engineer, the
Contractor shall be responsible for the water/air tightness of all joints;
iii) he will, at his own expense, repair, replace all such defective work and
all other works damaged thereby, during the term of guarantee.
15.2 After completion of the work, the Contractor shall obtain and handover
to the Engineer necessary certificates.
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SPECIFICATION NO. TCE CONSULTING ENGINEERS LTD SECTION D1
DATA SHEET - A
TCE-5178A-116-68 PRESSURE TYPE PNEUMATIC CONVEYING SYSTEM SHEET 1 OF 9
FOR FLY ASH, BED ASH & BED MATERIAL HANDLING
1.0 FLY ASH/BED ASH TRANSMITTERS
1.1 Type SUITABLE FOR DENSE PHASE

PRESSURE TYPE PNEUMATIC
CONVEYING
1.2 Material to be Handled FLY ASH / BED ASH/

BED MATERIAL
0
1.2.1 Temperature of material handled C REFER SYSTEM DATA SHEET
1.3 Material Properties
1.3.1 Range of bulk density kg/cu.m REFER SYSTEM DATA SHEET

Fly ash 800
Bed ash 1800
Bed material 1800
1.4 Quantity REFER SYSTEM DATA SHEET
1.5 Duty 24 HOURS/DAY
1.6 Holding Capacity of BIDDER TO INDICATE

Transmitters
1.7 Flow Through Transmitter Vessels

Below
1.7.1 Air preheater hoppers t/hr REFER SYSTEM DATA SHEET
1.7.2 ESP hoppers t/hr }

} AS PER SYSTEM DESIGN
1.7.3 Stack hopper t/hr }
1.7.4 Bed ash hopper t/hr }
1.8 Materials of Construction
1.8.1 Transmitter Vessel CAST IRON/FABRICATED OUT

OF MIN. 10 THK. MS PLATE
1.9 Construction of Vessel AS PER ASME CODE FOR

UNFIRED PRESSURE VESSEL
OR IS-2825
1.10 Accessories to be Provided
1.10.1 Level probe for hopper YES
1.10.2 Level probes for transmitters YES

DATA SHEET - A
1.10.3 Timers as back up for level YES

probes
1.10.4 Control panel YES
1.10.5 Pneumatically operated vent valve YES

and vent port at top of vessel to
release air displaced during ash
filling in case discharge valve
is provided
1.10.6 Safety valve on vessel YES
1.11 Tests to be Conducted
1.11.1 Visual and dimensional check at YES

works
1.11.2 Hydrostatic test at works, YES

with 1.5 times the maximum
operating pressure
1.11.3 Capacity test at site YES
1.11.4 Testing of the fabricated AS PER ASME SECTION VIII

transmitter vessels
1.12 The emptying of bed ash/fly ash hoppers

shall be controlled automatically by
level probes and timers. However,
it shall be possible to empty
them selectively as per operators wish
2.0 BED ASH/ FLY ASH VALVES
2.1 HOPPER ISOLATION VALVES/

BRANCH ISOLATION VALVES
2.1.1 Type KNIFE GATE VALVES
2.1.2 Location OUTDOOR BELOW BED ASH/

FLY ASH COLLECTING HOPPERS
BED ASH/FLY ASH PIPE LINES.
2.1.3 Number required REFER FLOW DIAGRAM
2.1.4 Operation - Branch Isolation valve PNEUMATIC CYLINDER

DATA SHEET - A
- Hopper Isolation valve OPERATED MANUAL

OPERATED
2.1.5 Flow rate through valve t/hr TO MEET SYSTEM DESIGN
2.1.6 Material of Construction and

Hardness
(a) Valve body CI FG-260
(b) Slide plate SS 304
(c) Valve seat CI FG-260
(d) Valve shaft SS-304
(e) Deflector cone( for branch isolation valve) Alloy C.I , 350 BHN
2.1.7 Provision of operating handle YES

for manual operation and position
indicator
2.2 FLY ASH INLET VALVES
2.2.1 Type DOME VALVES/KNIFE GATE

VALVES/ SWING DISC VALVE
2.2.2 Location AT INLET TO ASH

TRANSMITTER
2.2.3 Number required REFER FLOW DIAGRAM
2.2.4 Operation PNEUMATIC CYLINDER

OPERATED - SOLENOID
ACTUATED
2.2.5 Flow rate through valve TO MEET SYSTEM DESIGN
2.2.6 Material of Construction & DOME VALVE KNIFE GATE VALVE

Hardness
(a) Valve body CI FG-260
(b) Valve seat CI FG-260
(c) Valve plate/dome SS304, EDGE STELLITED TO

1 MM THICK
DATA SHEET - A
(d) Deflector cone for knife gate valve ALLOY CI, 350 BHN
(e) Dome CI FG-260
(f) Shaft SS 304
(g) Seal (for dome valve) INFLATED RUBBER SEAL
(NEOPRENE)
2.2.7 Life of valve seal BIDDER TO INDICATE IN HRS.
OF OPERATION.
2.2.8 Tests to be conducted
(a) Hydrostatic/vacuum test for YES
all valves
(b) Test certificates for YES
material of construction
2.3 Valves at Outlet of Transmitter
Vessel (If Required)
2.3.1 Type KNIFE GATE VALVE/BALL
VALVE
2.3.2 Operation PNEUMATIC CYLINDER

OPERATED - SOLENOID
ACTUATED
DATA SHEET - A
2.3.3 Material of construction KNIFE GATE VALVE BALL VALVE
(a) Valve body SAME AS ASTM A 216

SHOWN AGAINST
(b) Valve seat ITEM 2.2.6 SS 304-STELLITED
(c) Valve plate/ball SS 304 - HARD

CHROME PLATED
(d) Sleeve --
(e) Stem Ni HARD
3.0 AIR-ASH TRANSPORT PIPING AND

FITTINGS
3.1 Piping MS ERW pipe to IS-3589 for pipes

above 150 NB (min. 9.52 mm for
1st and 2nd field and 7mm for other
fields) For 150 NB and below, the
pipes shall conform to IS-1239.
3.2 Fittings Ni-Cr ALLOY CAST IRON AS

PER IS:4771, TYPE 1a WITH
MINIMUM AND HARDNESS OF
550 BHN
3.3 Type of Wear Back for Fittings INTEGRAL
3.4 Min. Thickness of Wearback TWICE THE PIPE WALL

THICKNESS
3.5 Radius of 900 bends MINIMUM 3 TIMES PIPE

DIAMETER
3.6 Type of Coupling for Fly Ash pipes SLEEVE TYPE WITH STEEL
SLEEVE & STEEL/CI FLANGES
3.7 Deflection in Coupling (Allowable) MINIMUM 3 DEG.
3.8 Gap between Ends of Pipes at SUFFICIENT TO TAKE CARE

Coupling OF EXPANSION IN PIPES.
3.9 Necessary Steel Hangers, Supports BY BIDDER

and Inserts in Concrete for Piping
3.10 Location OUTDOOR

DATA SHEET - A
3.11 Pipelines to be Included
3.11.1 Piping from fly ash hoppers to YES

fly ash silo
3.12 Hydrostatic Testing of all the YES

Piping after Installation at
Site, with 1.5 times the
Maximum Operating Pressure
3.13 Span between Piping Supports NOT TO EXCEED 3.0 M
4.0 AIR PIPING
4.1 Conveying Air Piping
4.1.1 Material - Piping GI

- Fittings FORGED STEEL
4.1.2 Velocity in air piping 10 M/S (AVERAGE) /

BIDDER TO INDICATE
4.2 Instrument Air Piping
4.2.1 Branch piping GI
4.2.2 From tap off point upto gauges, SEAMLESS COPPER TUBING
WITH SWITCHES, ETC.
COPPER ALLOY FLANGES &
FITTINGS
4.3 Hydrostatic Testing of all the YES

Piping after Installation at
Site, with 1.5 times the
Maximum Operating Pressure
5.0 BAG FILTER
5.1 Location AT FLY ASH SILO,
5.2 Type COMPRESSED AIR CLEANED,

REVERSE PULSE JET TYPE
5.3 Duty CONTINUOUS-24 HOURS/ DAY
5.4 Material Handled FLY ASH/BED ASH
5.5 Bulk Density of Handled Material kg/m3 REFER DATA SHEET C-13
DATA SHEET - A
5.6 Material of Construction
5.6.1 Bags POLYESTER NEEDLE FELT OF

ANTISTATIC TYPE
5.6.2 Cages GI
5.6.3 Casing & Duty MS
5.7 Volume of Dust Laden Air to be m3 SHALL MATCH THE FLOW

Handled RATE OF ASH-AIR MIXTURE
INTO FLY ASH SILO
5.8 Air-to-Cloth Ratio m/min ONE
5.9 Maximum Dust Concentration in mg/Nm3 100

Air that will be Let Out to
Atmosphere
5.10 All Required Accessories Provided YES - BIDDER TO FURNISH

LIST
5.11 Are Controls for Automatic YES

On-line Bag Cleaning System
Required?
5.12 Tests
5.12.1 Visual and dimensional check at YES

works
5.12.2 Site tests for functioning of the YES

automatic on-line bag cleaning
system
5.12.3 Check for dust concentration in YES

the air to be let out to
atmosphere at site
5.13 Bag Filter Cleaning Air TO BE OBTAINED FROM

PLANT AIR CONNECTION
6.0 EXHAUST FAN
6.1 a) Location AT THE AIR OUTLET OF BAG

FILTERS
b) Quantity BIDDER TO DECIDE

DATA SHEET - A
6.2 Type CENTRIFUGAL
6.3 Capacity m3/s *
6.4 Suction Pressure kPa *

(mWc)
6.5 Discharge Pressure kPa *

(mWc)
7.0 WHETHER THE COMPRESSORS/ IF YES, REFER COMPRESSOR

BLOWERS OF REQUIRED DATA SHEET.
CAPACITY AND NUMBER NEED
TO BE INCLUDED BY THE
VENDOR
7.1 If yes, the No of Compressors/ THREE (3) (2W+1S) SCREW

Blowers Operating & Standby COMPRESSORS
8.0 TYPE OF STANDBY FOR COLOUR CONVENTIONAL MIMIC-CUM-

MONITOR OF MICRO PROCESSOR CONTROL PANEL/
BASED CONTROL SYSTEM REDUNDANT STANDBY
COLOUR MONITOR
9.0 PERFORMANCE TEST AT SITE
Is Capacity Test for Fly Ash/Bed ash YES

Conveying Required to be conducted?
10.0 EXPANSION JOINTS
10.1 Type of Expansion Joints SS
11.0 Painting at site by VENDOR
11.1 Paintings shall as specified in YES

specification
12.0 NOTES
12.1 All parts of valves coming in contact with ash shall be wear resistant.
12.2 All supports and supporting structures for the pneumatic conveying equipment and
piping together with platform, hand railing and access ladders, as required shall be
provided.
12.3 All air + ash line valves and fittings shall be tested as per API-598.
12.4 All remote operated valves shall be pneumatically operated.

DATA SHEET - A
12.5 If the Bidder feels that purge air line is required for their system, the same shall be
provided.
12.6 All the vent valves (if provided) in transmitter vessel shall be connected 1 m above the
maximum ash level in ESP hoppers.
12.7 Provision shall be given to operate the ash transmitter selectively keeping other
transmitter isolated.
12.8 If fly ash discharge valve is offered by the bidders in their system, they shall give
minimum one year guarantee for the life of the valve for 1st and 2nd field of ESP hoppers.
For other fields, they shall give 2 years guarantee for the life of valve. If it is not
furnished, cost loading for the same will be done on their quoted price.
12.9 For 50 NB and smaller sizes air piping valve, 3 piece ball valves shall be provided.
* - Bidder to indicate.
.
SPEC NO. TCE CONSULTING ENGINEERS SECTION: D1
TCE.M4-116-68 TITLE SHEET 1 OF 10
PRESSURE TYPE PNEUMATIC CONVEYING
SYSTEM FOR FLY ASH / BED ASH HANDLING
1.0 SCOPE
This specification covers the general design, materials, construction features,

manufacture, shop inspection and testing at the VENDORs / SUB-
VENDORs works, delivery to site, commissioning and performance testing
at site of Pressure type pneumatic conveying system for fly ash / bed ash
handling.
2.0 CODES AND STANDARDS
The design, materials, construction, manufacture, inspection, testing and

performance of pneumatic conveying system equipment shall comply with all
currently applicable statutes, regulations and safety codes in the locality
where the equipment will be installed. Nothing in this specification shall be
construed to relieve the VENDOR of his responsibility.
The following are some of the important Indian Standards relevant to this
specification.
IS 1239 - Mild steel tubes, tubular & other wrought steel

fittings
(Parts I & II)
IS 2062 - Steel for general structural purposes
IS 2825 - Code for unfired pressure vessels
IS 3589 - Seamless or Electrically welded steel pipes for

water, gas and sewage (168.3 to 2032 mm OD)
IS 4771 - Abrasion resistant iron castings
IS 4894 - Centrifugal fans
IS 5456 - Code of practice for testing of positive displacement

type air compressors & exhausters
IS 6206 - Guide for selection, installation & maintenance of

reciprocating compressors upto 10 bars
IS 7938 - Air receivers for compressed air installations
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Other National standards are also acceptable, if they are proved to be equal or
superior to the relevant Indian standards or where equivalent Indian standards
do not exist.
3.0 DESIGN REQUIREMENTS
3.1 General
All rotating parts such as couplings, V-belts, shafts, etc. shall be covered with
suitable protective guards.
3.2 Pneumatic Conveying System
3.2.1 The pneumatic conveying system shall be lean phase/dense phase pressure
type and for conveying the fly ash / bed ash collected at various fly ash / bed
ash hoppers to the fly ash / bed ash silo, via buffer hoppers, if required and it
shall comply with this standards. This system shall be complete with air
compressors and accessories (if specified in Data Sheet-A), transmitter
vessels, buffer hoppers, remote operated fly ash / bed ash inlet valves and
isolation gates, piping, pipe supports, dust tight seals, bag filters and
extraction fans (if necessary) with drive motors, solenoid valves, etc.
3.2.2 The BIDDER shall calculate
a) Total air quantity required for conveying the ash.

b) Size of conveying pipes.
c) Pressure drop in the pipelines and equipment etc., based on the
following
i) Quantity of the ash to be conveyed from each hopper.
ii) Required system capacity.
iii) No. of cycles per hour.
iv) Distances and elevation difference between the ash
collecting hopper and the fly ash / bed ash silo, fly ash /
bed ash density range specified etc.
v) Cycle time.
Accordingly, the BIDDER shall select the pneumatic conveying units of
suitable size.
3.2.3 The capacity of transmitter vessels shall be decided based on one of the
following alternatives, whichever is more conservative:
ISSUE
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.
(a) The capacity of transmitter vessels shall be decided based on four (4)
hours or as specified in data sheet-A, continuous operation in a shift of
eight (8) hours. However, normally the vessels shall operate
intermittently in cyclic manner for all eight (8) hours in a shift.
Maximum number of cycles in which case is 40 cycles per hour / as
specified in data sheet-A.
(b) Maximum twenty (20) cycles per hour when operating in cyclic manner
for all eight (8) hours in a shift.
3.2.4 There shall be one independent transmitter vessel below each fly ash / bed ash
collecting hopper. The fly ash / bed ash collected in these hoppers shall be
transmitted to the fly ash / bed ash silo.
3.2.5 The allowable dust concentration in the air let out to atmosphere shall be
limited to that specified in Data Sheet-A. Based on this the BIDDER shall
select the type of the bag filter at the air outlet of silo.
3.2.6 Each fly ash / bed ash hopper as well as the buffer hoppers (if provided) shall
be provided with a level probe, knife gate valve for isolation and fly ash / bed
ash inlet valve. All the transmitter vessels connected to common fly ash / bed
ash lines shall operate sequentially / simultaneously depending upon the
manufacturers recommendation. In case manufacturer recommends the
operation of transmitter vessels connected to common fly ash / bed ash
conveying line, shall be one after another, there shall be remote operated
automatically controlled isolating valve between each transmitter vessel and
common conveying line.
(a) In case of pressure pneumatic system with ash transmitter vessels

without valves, the operation shall be as described below:
When adequate ash is collected in the fly ash / bed ash hopper / buffer
hopper, and the ash level reaches the level of the level probe in the ash
hoppers the level probe shall actuate opening of the inlet valve. The fly
ash / bed ash inlet valve shall open and after a preset time conveying air
shall enter the vessel and pressurise the vessel. When the preset pressure
is reached in the vessel, the air-ash mixture shall be conveyed to the
buffer hopper or to the fly ash silo. In case fly ash / bed ash is conveyed
from the fly ash hopper to the buffer hopper, the transmitter below the
buffer hopper shall convey fly ash / bed ash similarly to the fly ash / bed
ash silo.
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.
(b) In case of dense phase pressure pneumatic system with ash transmitters
with discharge and vent valves the operation shall be as described
below:
(i) When adequate ash is collected in the fly ash / bed ash hopper,
and fly ash / bed ash reaches the level probe level, the level
probe shall actuate the vent valve, allowing the air with ash
trapped in the vessel in the previous cycle to escape. After a
preset time inlet valve shall open allowing the fly ash to be let in
to the vessel. After a preset time, the inlet valve as well as vent
valve shall close and conveying air shall be let in to the vessel
and shall pressurise the vessel. After a preset time the discharge
valve shall open and the air-ash mixture shall be conveyed to
buffer hopper / fly ash / bed ash silo as described earlier.
(ii) Where fluidisation of ash in the vessel is required in the system,

fluidising air shall be admitted after inlet valve and vent valve
are closed.
3.2.7 A back up timer shall be provided to actuate the fly ash inlet valve in case the
level probe in the fly ash hopper / buffer hopper does not function.
3.2.8 The emptying of fly ash / bed ash hoppers shall be controlled automatically by
level probes and timers. However, the controls shall be such that it shall be
possible to empty the fly ash / bed ash hoppers selectively as per the will of
the operator.
3.2.9 The ash transport piping shall be complete with sleeve type coupling /
Flanged coupling with expansion joints, bends, laterals, gaskets, etc.
3.2.10 The air piping shall be designed, based on an average velocity of 10 m/s.
3.2.11 The fly ash / bed ash valves shall be complete with body, gate, seats /
neoprene seals, gaskets, connecting flanges, actuating mechanism and
solenoid valves (where required).
3.2.12 The equipment / piping shall be designed for indoor / outdoor operation as
specified in Data Sheet-A complete with all accessories.
3.2.13 The dense phase conveying system shall be complete with the following:
(a) Air compressors and accessories, if specified, in Section-C.
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.
(b) Air receivers with associated instrumentation, air piping, supporting

structures etc.
(c) Air dryers if specified in Data Sheet-A of this specification with

associated accessories, instrumentation, air / water piping, supporting
structures etc. to meet instrument air requirements.
(d) Motor / pneumatically operated type fly ash inlet valves / vent valves
and outlet valves (if required) for the transmitter vessels and knife gate
valves for isolation and expansion joint below each of the fly ash
collecting hoppers.
(e) Buffer hoppers if provided shall have two (2) numbers of transmitter
vessels, out of which one shall be operating while the other one shall be
standby or as specified in data sheet-A.
(f) Complete air-ash mixture piping from fly ash hoppers upto fly ash / bed
ash silo and/or from fly ash hopper / bed ash hopper to buffer hoppers
and from buffer hoppers to fly ash / bed ash silo.
(g) Complete air piping between air compressors and air receivers, between
air receivers and dryers, and from air dryers upto each of the transmitter
vessels, necessary butterfly valves and fittings as required.
(h) Supports and supporting structure for the pneumatic conveying

equipment and piping together with platform, hand railing and access
ladders.
(i) All anchor bolts, nuts, bolts, washers, base frame and loose fittings
required for erection.
(j) Final grouting of all the equipment.
(k) All pressure switches, level switches, timers and any other hardware
required for interlocking and controlling of the pneumatic conveying
system equipment.
(l) Micro processor based logic control system with redundant CPU, key
board, monitor, programming unit, back up control panel, necessary I/O
units with 10% spare capacity etc.
(m) All other equipment and/or materials which are not specifically
mentioned above, but are required for completeness and trouble free
ISSUE
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.
operation of the pressure type pneumatic conveying system and also to

ensure safe and satisfactory operation of the system.
4.0 CONSTRUCTIONAL REQUIREMENTS
4.1 Fly Ash Transmitters
4.1.1 The fly ash transmitter vessel shall be sized to convey the fly ash at the rate
specified in Data Sheet-A. The inlet and outlet shall be so designed as to
prevent any plugging & choking.
4.1.2 The fly ash transmitter shall be fitted with a connection for compressed air
inlet and fly ash outlet pipes.
4.1.3 The transmitter shall be cylindrical in shape with conical bottom and shall be
made out of 10 mm thick TISCRAL plates / cast iron (CI).
4.1.4 The fly ash inlet valve at ash vessel inlet shall be of sturdy construction
capable of operating against the head of material flowing through the ash
transmitter. The materials of construction of valves shall be as specified in
Data Sheet-A. The valves shall be motor / pneumatically operated. The valve
seat and valve disk shall match perfectly. The valve design shall be such that
it can be easily removed for checking and maintenance.
4.1.5 An air-cylinder operated vent valve and vent port shall be provided at the top
of the vessel to release displaced air during filling in case fly ash discharge
valve is provided.
4.1.6 Transmitter vessels should be constructed in accordance with either the

ASME code for unfired pressure vessels or IS 2825 code for construction of
unfired pressure vessels.
4.1.7 Safety valves set to relieve pressure in excess of the safe working pressure of
the vessel should be mounted directly on the vessel and the valve size shall be
determined by ASME code requirements.
4.2 Buffer Hopper
4.2.1 The buffer hopper shall have adequate capacity to store the fly ash collected
in one (1) hour.
4.2.2 The operation of the transmitter vessels installed below the buffer hopper
shall be actuated by the level switch / probe in the hopper and they shall be of
continuous duty type.
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.
4.2.3 The buffer hopper shall be made out of min. 10 mm thick MS plates.
4.3 Piping
4.3.1 The piping used for conveying air-ash mixture shall be as called for in Data
Sheet-A of this specification. All fittings such as bends, laterals, etc. shall be
of alloy cast iron construction having integral / removable type wear backs as
called for in Data Sheet-A. The nominal radius of 90 bends shall be three
times the nominal diameter of the pipe. Minimum thickness of wear backs
shall be twice the pipe wall thickness. The pipe shall have plain ends and
joining of pipe shall be achieved by sleeve type couplings. The coupling shall
have steel sleeve, steel / CI flanges, gaskets, tightening bolts and nuts. The
couplings shall be capable of taking a minimum of 3 deflection. Sufficient
gap between ends of pipe at coupling shall be provided to take care of
expansion of pipes. The gasket shall be of high temperature asbestos
compound. The couplings shall permit easy rotation of pipes, when required.
4.3.2 The compressed air piping other than branch connections to instruments shall
be of galvanized iron (GI) as specified in Data Sheet-A of this specification.
All fittings shall be of forged steel construction. For pipe sizes less than or
equal to 50 mm, the line joint shall be screwed type and for pipe sizes greater
than 50 mm, it shall be flanged type. The flanges shall be of forged steel with
serrated facing.
4.3.3 Instrument air piping for gauges, switches etc. from the tap off point shall be
of seamless copper tubing and shall have flanged joints. The flanges and
fittings shall be of copper alloy.
4.3.4 The piping supports shall conform to good engineering practice and the span
between the supports shall not exceed 3.0 m. The hangers and supporting
arrangement shall be approved by the PURCHASER / ENGINEER and as per
layout drawings.
4.4 Bag Filter
4.4.1 A bag filter shall be provided at the air outlet of silo to achieve an outlet dust
concentration in the exhaust air as specified in Data Sheet-A.
4.4.2 The bag filter shall be of compressed air cleaned, reverse pulse jet type and
shall be with low air-to-cloth ratio.
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.
4.4.3 The bag filter shall be complete with casing, bags, cages, ducting, valves,
dampers, supports, maintenance platforms, etc., as required.
4.4.4 The bag filter shall be suitable for outdoor installation.
4.4.5 The bag filter shall be provided with automatic on-line bag cleaning system
complete with necessary valves, solid state electronic timers, air piping etc.
The compressed air required for bag cleaning shall be obtained from the
compressed air system provided for pneumatic conveying. In case dry air is
envisaged for bag filter cleaning, the BIDDER shall provide suitable
arrangement
4.4.6 The bags shall be made of polyester needle felt of antistatic type or any other
material which gives long life while its casing and ducts shall be made of mild
steel with adequate thickness. Bag filter cages shall be of GI. Adequate access
for maintenance of bags and other components shall be available.
4.5 Valves
4.5.1 Fly ash / bed ash valves
(a) Hopper isolation valves
The isolation valves below fly ash hoppers shall be knife gate valves.
These shall be of rugged construction. The parts subject to wear due to
abrasive action of fly ash shall be made of nickel-chromium alloy cast
iron of hardness not less than 340 BHN. Provision shall be made to
operate the valve manually also in case solenoid / motor operated valves
are specified in Section-C / Data Sheet-A.
(b) Fly ash / bed ash inlet valves
These shall be fitted in the transmitter vessels. These shall be used for
feeding the fly ash from the collecting hoppers into the transmitter
vessel below it. These valves shall be air-electric type. The valves shall
be pneumatically operated and the operation shall be actuated by a
solenoid valve.
(i) Dome valves
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.
- There shall be inflatable rubber seal so that in the closed

position of dome valve, the gate will be air tight and there
will not be any escape of compressed air.
- All components of the valve subject to wear shall be made

out of Ni-Cr alloy cast iron having a hardness of not less
than 340 BHN.
(ii) Swing disc valves
- The body and the disc of Swing disc valve shall be of alloy
C.I having minimum hardness of 450 BHN.
(iii) - Any other types of valves shall be as specified in Data

sheet-A
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.
ANNEXURE
VENT VAVLE
DISCHARGE VALVE
FLUIDISING FLY / BED ASH

PAD HOPPER LEVEL
PROBE
FLUIDISING
~
AIR SUPPLY
ISOLATION
VALVE
INSTRUMENT AIR EXPANSION

~
JOINT
CONVEYING
~ ~
AIR
ASH+AIR ASH ASH+AIR
~
VESSEL
LINE LINE
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.
SPEC NO. TATA CONSULTING ENGINEERS SECTION: D1
TCE-M4-116-68 TITLE SHEET 1 OF 2
DATA SHEET C
DATA TO BE FURNISHED BY THE VENDOR

AFTER THE AWARD OF CONTRACT
1.0 Schedule of drawings and documents to be submitted for review, approvals

and information with submission dates.
2.0 Quality assurance plan (QAP).
3.0 Calculation for air quantity, pressure drop, line sizing, equipment sizing
thickness calculation ETC..
4.0 Detailed pi diagram indicating scope of supply of equipment, piping with line
sizes and material specifications, valves, specialties, expansion joints,
instrumentation and control and all the accessories. Drawing shall also
indicate all design data and information furnished in data sheets a and b.
5.0 Instrumentation data sheets.
6.0 Power wiring, control wiring, logic diagrams.
7.0 Control cabinet drawing.
8.0 ASH TRANSMITTERS
8.1 General arrangement drawings of ash transmitter vessel with supporting

structure, giving all necessary dimensions, space required for handling and
materials of construction. Above drawing should show the level probe and
also the control panel in position.
8.2 Material test certificates giving material composition and physical properties,
for material of construction of transmitter vessel, inlet & discharge valves,
vent valve etc.
8.3 Capacity test certificates.
8.4 Other data as called for in System Data Sheet-C in this specification.
8.5 Procedure for performance testing.
8.6 Calculations for the conveying air requirement.
ISSUE
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.
SPEC NO. TATA CONSULTING ENGINEERS SECTION: D1
8.7 Operation and maintenance manual with lubrication schedule.
9.0 BAG FILTERS
9.1 Detailed dimensioned general arrangement drawing of the bag filter with
mounting details, design parameters and dust concentration of air let out to
atmosphere, air to cloth ratio, quantity of dust laden air handled, materials of
construction loading data, etc.
9.2 Write-up on operation of the bag filter including the operation of the
automatic on-line bag cleaning system.
9.3 Rating on fan motor.
9.4 Material test certificates giving material composition and physical properties.
9.5 Procedure for performance testing.
9.6 Operation and maintenance manual with lubrication schedule.
ISSUE
R2

ISSUE NO. R2
SPECIFICATION NO. TATA CONSULTING ENGINEERS SECTION D1
DATA SHEET - B
TCE-M4-116-68 PRESSURE TYPE PNEUMATIC CONVEYING SYSTEM SHEET 1 OF 2
FOR FLY ASH / BED ASH HANDLING
ENQUIRY /SPECIFICATION NO.
SR.NO. ITEM BIDDER
1.0 GENERAL
1.1 Type of System Offered
1.2 Total Capacity of Conveying System from Fly Ash
Hoppers to Fly Ash Silo TPH
1.3 Compressed Air Requirement
1.3.1 Flow rate NM/S
1.3.2 No. of operating hours HRS
1.3.3 Pressure KPA
(KG/CM)
2.0 ASH TRANSMITTERS
2.1 Make and Type
2.2 Capacity of Ash Transmitter Vessel M
2.3 Diameter of Fly Ash / Bed Ash Conveying Pipes
from Various Hoppers MM
2.4 Pick-up Velocity of ash M/S

2.5 Velocity of Air-Ash Mixture in the Pipeline M/S
2.6 Type of Ash Inlet Valves
2.7 Material of construction for the inlet valve
components
2.8 Time Required for Emptying the Ash Transmitter

Vessel SECONDS
2.9 Average Ash Conveying Rate from Transmitter to

Silo / Buffer Hopper
a) ESP ash transmitter vessel TPH
b) Economiser transmitter vessel TPH
c) Air preheater ash transmitter TPH
d) Stack hopper ash transmitter vessel TPH
NOTE TO BIDDER SIGNATURE

1. ITEMS WHICH DEVIATE FROM THE SPECIFICATION SHOULD BE MARKED
WITHIN ASTERISK(*) (DETAILS TO BE GIVEN IN SCHEDULE OF DEVIATIONS) OF BIDDER
2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A COPY SHALL DATE
BE ENCLOSED WITH EACH COPY OF THE BID.
ISSUE NO. R2
SPECIFICATION NO. TATA CONSULTING ENGINEERS SECTION D1
DATA SHEET - B
TCE-M4-116-68 PRESSURE TYPE PNEUMATIC CONVEYING SYSTEM SHEET 2 OF 2
FOR FLY ASH / BED ASH HANDLING
SR.NO. ITEM BIDDER
2.10 Average Ash Conveying Rate from Buffer Hopper

to Fly Ash Silo TPH
2.11 Compressed Air Requirement for the Specified Fly

Ash Conveying Rate of Various Ash Transmitter
Vessels
- Flow rate NM/S
- Pressure KPA
(KG/CM)
2.12 Are All Tests as per Data Sheet-A included? YES/NO
2.13 Is Drawing Enclosed? YES/NO
3.0 BAG FILTERS

3.1 Type and Make
3.2 Number of Bag Filters
3.3 Volume of Dust Laden Air Handled M/S
3.4 Air to Cloth Ratio M/S
3.5 Dust Concentration of Air Let Out to Atmosphere MG/NM
Cleaning air requirement M3 / S,
KPA
3.6 Are Catalogues / General Arrangement Drawing of

Bag Filter Furnished? YES/NO
3.7 Is Descriptive / Write-up of Bag Filter Furnished? YES/NO
4.0 EXHAUST FAN

4.1 Type and Make
4.2 Capacity M/S
4.3 Suction Pressure KPA
(MWC)
4.4 Discharge Pressure KPA

(MWC)
4.5 Motor Rating KW

DATA SHEET A
`TCE-5178A-107-01 AIR COMPRESSORS AND ACCESSORIES SHEET 1 OF 5
1.0 Type SCREW - NON LUBRICATED /

WITH OIL FILTERS
2.0 No. Required/Service THREE (3) NOS. (2W + 1S)

ASH CONVEYING AIR
3.0 Capacity (FAD) m3/hr *
4.0 Suction Pressure kg/cm2(g) 0.935
5.0 Discharge Pressure kg/cm2(g) *
6.0 Type of Cooling WATER
7.0 Bearing Lubrication FORCED OIL LUBRICATION
8.0 Type of Control DUAL
9.0 CONNECTIONS
Flanged for 65 mm & larger flanged YES
Drilled to IS/BS/ASA screwed for
500 mm & below
10.0 MATERIALS OF CONSTRUCTION
10.1 Casing CI C.G.20
10.2 Rotor CARBON STEEL ST 50-2
10.3 Screw Elements CARBON STEEL ST 50-2 WITH

TEFLON COATING
11.0 Drive Motor by VENDOR
12.0 Type of Drive ELECTRIC MOTOR
Accessories to be Supplied by the

VENDOR
13.0 Suction Air Filter area twice compre- YES

ssor inlet size : Particle size retained
10 micron and above
14.0 Suction Silencer YES
15.0 Instrumentation required YES (AS PER STANDARD PRACTICE)
16.0 Foundation Bolts YES

DATA SHEET A
17.0 Counter Flanges with Gaskets, Nuts YES

and Bolts for Air and Cooling Water
connections
18.0 Test Certificates for Materials of YES

Construction for Compressor parts
NOTE :
Compressor shall be controlled by PLC and the control panel shall be integrated with
main ash handling system control panel.
TESTS TO BE WITNESSED BY
PURCHASER AT MANUFACTU-
RERS WORKS
19.0 Visual Inspection and Dimensional

Check YES
20.0 Check for Capacity at specified dis- YES

charge pressure. Flow measurement
as per ISO 1271
(B) INTERCOOLER AND

AFTERCOOLER
1.0 Designation Intercooler Aftercooler

(If applicable)
2.0 Number required One no. each for each compressor
3.0 Type Shell and tube type with removal

tube and bundle
4.0 Type of Flow -------- Counter current -----------
5.0 Capacity m3/hr * *
6.0 Operating Pressure Air side kg/cm2(g) * *
7.0 Design Pressure Air side kg/cm2(g) 1.25 times of operating pressure
8.0 Cooling Medium Air/Water Water Water
9.0 Water Temperature (maximum) C 34 34
10.0 Maximum acceptable outlet air/gas

Temperature C 8C above inlet water temp.
11.0 CONNECTIONS
Flanged for 65 mm & larger flanged YES
Drilled to IS/BS/ASA screwed for
DATA SHEET A
500 mm & below
MATERIAL OF CONSTRUCTION
12.0 Shell ------------------- Steel -------------
13.0 Tubes ------------------ Copper ------------
14.0 Tube sheets --------------Copper/Steel-----------
15.0 Tube support plates ------------------ Steel ---------------
16.0 Trap Body -----------------CI/Steel--------------

- Trim ------------------Bronze-------------
17.0 Centrifugal/baffle type moisture and ------------------- Yes ---------------

oil separator with moisture reservoir
18.0 Automatic bucket type trap to --------------------Yes----------------

Discharge moisture and oil to drain
19.0 Thermometers
Bi-metallic, dial type or filled

System type
Air inlet -------------------Yes------------------

Air outlet -------------------Yes------------------
Cooling water outlet -------------------Yes------------------
20.0 Safety valve to relieve full compressor -------------------Yes------------------

Discharge
21.0 Foundation bolts -------------------Yes------------------
22.0 Counter flanges for air inlet and outlet -------------------Yes------------------

connection, with gaskets, bolts and
nuts
23.0 Pressure gauge at air inlet and outlet -------------------Yes------------------
TESTS AT MANUFACTURERS
WORKS TO BE WITNESSED BY
PURCHASERS REPRESENTATIVE
24.0 Visual inspection and dimensional -------------------Yes------------------

check against approved manufacturers
drawing
DATA SHEET A
25.0 Hydrostatic test of shell and tube side -------------------Yes------------------

at 1.5 times the design pressure
26.0 Test certificates for material of cons- -------------------Yes------------------

truction of inter and/or after cooler
parts
(C) AIR RECEIVER
1.0 Designation Air Receiver
2.0 Number required Two (2) nos.
3.0 Type Vertical
4.0 Working Pressure kg/cm2(g)
5.0 Design Pressure kg/cm2(g) 1.25 times of operating pressure
6.0 Nominal Volume of each receiver m3 Bidder to indicate suitable capacity

of ash handling system
7.0 Material IS 2062
8.0 Corrosion Allowance mm 3.0
9.0 Code of Construction BS 487 (Part-I)/ Yes

IS 2825 ASME Section VII
10.0 Supporting Stand Yes
11.0 Manhole with cover for inspection & Yes

cleaning
12.0 One suitably sized safety valve set at Yes

1.25 times the operating pressure of the
receiver to relieve full compressor
discharge capacity
13.0 One Pa range pressure gauge with Yes

isolating valve branch tap-off with
isolating valve for Purchasers test
pressure gauge and fittings for
mounting on the receiver
14.0 Counter flanges for all flanged Yes

connections with gaskets, bolts and nuts
15.0 Foundation Bolts Yes
16.0 Blowdown connection with isolating No

DATA SHEET A
valve required
17.0 Auto drain trap Yes
18.0 Piping from receiver to auto drain trap Yes
19.0 Pressure switches for start/stop of Yes

compressors
20.0 Material test certificate required? Yes

TESTS AT MANUFACTURERS
WORKS TO BE WITNESSED BY
PURCHASERS REPRESENTATIVE
21.0 Visual inspection and dimensional Yes
check against approved manufacturers
drawing
22.0 Hydrostatic test at 1.5 times the Yes
design pressure
23.0 Flanged connections for air inlet and Yes, as applicable

air outlet
24. All flanges to Indian/ASA standards Yes
25.0 Screwed connections (BSP/NPT) for Yes
pressure gauge, pressure switch, drain
valve / relief vale
(D) Oil Filter
1.0 Oil content in outlet air 3 ppm (max)
2.0 Efficiency of filter *
3.0 Material of filter element *
4.0 Life of filter element *
* Bidder to indicate
SPECIFICATION NO. TCE CONSULTING ENGINEERS LIMITED SECTION : D
ISSUE NO. R5
TCE.M4-107-01 DATA SHEET B

AIR / GAS COMPRESSORS SHEET : 1 OF 7
ENQUIRY/ SPECIFICATION NO. TCE.
SL. BIDDER
NO. ITEM
1. DESIGNATION COMPRESSORS FOR
2. NUMBER OFFERED (W+S)

3. TAG NUMBERS
GENERAL
4. TYPE OF COMPRESSOR RECIPROCATING/CENTRIFUGAL/SCRE

W
LUBRICATED / NON-LUBRICATED
5. MAKE AND MODEL NUMBER
6.
7.
RECIP CENT SCREW
8. NUMBER OF STAGES
9. NUMBER OF CYLINDERS PER NA NA
STAGE
10. TYPE OF CYLINDER VER / HOR NA NA
11. CYLINDER LINER PROVIDED YES / NO NA NA
COMPRESSOR DATA
12. SINGLE ACTING /DOUBLE SINGLE/

ACTING DOUBLE NA NA
13. CAPACITY (FAD) M3/ Hr
14. MASS FLOW RATE Kg/Hr NA NA
15. TYPE OF SUCTION AND PLATE / IGV/ BUTTERFLY
DISCAHRGE VALVE CHANNEL BUTTERFLY / PISTON
TYPE VALVE (OP) VALVE (OP)
AT SUCTION AT SUCTION
16 SUCTION PRESSURE 2
Kg/ cm (g)
17. DISCHARGE PRESSURE Kg/ cm2(g)
LEGEND : RECIP = RECIPROCATING, CENT= CENTRIFUGAL, VER = VERTICAL,
HOR = HORIZONTAL,IGV = INLET GUIDE VANES, OP = OPTIONAL, NA = NOT
APPLICABLE
NOTES TO BIDDER
1. DATA SPECIFIED IN DATA SHEET-A HAS NOT BEEN
SIGNATURE OF BIDDER
REPRODUCED IN DATA SHEET-B. IN CASE OF DEPARTURE
FROM DATA SHEET-A, BIDDER SHALL BRING OUT THE
SAME IN SCHEDULE OF DEVIATIONS, FAILING WHICH IT
SHALL BE CONSTRUED THAT BIDDER COMPLIES WITH THE
REQUIREMENTS STIPULATED IN DATA SHEET-A.
DATE
2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND
A COPY SHALL BE ENCLOSED WITH EACH COPY OF THE
BID.
FILE NAME: DB10701R5.DOC TCE FORM NO. 294 R1

ISSUE NO. R5

SL. BIDDER
NO. ITEM
RECIP CENT SCREW
18. SUCTION TEMPERATURE -
0
EACH STAGE C
19. DISCHARGE TEMPERATURE -
0
EACH STAGE C
20. SELECTED COMPRESSOR SPEED RPM
21. BKW AT SELECTED COMPRESSOR
SPEED KW
22. RECOMMENDED MAXIMUM
COMPRESSORS DATA (CONTD.)
SPEED RPM
23. BKW AT RECOMMENDED
MAXIMUM SPEED KW
24. VOLUMETRIC EFFICIENCY %
25. MECHANICAL EFFICIENCY %
26. MOTOR RATING AND SPEED KW/RPM / / /
27. LUBE OIL CONSUMPTION
FOR EACH COMPRESSOR LPM
28. LUBE OIL PUMP DRIVEN BY
COMPRESSOR MOTOR YES/ NO YES/ NO YES/ NO
29. MOTOR RATING, IF LUBE OIL
PUMP IS DRIVEN BY SEPARATE KW
MOTOR
30. AUXILIARY LUBE OIL PUMP WHETHER PROVIDED
TO BE PROVIDED YES/ NO
31. AUXILIARY LUBE OIL PUMP
/ / /
MOTOR RATING AND SPEED KW/RPM
32. TYPE AND MAKE OF BEARINGS
NOTES TO BIDDER
SIGNATURE OF BIDDER
DATE
BID.

ISSUE NO. R5

SL. BIDDER
NO. ITEM
RECIP CENT SCREW
33. COOLING WATER
REQUIREMENTS (NOTE 1)
33.1 FOR COMPRESSOR COOLING
33.1.1 FLOW RATE M3/ Hr
33.1.2 INLET AND MINIMUM OUTLET / / /
PRESSURE 2
Kg/cm (g)
33.1.3 INLET AND MAXIMUM OUTLET / / /
0
TEMPERATURE C
33.1.4
33.1.5
COMPRESSOR DATA (CONTD.)
33.1.6
33.2 FOR BEARING COOLING -
IF REQIRED
33.2.1 FLOW RATE M3/ Hr
33.2.2 INLET AND MINIMUM OUTLET / / /
PRESSURE Kg/cm2 (g)
33.2.3 INLET AND MAXIMUM OUTLET / / /
0
TEMPERATURE C
33.2.4
33.2.5
34. INTAKE FILTER TYPE
34.1 FILTER ELEMENT
34.2 RATED CAPACITY M3/ Hr

34.3 EFFICIENCY %
34.4 DESCRIPTIVE LITERATURE WHETHER ENCLOSED
TO BE ENCLOSED YES/ NO
34.5
NOTES TO BIDDER
SIGNATURE OF BIDDER
FROM DATA SHEET-A, BIDDER SHALL BRING OUT THE SAME
IN SCHEDULE OF DEVIATIONS, FAILING WHICH IT SHALL BE
CONSTRUED THAT BIDDER COMPLIES WITH THE
DATE
2. THIS DATA SHEET SHALL BE FILLED UP COMPLETELY AND A
COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

ISSUE NO. R5

SL. BIDDER
NO. ITEM
RECIP CENT SCREW
35. CAPACITY CONTROL
35.1 TYPE AND NUMBER OF STEPS BY SPEED VARIATION / AT CONSTANT
SPEED AND
35.2 METHOD EMPLOYED IN CASE OF
CONSTANT SPEED TYPE
35.3 CONTROL SYSTEM WRITE-UP TO WHETHER ENCLOSED
BE ENCLOSED YES/ NO
35.4 WIRING AND TUBING DIAGRAM WHETHER ENCLOSED
WITH CONTROL SCHEME TO BE YES / NO
ENCLOSED
36. EQUIPMENT AND ACCESSORIES
MOUNTED ON COMMON BASE

FRAME WITH THE COMPRESSOR
36.1 WEIGHT OF ENTIRE UNIT MOUNTED
ON COMMON BASE FRAME Kg
36.2 OVERALL DIMENSIONS OF X X X
COMMON BASE FRAME L X W M
37. EQUIPMENT AND ACCESSORIES
MOUNTED ON SEPARATE BASE
FRAME
37.1 WEIGHT OF EQUIPMENT AND
ACCESSORIES MOUNTED ON Kg
SEPARATE BASE FRAME
37.2 OVERALL DIMENSIONS OF X X X
SEPARATE BASE FRAME L X W M
38. NAME AND OVERALL DIMENSIONS
OF SINGLE LARGEST COMPONENT
TO BE LIFTED LXWXH M X X X
39. NAME AND WEIGHT OF HEAVIEST
SINGLE COMPONENT TO BE LIFTED Kg
NOTES TO BIDDER
SIGNATURE OF BIDDER
DATE
BID.

ISSUE NO. R5

SL. BIDDER
NO. ITEM
RECIP CENT SCREW
40. SUCTION FLANGE - FIRST STAGE mm
SIZE/ STANDARD/ RATING NB/
41. DISCHARGE FLANGE -FINAL mm
STAGE - SIZE/ STANDARD/ NB/

RATING
42. IF DRIVE MOTOR IS TO BE
FURNISHED BY THE PURCHASER
42.1 RATING/ SPEED KW/RPM
42.2 STARTING TORQUE Kg M
42.3 DIRECTION OF ROTATION OF / / /
MOTOR AS VIEWED FROM
COUPLING END
43. ALL THE ACCESSORIES AS WHETHER INCLUDED
CALLED FOR IN DATA SHEET A YES / NO
TO BE INCLUDED
44.
I/C A/C
1 STG 2 STG 3 STG

INTER-COOLERS / AFTER-COOLERS
45. DESIGNATION
46. NUMBER OFFERED
47. TAG NUMBERS
48. TYPE VER/ HOR VER/HOR

49. CAPACITY (FAD) 3
M /Hr
50. COOLING WATER FLOW RATE M3/ Hr
51. AIR/ GAS INLET/OUTLET / / / /
TEMPERATURE 0
C
52. COOLING WATER INLET/ MAXI- / / / /
MUM OUTLET TEMPERATURE 0
C
NOTES TO BIDDER
SIGNATURE OF BIDDER
DATE
A COPY SHALL BE ENCLOSED WITH EACH COPY OF THE BID.

ISSUE NO. R5

SL. BIDDER
NO. ITEM
I/C A/C
53. AIR/ GAS INLET AND OUTLET / / / /
PRESSURE Kg/cm (g)2
INTER-COOLERS / AFTER-COOLERS (CONTD.)
54. COOLING WATER INLET/ / / / /

MINIMUM OUTLET PRESSURE Kg/cm (g)2
55. COOLING SURFACE AREA M2

56. DESIGN PRESSURE - AIR/ GAS SIDE Kg/cm2(g)
57. DESIGN PRESSURE - WATER SIDE Kg/cm2(g)
58. CODE OF CONSTRUCTION
59. CORROSION ALLOWANCE mm 3 3 3 3
60. NUMBER OF PASSES
61. EMPTY WEIGHT Kg
62. OPERATING WEIGHT Kg
63. WATER FILLED WEIGHT Kg
64. ALL THE ACCESSORIES
AS CALLED FOR IN DATA SHEET A WHETHER INCLUDED
TO BE INCLUDED YES / NO
65. DESIGNATION RECEIVERS FOR
66. NUMBER OFFERED
67. TAG NUMBERS
68. TYPE VER/ HOR VER/ HOR VER/ HOR
RECEIVERS
69. CAPACITY 3
M
70. SIZE
70.1 DIAMETER mm
70.2 HEIGHT TAN TO TAN mm
71. DESIGN PRESSURE Kg/cm2(g)
72. CODE OF CONSTRUCTION
73. CORROSION ALLOWANCE mm
NOTES TO BIDDER
SIGNATURE OF BIDDER
DATE

ISSUE NO. R5

SL. BIDDER
NO. ITEM
74. THICKNESS
74.1 SHELL mm
RECEIVERS (CONTD.)
74.2 DISHED ENDS mm

75. WEIGHT
75.1 EMPTY Kg
75.2 OPERATING Kg
75.3 FILLED WITH WATER Kg
76. ALL THE ACCESSORIES AS CALLED
FOR IN DATA SHEET A TO BE WHETHER INCLUDED
INCLUDED YES / NO
77. ALL THE VALVES, SPECIALITIES,
MISCELLANEOUS
INSTRUMENTS, COUNTER FLANGES,

FOUNDATION BOLTS ETC. AS
CALLED FOR IN DATA SHEET A AND WHETHER INCLUDED
AS PER ENCLOSED P & I D TO BE YES / NO
INCLUDED
78. CAPACITY OF COMPRESSOR M3/ Hr (+) ()
PERFORMANCE GUARANTEES
79. DISCHARGE PRESSURE Kg/cm2(g) (+) ()

80. POWER CONSUMPTION KW
(+) ()
81. TEMPERATURE OF AIR AT OUTLET 0
C
OF AFTER-COOLER (+) ()
82. COOLING WATER FLOW RATE 3
M / Hr (+) ()
83. COOLING WATER OUTLET TEMP. 0
C (+) ()
84. COOLING WATER PRESSURE DROP 2
Kg/cm (g) (+) ()
85.
NOTES
1. IF AIR COOLED COMPRESSOR IS OFFRERED, BIDDER TO FURNISH COOLING SYSTEM
DETAILS LIKE NATURAL OR FORCED COOLING, FAN CAPACITY, MOTOR RATING ETC.
LEGEND : I/C = INTER-COOLER, A/C = AFTER-COOLER, STG = STAGE

NOTES TO BIDDER
SIGNATURE OF BIDDER
DATE

SPEC.NO.
TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M4-107-01 SHEET 1 OF 10
AIR / GAS COMPRESSORS
1.0 SCOPE

manufacture, shop inspection and testing at manufacturers works, delivery at
site, handling at site, erection, testing, commissioning, performance testing
and handing over of Air / Gas Compressors and Accessories.
2.1 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.
2.2 The following are some of the important codes and standards relevant to this
specification.
API 617 Centrifugal Compressors for Petroleum, Chemical, and Gas
Service Industry Services
API 618 Reciprocating Compressors for Petroleum, Chemical, and Gas
Industry Services
API 619 Rotary Type Positive Displacement Compressors for
Petroleum, Chemical, and Gas Industry Services
API 672 Packaged, Integrally Geared Centrifugal Air Compressors for
Petroleum, Chemical, and Gas Industry Services
ASME SEC. Boiler and Pressure Vessel Code
VIII DIV.1
TEMA Standards of the Tubular Exchanger Manufacturers Association
IS 2825 Code for Unfired Pressure Vessels
IS 5456 Code of Practice for Testing of Positive Displacement Type Air
Compressors and Exhausters
IS 6206 Guide for Selection, Installation and Maintenance of Air
Compressor Plants with Operating Pressures up to 10 bars
IS 7938 Air Receivers for Compressed Air Installation
IS 11780 Code for Selection and Testing of Rotary Screw Air
Compressors (Oil Flooded)
IS 13124 Reciprocating Gas Compressors - Technical Supply Conditions
ISSUE
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FILENAME : M410701R6.DOC TCE FORM NO. 329 R3

SPEC.NO.
3.0 DESIGN AND CONSTRUCTION FEATURES
The compressor shall be of reciprocating or centrifugal or screw type as

specified in data sheet A.
3.1 RECIPROCATING COMPRESSORS
3.1.1 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.
3.1.2 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.
3.1.3 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.
3.1.4 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.
3.1.5 Connecting Rod and Crank Shaft
ISSUE
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SPEC.NO.
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.
3.1.6 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.
3.1.7 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.
3.1.8 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.
3.1.9 Lubrication
(a) 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.
(b) Cylinder Lubrication

ISSUE
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SPEC.NO.
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.
3.2 CENTRIFUGAL COMPRESSORS
3.2.1 Casing
Casing shall be either horizontally split or vertically split type made of cast
iron for moderate pressure applications, cast steel for high pressure
applications or as specified in data sheet A. The thickness of casing shall be
suitable for maximum working and test pressures and shall have a corrosion
allowance of at least 3 mm.
3.2.2 Impellers
Impellers shall be open, semi-open or closed type consisting of disk, hub and
blades. The blades shall be either radial or backward leaning type only. The
material of construction shall be as specified in data sheet A. The design shall
be such as to produce low operating stress levels giving high mechanical
integrity.
3.2.3 Gears
The gears shall be of high speed precision helical type designed as per AGMA
standards. The bull gear shall be directly connected to the driver by a low
speed coupling. The bull gear may be integrally forged with its shaft. In case
bull gear is forged separately, same shall be assembled with an interference fit
on its shaft. The pinion shall be integrally forged with its shaft. It shall be
hardened and precision ground to AGMA 13 quality of AGMA 2000-A88 for
longer life.
3.2.4 Bearings and Seals
The bearings used for pinion and impeller shall be such that high stability and
low vibrations are achieved. Tapered - land thrust bearings shall be provided
for rotor assembly. Bearing shoes shall be pressure lubricated and steel
babbited. Bearings shall be comparatively insensitive to load changes and
variations in oil supply pressure. Hydrostatic squeeze film bearings are also
acceptable. The bull gear shall be supported by horizontally split sleeve
journal bearings and thrust shall be absorbed in either direction by thrust
bearings. To prevent any oil vapour contamination and to ensure oil-free air,
mechanical type air and oil seals shall be provided on the pinion shaft.
ISSUE
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SPEC.NO.
3.2.5 Rotor Assembly
Rotor assembly shall consist of pinion shaft to which impellers are attached.
The shaft shall be of forged carbon steel or stainless steel or as specified in
data sheet A. A thrust collar shall be provided on pinion shaft.
3.3 SCREW COMPRESSORS
3.3.1 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.
3.3.2 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 timing gears and thrust collars. The rotors shall be
ultrasonically tested. For non-lubricated screw compressors rotors shall be
lined with PTFE.
3.3.3 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.
3.3.4 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.
3.3.5 Air- Oil Separator
In case of lubricated screw compressors, high efficiency air-oil separation

system shall be provided to ensure removal of oil.
4.0 ACCESSORIES
ISSUE
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SPEC.NO.
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.
4.1 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 .
4.2 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 as specified in data sheet A. The material of construction and
design shall be as specified in data sheet A.
4.3 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.
4.4 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.
5.0 MOTOR RATING
Motor shall be of suitable rating considering compressor power requirements.

Motor rating shall be calculated as follows :
ISSUE
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SPEC.NO.
(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
6.0 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

(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.
6.1 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.
6.1.1 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.
6.1.2 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
ISSUE
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SPEC.NO.
(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.
6.1.3 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.
6.1.4 Each compressor shall be provided with one selector switch having three
positions marked AUTO-OFF-ON for the following functions :
(a) OFF - Stops the motor.
ISSUE
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SPEC.NO.
(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.
6.1.5 Two (2) Compressors Operation
A master selector switch common to both the compressors shall be provided

having two positions marked AB and BA. When the master selector switch
is in position ABand the individual compressor control switches are in
AUTO position, compressor A shall have continuous run-load-unload
regulation and compressor B shall have auto start-stop regulation. In the
other position of the master selector switch BA, compressor B shall have
continuous run-load-unload regulation while compressor A shall have start-
stop regulation.
6.1.6 Three (3) Compressors Operation
A master selector switch common for three (3) compressors shall be provided
having three (3) positions marked AB/C, BC/A and CA/B. When the
individual compressor control switch is in AUTO position and the master
selector switch is in position AB/C, compressors A and B shall have
continuous run-load-unload regulation and compressors C shall have auto
start-stop regulation. Similarly with master selector switch in position BC/A,
compressors B and C shall have continuous run-load-unload regulation and
compressor A shall have auto start-stop regulation. With master selector in
position CA/B, compressors C and A shall have the continuous run-load-
unload regulation while compressor B shall have auto start-stop regulation.
6.1.7 Four (4) Compressors Operation
A master selector switch common for four (4) compressors shall be provided
having four (4) positions marked AB/C, BC/D, CD/A, DA/B. When the
individual compressor control switches are in AUTO position and the master
selector switch is in position AB/C, compressors A and B shall have
continuous run-load-unload regulation and compressor C shall have auto
start-stop regulation. Similarly with master selector switch in position BC/D,
compressors B and C shall have continuous run-load-unload regulations
and compressor D shall have auto start-stop regulation. With master selector
in position CD/A compressors C and D shall have continuous run-load-
unload regulation while compressor A shall have auto start-stop regulation.
With master selector in position DA/B compressors D and A shall have
the continuous run-load-unload regulation while compressor B shall have
ISSUE
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SPEC.NO.
TCE.M4-107-01 SHEET 10 OF 10
auto start-stop regulation. Fourth compressor not indicated in the selector

position shall be on manual control.
6.2 Two pressure switches shall be provided to monitor receiver pressure for each
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.
6.3 Pressure switches with alarm initiating contacts shall be provided for the
receiver high and low pressures.
6.4 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.
6.5 For centrifugal compressors anti-surge control shall also be provided to protect
compressor from surging.
6.6 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.
6.7 Green and red lamps shall be provided to indicate motor running and stop
conditions respectively.
6.8 Motors shall be provided with motor winding over-heat sensors and bearing
temperature sensors for alarm indication and to trip the motor.
6.9 For compressors driven with turbine, the required turbine control and
instrumentation shall be provided.
6.10 For air / gas compressors, depending on the hazardous area classification,
motors and instrument enclosures shall be explosion-proof certified for the
specific area.
7.0 NOISE AND VIBRATIONS
7.1 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.
7.2 The overall vibration level shall be as per zones A and B of ISO 10816-1.
Vibration dampening pads if required, shall be provided.
ISSUE
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SPEC.NO.
TCE.M4-107-01 SHEET 11 OF 10
8.0 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.
BIDDER 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.
ISSUE
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SPEC.NO.
DATA SHEET C
DATA TO BE FURNISHED BY THE CONTRACTOR 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 compressor capacity, drive motor rating, selection of speed

reducers and couplings. Torsional vibration analysis for centrifugal and screw
compressors
4. Thermal design calculations for inter-coolers, after-coolers and oil-coolers
5. Detailed P&I diagram showing clearly the scope of supply of equipment,

piping with line sizes and material specifications, valves, specialities,
instrumentation and control and all the accessories. All equipment, lines,
valves, specialities and instruments shall be tagged as per the PURCHASERs
procedure to be given to the successful BIDDER. All terminal points shall be
clearly identified. All design data and other information furnished in data
sheets A and B shall be covered either in this drawing or other relevant
drawings or documents mentioned below.
6. Detailed equipment list and bill of materials of all items in the

CONTRACTORs scope
7. Sub-vendor list for all bought-out items
8. Mechanical design calculations for inter-coolers, after-coolers, oil-coolers,

moisture and oil separator and receivers
9. Characteristic curves of compressors. For centrifugal compressors, 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
10. Dimensioned to-scale equipment layout drawing showing all equipment,

accessories, relevant external dimensions, location and elevation of terminal
points, details of piping and electrical connections to be made by the
PURCHASER, clearances required for erection, dismantling, operation and
maintenance
ISSUE
R4

SPEC.NO.
DATA SHEET C (CONTD.)
11. Dimensioned cross-section drawings of compressors and other proprietary

items with part list and materials of construction
12. Detailed fabrication drawings of all fabricated equipment like inter-coolers,

after-coolers, air receivers etc.
13. Line designation schedule for all lines in the CONTRACTORS scope
14. List of valves, specialities and instruments in the CONTRACTORS scope

with tag numbers, type, makes, pressure ratings, materials of construction and
ranges for instruments etc.
15. Manufacturers drawings, data sheets and catalogues for valves, specialities
and instruments etc.
16. Dimensioned to-scale piping layout drawing for piping in the

CONTRACTORs scope with allowable forces and moments on the piping
nozzles and displacement of the nozzles
17. Overall foundation plan, base frame drawing for each equipment, static and
dynamic loads on each of the anchor bolts and dimensional details of pockets
and anchor bolts
18. Motor drawings
19. Electrical control wiring diagrams with all interlocks
20. Control philosophy, interlock description and logic diagrams
21. Dimensional to-scale general arrangement and section drawings of MCC and
instrument control panel with complete bill of materials
22. List of alarms and trip settngs
23. Erection, start-up, operation and maintenance manual complete with

lubrication schedule etc.
ISSUE
R4

DATA SHEET - A
`TCE-3472-107-02 DUAL TYPE CONTROL FOR AIR COMPRESSORS SHEET 1 OF 2
GENERAL DATA
1.0 DESIGNATION CONVEYING AIR COMPRESSORS .
2.0 TYPE --DUAL FOR A SET OF

4COMPRESSORS FOR CONV.AIR
---DUAL FOR A SET OF 2
COMPRESSORS FOR INST. AIR3
3.0 NOS. REQUIRED TWO(2)
4.0
5.0
DESIGN DATA
6.0 ADJUSTABLE RANGE FOR PRESSURE Pa SHALL BE ADJUSTABLE

SWITCHES THROUGHOUT THE RANGE
7.0 EXPECTED SETTING OF PRESSURE

SWITCHES FOR -
7.1 LOADING UNLOADING REGULATION Pa(g)
(a) Loading *
(b) Unloading *
7.2 AUTOMATIC START-STOP REGULATION Pa(g)
(a) Start *
(b) Stop *
7.3 VERY LOW AIR RECEIVER PRESSURE Pa(g) *

ALARM
7.4 HIGH AIR RECEIVER PRESSURE ALARM Pa(g) *
7.5 DETAILS OF POWER SUPPLY TO -
7.5.1 CONTROLS V, Ph, Hz 110V, 1 Ph, 50 Hz
7.5.2 ALARM CONTACTS V, AC/V, 110V, 1 Ph, 50 Hz

DC
7.6 SOLENOID VALVE SUITABLE FOR VOLTS 110V, 1 Ph, 50 Hz

OPERATION
DATA SHEET - A
`TCE-3472-107-02 DUAL TYPE CONTROL FOR AIR COMPRESSORS SHEET 2 OF 2
NOTES
1)Conveying air compressors

Out of four (4) compressors provided, two(2)
compressors shall be operating normally on
load unload control, while another two
compressors will be on auto standby.
2)Instrument air compressors

Out of twor (2) compressors provided, one (1)
compressor shall be operating normally on
load unload control, while another one
compressor will be on auto standby.
* BIDDER TO INDICATE
DATA SHEET - A
TCE-5178A- 116-57 ASH DISPOSAL SYSTEM FLY ASH & BED ASH SHEET 1 OF 3
STORAGE SILO AND ACCESSORIES
1.0 GENERAL DESIGN DATA
1.1 Type of Silo Construction /Quantity RCC FLY ASH & BED ASH
SILOS / 2 NOS.
1.2 Construction of Silo by BY VENDOR
1.3 Bulk Density of Ash for Volume kgs/cu.m (REFER SYSTEM DATA SHEET)
Calculations
Fly ash 800
Bed ash 1800
1.4 Bulk Density of Fly Ash for Struc- kgs/cu.m

tural Design Calculations
Fly ash 1600
Bed ash 3600
1.5 Amount of Ash to be Stored

Bed Ash 280 tonnes
Fly Ash 665 tonnes
1.6 Method of Venting Conveying THROUGH BAG FILTER TO

Air from Silo ATMOSPHERE
1.7 Type of Bunker Level Measurement CONTINUOUS/RF TYPE
1.8 No. of Outlets Required with THREE (3) FOR FLY ASH SILO -
Purpose -- TWO FOR UNLOADING
FLYASH TO CLOSED TRUCKS
IN DRY FORM.
.--ONE FOR SLURRY PUMPING
UPTO ASH SLURRY SUMP.
TWO (2) FOR BED ASH SILO -

-- ONE FOR UNLOADING
BED ASH TO CLOSED TRUCKS
IN DRY FORM.
.--ONE FOR SLURRY PUMPING
UPTO ASH SLURRY SUMP.
1.9 Type of valve at silo outlets Knife gate valve-Pneumatically

operated)
2.0 ACCESSORIES AND MOUNTINGS TO BE SUPPLIED BY BIDDER
2.1 Manhole YES
2.2 Ladder for Access Inside Silo YES (SS - LADDER)

DATA SHEET - A
2.3 Pressure and Vacuum Relief Door YES
2.4 Vent Bag Filter YES
2.4.1 Bag material type ANTI STATIC
2.4.2 Air to cloth ratio m/min 1.0
2.4.3 Ash particles in the exhaust of mg/ 100

bag filter NCu.m
2.4.4 Materials of construction
a) Casing G.I
b) Hopper (if required) M.S
2.5 Access Staircase from Ground YES

Level to Silo Top
2.6 Silo Fluidising Equipment with YES

Air Slides
2.7 Adequately Sized Openings YES
2.8 Operating Floor at Slurry Preparation YES
2.9 Floor Opening as Required YES
2.10 Silo Ash Level Indication YES
2.11 Hand Rails and Toe Plates all YES

Round Roof Area Required
2.12 Silo Lining Material REFRACTORY LINING
2.13 Silo Top Cover AIR & WATER TIGHT RCC

SLAB
2.14 Clear head room from the ash 5 m CLEAR

discharge chute upto ground
level for trucks to pass through
2.15 Steel bracket assemblies YES

including brackets for vertical
pipe runs attached to fly ash
silo
2.16 Mono rail with hoist to handle YES

DATA SHEET - A
equipment from silo top to ground
2.17 Grating platform for inter- YES
connecting silos at
silo unloading platform level and
also at silo top
3.0 TESTS AT MANUFACTURER'S WORKS
3.1 Visual and Dimensional Check YES
of all the Accessories of Silo
3.2
4.0 NOTES
SPECIFICATION NO. TCE CONSULTING ENGINEERS LIMITED SECTION D4
ISSUE NO. R6
DATA SHEET - B
TCE.M4-116-57 ASH DISPOSAL EQUIPMENT FLY ASH / FURNACE SHEET 1 OF 1
ASH STORAGE SILO AND ACCESSORIES
SR.NO. ITEM BIDDER
1.0 CONSTRUCTION OF SILO BY:
2.0 QUANTITY OF ASH TO BE STORED Tonnes
3.0 METHOD OF VENTING CONVEYING AIR

FROM SILO
4.0 SILO LINING MATERIAL, IF PROVIDED
5.0 IS PAINTING AS SPECIFIED INCLUDED YES/NO
6.0 VENT FILTER:
6.1 Manufacturer
6.2 Material of Filter Bags
6.3 Type of Bag Cleaning Arrangement
6.4 Materials of Construction
6.4.1 Casing
6.4.2 Hopper
7.0 TYPE AND MAKE OF SILO LEVEL

INDICATING DEVICE
8.0 IS CATALOGUE FOR LEVEL INDICATOR YES/NO

ENCLOSED?
9.0 NO OF OUTLETS PROVIDED

FILE NAME : DB11657R6.DOC TCE FORM NO. 294 R1
.
SPEC NO. TCE CONSULTING ENGINEERS LIMITED SECTION: D
TCE.M4-116-57 TITLE SHEET 1 of 1
ASH DISPOSAL EQUIPMENT FLY ASH / BED ASH

DATA SHEET C

AFTER AWARD OF THE CONTRACT
1.0 Dimensional drawing of the silo indicating loadings, openings, connections,

etc., to enable the PURCHASER to make detailed design drawings if silo
construction is by the PURCHASER.
2.0 Detailed dimensional drawings of silo, indicating all the equipment included
in the VENDORs scope of supply and are to be mounted on the silo,
platforms, staircases, handrails, arrangement of silo unloading equipment,
(both plan and elevation), if included in the VENDORs scope of supply,
with loading details, fixing details, details of openings required in the floors
etc.
3.0 QAP for all the equipment shall be submitted for approval.
4.0 Manufacturers test certificates for the material of equipment supplied.
5.0 Operation and maintenance manuals for silo mounting equipment.
ISSUE
R6
FILE NAME : M411657R6.DOC TCE.FORM NO. 329 R3

ASH DISPOSAL SYSTEM - JET PUMP

TCE-3990A-C-570-04 DATA SHEET - A SHEET 1 OF 3
JET PUMP
1.0 DESIGN DATA
1.1 Number Required

At bottom of Fly Ash Silo One (1)
At bottom of Bed Ash Silo One(1)
1.2 Location
At bottom of Fly Ash Silo One (1)
At bottom of Bed Ash Silo One(1)
1.3 Max. Size of Ash Particles to be handled (mm) REFER SYSTEM DATA SHEET IN SECTION C-13
1.4 Design Rate at which Ash has to be Conveyed

Fly Ash 50 TPH
Bed Ash 20 TPH
1.5 Discharge Point ASH SLURRY SUMP
2.0 MATERIALS OF CONSTRUCTION MATERIAL HARDNESS

BHN (Min.)
2.1 Inlet Piece ALLOY CI TO IS 4771

WITH MIN. 2.5% NICKEL - 340
2.2 Nozzle Tip (Replaceable) TUNGSTEN CARBIDE - 500
2.3 Discharge Piece ALLOY CI TO IS 4771

WITH MIN.2.5% NICKEL - 340
2.4 Nozzle - DO - - 340
2.5 Throat - DO - - 340
2.6 Gaskets RUBBER COMPOUND
3.0 TESTS TO BE CONDUCTED AT

MANUFACTURERS WORKS
3.1 Visual Inspection and Dimensional Check

against Manufacturers Approved Drawing
3.2 Hydrotest at 1.5 times the design pressure for

various components of jet pump
REV. NO. 01 PPD. BY DS JOB NO. OWNER : BORL ; EPCC:BHEL

DATE CKD. BY KG TCE-
3990A
REV. BY DATE 26-05-08 PROJECT: 3x 33MW CPP BINA
TCE FORM 330 R1

DATA SHEET A
`TCE-5178A -116-53 ASH HANDLING SYSTEM- ROTARY FEEDER SHEET 2 OF 3
2.0 ROTARY FEEDER
2.1 Designation FLY ASH & BED ASH
2.2 Number Required NOS.

2 dry outlet+1 Slurry outlet for FA THREE FOR FLY ASH SILO
1 dry outlet+1 Slurry outlet for FA TWO FOR BED ASH SILO
2.3 Design Capacity

Slurry Disposal
Bed Ash (Design) TPH 20
Fly ash (Design) TPH 50
Dry Form Disposal

Bed Ash (Design) TPH 40
Fly ash (Design) TPH 98 x 2 Outlets,
2.4 Duty hrs/day 24
2.5 Material Handled BED ASH/FLY ASH
2.6 Maximum Lump Size mm REFER SYSTEM DATA SHEET
2.7 Density (BED ASH /FLY ASH) kg/m3 1800/800

0
2.8 Temperature C REFER SYSTEM DATA SHEET
2.9 Abrasive Property HIGHLY
2.10 Inlet NOTE-1
2.11 Rotor NOTE-1
2.12 Shaft FORGED STEEL
2.13 Housing Outlet NOTE-1
2.14 Motor by BY VENDOR
2.15 Control Cabinet BY VENDOR
2.16 Types of Coupling V BELT TRANSMISSION,

Transmission Details FLEXIBLE COUPLING
2.17 Type of Construction SPARK RESISTANT CLASS

A/B/C
Notes
DATA SHEET A
`TCE-5178A -116-53 ASH HANDLING SYSTEM- ROTARY FEEDER SHEET 3 OF 3
1. Alloy CI - Type 1a as per IS-4771 with hardness of 500 BHN min., for all parts
coming in contact with fly ash/bed ash. Alternatively MS fabricated with 10 thick
TISCRAL/ SAILHARD liners construction.
ISSUE NO. R4
DATA SHEET - B
TCE.M4-116-53 ASH DISPOSAL EQUIPMENT SHEET 1 OF 2
CONTINUOUS DUST CONDITIONER UNLOADER &
ROTARY FEEDER
SR.NO. ITEM BIDDER
1.0 CONTINUOUS DUST CONDITIONER &

UNLOADER
1.1 Number
1.2 Capacity T/hr
1.3 Water quantity required m3/hr
1.4 Pressure of inlet water Kg/cm
1.5 Location of spray headers
1.6 Paddle Mixer
1.6.1 Diameter of paddle mixer
1.6.2 Speed
1.6.3 Outlet type
1.6.4 Shaft of mixer (Type & diameter)
1.6.5 Type of trough
1.6.6 Type of shaft
1.6.7 Material of Construction
i) Trough/top cover
ii) Paddles
iii) Shaft
iv) Spray nozzles
1.7 Head room required for installing the conditioner

including metering device (Enclose a sketch)

ISSUE NO. R4
DATA SHEET - B
CONTINUOUS DUST CONDITIONER UNLOADER &
ROTARY FEEDER
SR.NO. ITEM BIDDER
2.0 ROTARY FEEDER
2.1 Capacity T/hr
2.2 Speed of feeder RPM
2.3 Pressure differential for which feeder can seal
2.4 Material of Construction and thickness of
2.4.1 Feeder housing
2.4.2 Inlet piece
2.4.3 Rotor Vanes
2.5 Material of rotor shaft
2.6 Drive Unit
2.6.1 KW rating of motor kW
2.6.2 Type of enclosure for the motor
2.7 Feeder inlet opening size
2.8 Feeder outlet opening size
NOTE TO BIDDE SIGNATURE

.
SPEC NO. TCE CONSULTING ENGINEERS LIMITED SECTION: D
ASH DISPOSAL EQUIPMENT
CONTINUOUS DUST CONDITIONER, UNLOADER &
ROTARY FEEDER
DATA SHEET C

1.0 General arrangement drawings indicating the dimensions, design data and
materials of construction.
2.0 Water requirement giving the quantity and pressure.
3.0 Detailed dimensioned general arrangement drawing giving fixing details,

loading data, etc. of rotary feeder and conditioner.
4.0 Motor data for rotary feeder and conditioner.
5.0 Operation and maintenance manuals.
6.0 All test certificates
ISSUE
R4
FILE NAME : M411653R4.DOC TCE.FORM NO. 329 R3

SPEC. NO. TCE CONSULTING ENGINEERS LIMITED SECTION: D 6
TCE.M4-106-01 AIR BLOWERS SHEET 1 OF 3
1.0 SCOPE

manufacture, shop inspection and testing at the manufacturers works and
delivery at site of Air Blowers.

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 VENDOR of this responsibility.
3.0 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.
3.1 CASING
3.1.1 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.
3.1.2 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.
3.2 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 as specified in data sheet A. 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.
ISSUE
R4
FILE NAME: M410601R4.DOC TCE FORM NO. 329 R3

3.3 SHAFT, SLEEVES AND BEARINGS
3.3.1 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.
3.3.2 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.
3.3.3 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.
3.3.4 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 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.
3.4 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.
3.5 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 VENDOR shall furnish both halves of the coupling. Coupling halves
shall be bored and keyed to fit shafts of the blower and the motor by VENDOR.
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 VENDOR shall supply both the halves of coupling duly machined and
keyed and base plate with motor mounting bolt holes.
4.0 GENERAL REQUIREMENTS
4.1 Blower shall also be suitable to operate as an exhauster for the vacuum specified.
ISSUE
R4

4.2 Air filter if specified in data sheet A shall have filtering efficiency of 99% down
to a particle size of 5 microns.
4.3 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.
4.4 All rotating parts such as coupling, chain or belt drives etc. shall be covered with
suitable protective guards. Guards shall be easily removable type.
4.5 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.
4.6 Suitable drain connection shall be provided.
5.0 PERFORMANCE GUARANTEE
Performance parameters to be guaranteed by the VENDOR 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. Blower or
any portion thereof is liable for rejection, if it fails to give any of the guaranteed
performance parameters.
ISSUE
R4

DATA SHEET C

AFTER THE ISSUE OF PURCHASE ORDER
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 A and 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
ISSUE
R2

DATA SHEET A
`TCE-3037-106-01 AIR BLOWER SHEET 1 OF 2
1.1 Designation *
1.2 Number Required **
1.3 Capacity m3/hr *
1.4 Discharge Pressure kg/cm2(g) *
1.5 Medium Handled AIR
1.6 Specific Gravity of Medium
1.7 Maximum Speed rpm 1500
1.8 Type of Coupling V.BELT
1.9 Type of Shaft Sealing MFG. STD
1.10 Type of Drive ELECTRIC MOTOR
2.0 MATERIAL OF CONSTRUCTION
2.1 Casing STEEL
2.2 Shaft EN-8
2.3 Base Plate MS/CI
2.4 Rotor STEEL/MFG STD
2.5 Shaft Sleeves MFG. STD
2.6 Bearings ANTI FRICTION
3.0 MOTOR DETAILS
3.1 Drive Motor By VENDOR
3.2 Insulation Class B
3.3 Supply 415 V, 3 PHASE, 50 Hz
3.4 Common/Separate Base Plate By VENDOR/PURCHASER

REV. NO. PPD. BY : DS JOB NO. OWNER: BORL ; EPCC:BHEL
DATE CKD. BY : KG 5178A PROJECT : 2 X 250 MW UNITS 3 & 4
REV. BY DATE : 26.05.08 GHTP STAGE-II
TCE FORM 330 R1
DATA SHEET A
`TCE-3037-106-01 AIR BLOWER SHEET 2 OF 2
4.0 DATA TO BE FURNISHED BY

VENDOR AFTER THE AWARD OF
CONTRACT
4.1 Characteristic Curves to be Yes

Compute Delivery Capacity for Air
4.2 Operating Instructions and Yes

Maintenance Manuals
5.0 NOTES
5.1 * - Bidder to decide/furnish
5.2 ** - Please refer following table and flow diagram
---------------------------------------------------------------------------------------------------
SL. DESIGNATION QUANTITY LOCATION
NO.
---------------------------------------------------------------------------------------------------
1. Fly ash/bed ash silo fluidising 2(1W +1S) In door at AHEH
blower for both
silos
2. Ash hopper fluidising 2(1W +1S) In door at AHEH

blowers
--------------------------------------------------------------------------------------------------
REV. NO. PPD. BY : DS JOB NO. OWNER: BORL ; EPCC:BHEL

DATE CKD. BY : KG 5178A PROJECT : 2 X 250 MW UNITS 3 & 4
REV. BY DATE : 26.05.08 GHTP STAGE-II
TCE FORM 330 R1
SPECIFICATION NO. TCE CONSULTING ENGINEERS LIMITED SECTION: D6
ISSUE NO. R4 TCE.M4-106-01 DATA SHEET B

SHEET: 1 OF 3
AIR BLOWERS
ENQUIRY/SPECIFICATION NO. TCE.
SL. BIDDER
NO.
ITEM
1. DESIGNATION AIR BLOWER FOR

2. NUMBER OFFERED (W + S)
GENERAL
3. TAG NUMBERS
4. MAKE AND MODEL NUMBER
5.
6.
7. CAPACITY (FAD) NORMAL/ MAXIMUM M/Hr /
DESIGN AND PERFORMANCE
8. VACUUM CREATED cm Hg VACUUM

9. DISCHARGE PRESSURE Kg/cmg
10. SELECTED SPEED OF BLOWER RPM
11. CASING MATERIAL/THICKNESS / mm
12. IMPELLER OR ROTOR DIAMETER mm
13. IMPELLER OR ROTOR MATERIAL/
THICKNESS / mm
14. SHAFT MATERIAL/DIAMETER / mm
15.
16. MATERIAL OF CONSTRUCTION/ /
EFFICIENCY OF AIR FILTER
17. PRESSURE DROP ACROSS AIR FILTER mm WC MAXIMUM
18. SIZE/MATERIAL OF CONSTRUCTION OF mm NB/
ACCESSORIES
CASING DRAIN VALVE

19. SIZE/MATERIAL OF CONSTRUCTION OF INLET___INCH, OUTLET___
INCH
RELIEF VALVE ORIFICE_____ /
20. SIZE/MATERIAL OF CONSTRUCTION OF mm/
OUTLET DAMPER
21. VIBRATION DAMPENING PADS CUSHYFOOT(DUNLOP)/
22.
NOTES TO BIDDER
1. DATA SPECIFIED IN DATA SHEET-A HAS NOT BEEN SIGNATURE OF
REPRODUCED IN DATA SHEET-B. IN CASE OF DEPARTURE BIDDER
DATE

SPECIFICATION NO. TATA CONSULTING ENGINEERS SECTION: D6

SHEET: 2 OF 3
AIR BLOWERS
SL. BIDDER
NO.
ITEM
MOTOR COUPLING V-BELT

23. TYPE
24. MAKE
25. MODEL NUMBER
DRIVE DATA
26. ABSORBED POWER AT SHAFT KW NA NA

27. POWER INPUT AT DUTY POINT KW NA NA
28. RATING KW
29. SPEED RPM
30. REDUCTION RATIO NA NA
31. EFFICIENCY % NA
32. SERVICE FACTOR NA
33. NOISE LEVEL AT 1.5 M DISTANCE FROM
dBA
BLOWER
34. WEIGHT OF ENTIRE UNIT MOUNTED ON
Kg
COMMON BASE PLATE
35. TOTAL DYNAMIC LOAD Kg
36. DOCUMENTS TO BE ENCLOSED WHETHER ENCLOSED
MISCELLANEOUS
36.1 GENERAL ARRANGEMENT DRAWING

YES/NO
WITH MAJOR DIMENSIONS
36.2 PART LIST WITH CODES AND MATERIALS
YES/NO
OF CONSTRUCTION
36.3 PERFORMANCE CURVE WITH DUTY
YES/NO
POINT MARKED
36.4 SELECTION CHARTS OR CURVES YES/NO
36.5 LIST OF START-UP SPARES YES/NO
36.6 LIST OF RECOMMENDED SPARES FOR 2
YES/NO
YEARS NORMAL OPERATION
LEGEND: NA: NOT APPLICABLE

NOTES TO BIDDER
DATE

SPECIFICATION NO. TCE CONSULTING ENGINEERS LIMITED SECTION: D6

SHEET: 3 OF 3
AIR BLOWERS
SL. BIDDER
NO.
ITEM
39. CAPACITY (FAD) M/Hr (+) ()

PERFORMANCE
GUARANTEES
40. DISCHARGE PRESSURE Kg/cmg (+) ()

41. POWER CONSUMPTION KW (+) ()
42.
43.
NOTES TO BIDDER
DATE

SPEC.NO.
TCE CONSULTING ENGINEERS LIMITED SECTION: D7
TCE.M4-113-54
ELECTRICALLY OPERATED HOISTS SHEET 1 OF 5
1.0 SCOPE

manufacture, shop inspection and testing at the manufacturers works, delivery
at site and performance testing at site of Electrically Operated Hoists.

performance of electrically operated hoist 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 of this responsibility.
Electrically operated hoist shall be a complete unit with travelling trolley,

hoisting motor, travel motor (if travelling trolley is motor operated), rope drum,
wire rope, necessary gearing, sheaves, brakes, hook, pendent push button
station, contactor panel, all wiring, conductor for travel motion (if travelling
trolley is motor operated), limit switches, end stops, buffers, earthing terminals
and other accessories to make the equipment complete in all respects.
Electrically operated hoist shall have minimum factor of safety as five (5).
3.1 TRAVELLING TROLLEY
The travelling trolley shall be motor driven or push pull or manual geared type
as specified in data sheet A. Trolley frames shall be fabricated from rolled
structural steel sections. The side plates of the trolley shall extend beyond
wheel flanges, thus providing bumper protection for the wheels. The two side
plates shall be connected by means of an equalising pin. The wheels shall be
machined on their treads to match the profile of the monorail.
3.2 ROPE DRUM
Rope drum shall be as per IS 3938. Rope drum shall be either cast or welded to
sustain concentrated loads resulting from rope pull. Drum shall be machine
grooved right and left with grooves of a proper shape for the rope used.
Grooving shall be of proper length to handle entire rope required to make the
specified lift plus the two dead laps at each anchor point, without overlapping.
ISSUE
00
FILE NAME : M411354R5.DOC TCE FORM NO. 329 R3

SPEC.NO.
TCE.M4-113-54
3.3 WIRE ROPES
Wire ropes shall be extra flexible with well lubricated hemp core having six (6)
strands of thirty-seven (37) or thirty-six (36) wires per strand with ultimate
tensile strength of 1.6 106 KN/M. Wire ropes shall be of Right Hand
Ordinary (RHO) lay construction. The rope shall be fastened to the drum with
an attachment having strength equal to that of the rope. The rope fastening at
the swinging end shall be aligned so as to prevent rope coming off its reeving.
Rope shall be of sufficient length so that two (2) full laps shall remain on the
drum at extreme low position of the hook. Reverse bends or cross bends and
bird caging shall be avoided. The breaking loads for the hoist ropes shall not be
less than the factor specified in IS 3938. The load shall include rated load on
hooks, weight of the bottom block and the weight of rope.
3.4 LOAD CHAIN AND LOAD CHAIN WHEEL
In case chain is employed for lifting the load instead of wire rope, it shall be
heat treated to give required ductility and toughness so that it stretches before
breaking. The total length of the load chain shall exceed the minimum length
required to give the specified range of lift by not less than three (3) links per
fall to ensure that the slack end anchorage is not loaded. The load chain wheel
shall be of adequate strength and shall be suitably designed to ensure effective
operation of the chain and shall be properly secured with shaft, preferably with
splines
3.5 SHEAVES
Sheaves shall be as per IS 3938. These shall be equipped with anti-friction

bearings and shall be fully guarded to prevent the rope coming off. Equalising
sheaves, if provided, shall also be as per IS 3938. Grooves shall be machined to
proper shape for the rope used.
3.6 GEARS
Gears shall be cut from solid cast or forged steel blanks or shall be of stress-
relieved welded steel construction or built-up from steel billets and welded
together to form a one piece gear section. Pinions shall be of forged carbon or
heat treated alloy steel. All gears and pinions shall be totally enclosed type upto
last stage of reduction in all motions and shall be carried in fabricated steel gear
boxes which shall be dust proof and firmly sealed to prevent oil leakages. For
travel motion, creep speed if specified shall be achieved by one of the
following methods :
(a) Planetary gear box integral with main gear box
(b) Planetary gear box independent with motor
ISSUE
00

SPEC.NO.
TCE.M4-113-54
(c) Worm reducer with clutch

However, for hoisting motion, creep speed shall be achieved only by methods
(a) or (b) indicated above. Creep speed shall be generally 10 % of main speed.
3.7 BEARINGS
Bearings may be ball or roller type. All anti-friction bearings shall be of

approved make, which are interchangeable with corresponding size bearings of
other make. Bearing housings shall be of split type or so designed to permit
easy removal of the shaft. The design shall be such that there is no ingress of
dust and oil or grease does not leak out. Bearings shall have a minimum life
expectancy of 20 years based on equivalent running time as per specified class.
3.8 SHAFTS AND AXLES
Shafts and axles shall be of forged steel and shall have ample strength, rigidity
and adequate bearing surface for intended duties. Shafts and axles shall be
accurately machined and properly supported. Shafts shall, as far as possible, be
furnished straight. If shouldered, these shall be provided with fillets of ample
radius or shall be tapered to avoid loss of strength and stress concentration.
These shall be designed considering allowances for keys and splines.
3.9 BRAKES
All brakes shall be of fail-safe design and shall operate automatically in case
of power failure. Each of the trolley and hoisting motors shall be equipped with
electrically released, spring set, friction shoe type brakes. Hoisting brake shall
be designed to hold 1.5 times full load torque while trolley travel brake shall be
designed to hold 1.25 times full load torque. Separate brakes shall be provided
for creep motions. All brakes shall have weather-proof enclosures. Coupling
halves shall not be used as brake drums.
3.10 LIFTING HOOK
The lifting hook shall be single hook type, solid, forged, heat treated, of rugged
construction and provided with a standard depress type safety latch. Lifting
hook shall have swivels and operate on ball or roller thrust bearings with
hardened races. Lock to prevent hook from swivelling shall be provided.
3.11 BUFFERS, STOPS AND SWEEPS
ISSUE
00

SPEC.NO.
TCE.M4-113-54
3.11.1 Spring or rubber buffers shall be provided on the trolley. Suitable end stops
shall be provided which shall be welded on the ends of monorail to contact the
buffers mounted on the trolley.
3.11.2 Trolley wheel stops shall be provided before the end stops. These shall match
to wheel radius. Stops to prevent trolley from running off the monorail shall be
abutted against ends of monorail. Stops shall be welded to the monorail.
3.11.3 Sweeps shall be attached to the trolley to remove foreign material from the
rails.
3.12 GUARDS
3.12.1 All exposed couplings, shafts, gear wheels, pinions, drives etc. shall be safely
encased and guarded.
3.12.2 The sheaves of hook blocks shall be guarded to prevent trapping of hand
between a sheave and the in-running rope.
4.0 ELECTRICAL EQUIPMENT
4.1 MOTORS
Drive motors shall be as per IS 325 and companion specification TCE.M4-203-

01. Motor shall be suitable for frequent reversal, braking and acceleration. Pull-
out torque shall be 2.15 times the rated torque.
4.2 PENDENT PUSH BUTTON STATION
The pendent push button station shall be supported independently, earthed

separately independent of suspension and shall comprise the following push
buttons and indicating lamps :
(a) Start and Stop

(b) Trolley travel - To and Fro
(c) Hook - Hoist and Lower
Red lamp shall indicate supply ON
4.3 MISCELLANEOUS
ISSUE
00

SPEC.NO.
TCE.M4-113-54
Controllers and resistors, controls, electrical protective devices, cables and

conductors, earthing guards etc. shall be as per IS 3938. Limit switches shall be
provided for overhoisting and overlowering and for two extreme ends of trolley
travel.
ISSUE
00

TCE.M4-113-54 TCE CONSULTING ENGINEERS LIMITED SECTION : D7
ENQ. SPEC. NO. DATA SHEET A

ELECTRICALLY OPERATED HOISTS SHEET : 1 OF 2
1. DESIGNATION: NOTE-3 23. TYPE OF TROLLEY : MOTOR DRIVEN /
24. HOISTING SPEED : 5.0 M/min.

2. NUMBER REQUIRED : NOTE-3 25. TROLLEY TRAVEL SPEED : 10.0 M/min.
3. TAG NUMBERS : NOTE-3 26. CREEP SPEED REQUIRED FOR :
4. LOCATION IN HAZARDOUS AREA: NO 26.1 HOIST AND TROLLEY : NO
GENERAL
5. HAZARDOUS AREA CLASSIFICATION
DESIGN DATA (CONTD.)

27. TYPE OF DOWN SHOP LEAD :
AS PER IS 5572 ZONE 0/1/2 FLEXIBLE TRAILING CABLE / PVC
6. LOCATION: INDOOR SHROUDED BUS BAR
7. APPLICABLE STANDARD : IS 3938 28. METHOD OF OPERATION : PENDENT
8. DUTY CLASS : 2 PUSH BUTTON STATION
9. HOT METALS HANDLED : NO 29. INCHING AND PLUGGING CONTROLS
10. 29.1 INCHING CONTROL REQUIRED FOR :
11. HOISTING AND / OR TRAVEL
12. TYPE : LUG OR HOOK OR TROLLEY : 29.2 PLUGGING CONTROL REQUIRED FOR
SUSPENDED OR BASE MOUNTED HOISTING AND / OR TRAVEL
13. CAPACITY: BY BIDDER T 30. MOTORS : REFER TCE.M4-203-01 AND /
14. RANGE OF LIFTING: AS PER VENDOR OR TCE.M4-203-02
REQUIREMNTS
ELEVATION FROM TO 31. TROLLEY WHEELS : RIM TOUGHENED,
M
MATERIALS AND CODES OF CONSTRUCTION
15. OPERATING FLOOR ELEVATION: HEAT TREATED CAST OR FORGED OR

AS PER VENDOR REQUIREMNTS ROLLED STEEL / GRADED CAST IRON
DESIGN DATA
16. BOTTOM OF MONORAIL ELEVATION: (NOTE 1)

BY BIDDER 32. ROPE DRUM AND SHEAVES : IS 3938
17. LENGTH OF MONORAIL: BY BIDDER M (NOTE 1)
18. MONORAIL TRACK : BIDDER TO 33. WIRE ROPE : IS 2266
DECIDE
STRAIGHT/ CURVED 34. CHAIN DRUM OR CHAIN WHEEL :
19. RADIUS OF CURVATURE OF HEAVY DUTY MALLEABLE CASTING /
MONORAIL : BY BIDDER M PRESSED SHEET STEEL (NOTE 1)
20. MONORAIL BY : PURCHASER 35. CHAIN : ALLOY STEEL IS 3109 / IS 6216
21. SIZE OF MONORAIL ( IF PROVIDED BY 36. GEARS AND PINIONS : SPUR/ HELICAL
PURCHASER) : AS PER IS 4460/ BS 436/ BS 721/
22. TYPE OF HOIST : WORM / SPUR GEAR AGMA STANDARDS (NOTE 1)
REV.NO 01 PPD.BY : JOB NO. CLIENT : BORL; EPCC:BHEL

. DS/KS
DATE 23-5-08 CHD.BY : KG TCE. PROJECT : 3x33 MW CPP AT BINA
5178A
REV.BY
FILE NAME: DA11354R5.DOC TCE FORM NO. 330 R1

ISSUE NO. R5 TCE.M4-113-54 TCE CONSULTING ENGINEERS LIMITED SECTION : D7
ENQ. SPEC. NO. DATA SHEET A

TCE. 5178A-C-563-015 ELECTRICALLY OPERATED HOISTS SHEET : 2 OF 2
37. BEARINGS : BALL OR ROLLER TYPE 48. TCE.M4-904 AND / OR TCE.M4-185-01
ANTI-FRICTION BEARINGS AS PER AND TCE.M4-185-69 OR TCE.M4-186-11
MATERIALS AND CODES OF CONSTRUCTION
IS 5669/ IS 5692/ IS 5932/ IS 5935

38. SHAFTS AND AXLES : CARBON STEEL 49. OVERLOAD TEST WITH 125 % OF
TESTS AND INSPECTION

39. BRAKES : ELECTROMAGNETIC / SPECIFIED LOAD : YES
ELECTRO THRUSTORS 50. TEST LOADS : BY VENDOR /
40. LIFTING HOOK : FORGED AND HEAT
TREATED ALLOY STEEL / CARBON 51. SPEED CHECK FOR ALL MOTIONS: YES
STEEL AS PER IS 2758 / IS 2759 / IS 3813 52. INSULATION TEST FOR ALL
/ IS 3815 TABLE 1 / IS 3815 TABLE 3 / ELECTRICAL EQUIPMENT : YES
IS 3822 / IS 4164 / IS 8610 53. PERFORMANCE TEST AT SITE BY
41. LUBRICATION : CENTRALISED VENDOR : YES /
NO
GREASE LUBRICATION WITH HAND 54.
OPERATED GREASE PUMP 55.
42. 56. MOTORS :
LIST OF APPROVED SUB-
43. REFER TCE.M4-907

MAINTENANCE TOOLS
AND TACKLES
44. ESSENTIAL SPARES 57. BRAKES :

SPARES AND
VENDORS
44.1
44.2 58. LIMIT SWITCHES :
44.5 59. BEARINGS :
45. FINISH PAINT : SYNTHETIC ENAMEL 60. MINIMUM ONE ELECTRIC HOIST FOR
ILMS AND CRUSHER IN CRUSHER HOUSE
AND ONE FOR SCREEN IN SCREEN
HOUSE .
NOTES
1. BIDDER SHALL DECIDE NUMBER, CAPACITY, LIFT ETC TO SUIT HIS LAYOUT AND EQUIPMENT .
2. ALL ELECTRICAL EQUIPMENT SHALL BE SUITABLE FOR SPECIFIED HAZARDOUS ZONE AS PER
IS 5572.
3. BIDDER HAS TO SPECIFY AND JUSTIFY THE REQUIREMENT.
REV.NO 01 PPD.BY : JOB NO. CLIENT : BORL; EPCC: BHEL

. DS/KS
DATE 23-05-08 CHD.BY : KG TCE. PROJECT : 3 X 33 CPP AT BINA
5178A
REV.BY
FILE NAME: DA11354R5.DOC TCE FORM NO. 330 R1

SPECIFICATION NO. TCE CONSULTING ENGINEERS LIMITED SECTION : D7
ISSUE NO. R5

SL. BIDDER
NO. ITEM
1. DESIGNATION ELECTRICALLY OPERATED HOIST
FOR
GENERAL
2. NUMBER OFFERED
3. TAG NUMBERS
4. CAPACITY T
5. MANUFACTURER
6. MAKE
HOIST
7. MODEL NUMBER
8.
9.
10. MANUFACTURER
TROLLEY
11. MAKE
12. MODEL NUMBER
13.
14. HOIST MOTOR : MAIN CREEP
14.1 MAKE
14.2 TYPE
14.3 RATING KW
ELECTRICAL REQUIREMENTS
14.4 SPEED RPM

15. TROLLEY MOTOR : MAIN CREEP
15.1 MAKE
15.2 TYPE
15.3 RATING KW
15.4 SPEED RPM
16. LIMIT SWITCHES FOR :
16.1 HOISTING : MAKE, TYPE AND NUMBERS
PROVIDED
16.2 TRAVELLING: MAKE, TYPE AND NUMBERS
PROVIDED
NOTES TO BIDDER
SIGNATURE OF BIDDER
DATE

ISSUE NO. R5

SL. BIDDER
NO. ITEM
17. TYPE OF DOWN SHOP LEAD
ELECTRICAL REQUIREMENTS (CONTD.)
17.1 MAKE
17.2 SIZE
17.3 LENGTH M
17.4 SUPPORTING ARRANGEMENT
17.5 IF CURVED MONORAIL, NUMBER OF CABLE NO./
TROLLEYS PROVIDED AND WIDTH OF EACH mm
TROLLEY
18.
19.
20.
21.
22. MONORAIL IF PROVIDED BY VENDOR :
INDICATE BEAM SIZE MINIMUM/ MAXIMUM mm ISMB / ISMB
SUITABLE FOR TROLLEY MOVEMENT
23. MONORAIL IF PROVIDED BY PURCHASER : YES/ NO
DIMENSIONS
IS SIZE SPECIFIED IN DATA SHEET A SUITABLE IF NO, INDICATE SUITABLE

FOR TROLLEY MOVEMENT SIZE ISMB
24. DISTANCE BETWEEN HIGHEST HOOK
POSITION
TO BOTTOM OF MONORAIL mm
25. IF MONORAIL IS CURVED, MINIMUM RADIUS
TROLLEY CAN NEGOTIATE mm
26.
27. IF HOIST IS IN HAZARDOUS AREA :
CONSTRUCTION
MATERIALS OF
27.1 TROLLEY WHEELS

27.2 ROPE DRUM AND SHEAVES
27.3 GEARS AND PINIONS
28.
29.
NOTES TO BIDDER
SIGNATURE OF BIDDER
DATE

ISSUE NO. R5

SL. BIDDER
NO. ITEM
30. WIRE ROPE DIAMETER mm
31. WIRE ROPE BREAKING LOAD KN
32. WEIGHT OF COMPLETE HOIST AND TROLLEY
ASSEMBLY Kg
33. WEIGHT OF HOIST Kg
MISCELLANEOUS
34. WHEEL LOAD WITH IMPACT AND WITHOUT Kg

IMPACT /
35. PRELIMINARY DIMENSIONED GENERAL
ARRANGEMENT DRAWING OF ELECTRICALLY WHETHER FURNISHED
OPERATED HOIST ALONG WITH WHEEL STOP YES/ NO
DETAILS TO BE FURNISHED
36.
37.
38.
39.
NOTES TO BIDDER
SIGNATURE OF BIDDER
DATE
FILE NAME: DB11354R5.DOC TCE FORM NO.294 R1

DATA SHEET - A
TCE-3473-116-50-13 ASH SLURRY TRANSPORT PIPING & FITTINGS SHEET 1 OF 2
1.1 Material of all Piping Except CAST IRON PIPES TO IS:1536,

2.2 CLASS-D (OF STANDARD
LENGTH)
1.2 Material of Piping for Items No. MS ERW PIPES TO IS: 3589
2.6 & 2.7 MIN. 6 mm THICK OR
MS PIPE TO IS:1239 PART-I,

HEAVY CLASS
1.3 Material of Piping for Item No. MS ERW PIPES MIN.9.3MM

2.1,2.4,2.3 THICK AS PER IS : 3589 OR MS
ERW PIPES OF MIN. 6.53 MM
THICK AS PER IS:3589 WITH 20
MM THICK CAST BASALT
LINING
1.4 Material of fittings Ni-Cr ALLOY CAST IRON WITH

MINIMUM 500 BHN 600
BHN(AS PER IS-4771 Type-1a)
OR 25 THK.BASALT LINERS
1.5 Type of Wearback for Fittings INTEGRAL
1.6 Necessary Steel hangers, supports BY VENDOR

and inserts in concrete for
Piping
1.7 Thickness of Wearbacks MINIMUM TWICE THE PIPE

WALL THICKNESS
1.8 Radius of 900 Bends MINIMUM THREE TIMES

NORMAL PIPE DIAMETER.
1.9 Pipe Joints FLANGED WITH EVERY

THIRD JOINTOF SLEEVE
COUPLING
1.10 Deflection in Sleeve Coupling MINIMUM 3 DEG.
1.11 Gap between ends of Pipes at SUFFICIENT TO TAKE CARE

Coupling OF EXPANSION OF PIPES
1.12 Material for Sleeve Coupling STEEL SLEEVE WITH

STEEL/C.I FLANGES AND
RUBBER GASKETS.
DATA SHEET - A
TCE-3473-116-50-13 ASH SLURRY TRANSPORT PIPING & FITTINGS SHEET 2 OF 2
1.13 Location OUTDOOR
2.0 LINES INCLUDED
2.1 Piping from silo jet pumps to YES

ash slurry sumps.
2.2 Discharge piping f drain sump pumps

and B.A.overflow pumps YES
2.3 Piping from B.A jet pumps to YES

slurry sump
2.4 Piping from slurry pumps to YES

slurry disposal area
2.5 All other piping not specified YES

above but required for the
system envisaged.
2.6 Sludge piping YES
2.7 Ash water recovery system YES
3.0 TESTS AND TEST CERTIFICATES
3.1 Test certificates for materials YES

of Construction of Piping and
Fittings
3.2 Hydrostatic Test at Works YES

for Piping and Fittings
4.0 NOTES
4.1 Ni-Cr Alloy C.I Used for Fittings shall be of Ni-Hard/Ni-Resist Type as per ASME.
4.2 All other ash slurry piping not listed here but required to make the system complete shall
be included in the BIDDER's scope of supply.
DATA SHEET - A
TCE-3472-116-60 ASH SLURRY LINE VALVES SHEET 1 OF 1
1.0 GENERAL DATA

REMOTE MANUALLY
OPERATED OPERATED
VALVES VALVES
--------- ----------
1.2 Number Required REFER FLOW DIAGRAM
1.3 Type PLUG VALVE/ PLUG VALVE/

KNIFE EDGE KNIFE EDGE
TYPE GATE TYPE GATE
VALVE VALVE
1.4 Ash Slurry Flow Through Valve Cu.m/hr BY BIDDER
1.5 Size of Valves BY BIDDER
2.1 Knife Gate Valves
2.1.1 Body & Seat material and SS 304 NITRIDED TO 500 - 600
hardness BHN
2.1.2 Plate/flap Material and Hardness SS 304 EDGE STELLITED TO

MIN. 1 MM THICK
2.1.3 Shaft Material and Hardness SS - 316
2.1.4 Deflector Cone Ni-HARD ALLOY CI 450 BHN
2.2 Taper Plug Valves
2.2.1 Body material CI
2.2.2 Plug material and hardness CASE HARDENED CARBON

STEEL WITH ANTIFRICTION
PTFE COATING ON THE PLUG
3.0 NOTES
3.1 All Parts of Valves Coming in WEAR AND CORROSION

Contact with Slurry shall be RESISTANT
3.2 The Valves shall be Provided YES

with Operating Hand Wheel and
Position Indicator
ISSUE NO. R6 SPECIFICATION NO. TCE CONSULTING ENGINEERS LIMITED SECTION D9
DATA SHEET A
ASH SLURRY LINE VALVES
1.0 GENERAL DATA
1.1 Type REMOTE / MANUALLY

OPERATED
1.2 Number required
1.3 Type of water used in ash slurry FRESH WATER SEA WATER
1.4 Ash Slurry Flow Through Valve Cu.m/hr
2.1 Knife Gate Valves
2.1.1 Body material and hardness SS 304 Nitrided SS 316 Nitrided

to 500 TO 600 TO 500 TO 600
BHN BHN
2.1.2 Plate/flap : SS 304 edge SS 316 EDGE

Material and hardness stellited to min. stellited to min. 1
1 MM thickness MM thickness
2.1.3 Shaft Material SS 316 SS 316
2.1.4 Deflector cone Alloy cast iron Alloy cast iron

450 BHN 450 BHN
2.2 Taper Plug Valves
2.2.1 Body material and hardness Cast Iron FG 260 ALLOY CAST
IRON, 340 BHN
2.2.2 Plug material and hardness Case hardened Corrosion

carbon steel with resistant Alloy
antifriction Cast Iron with
PTFE coating PTFE coating
3.0 Type of actuation for remote operated valves Motor/Cylinder Motor/Cylinder

operated operated
4.0 Hydrostatic Test for Valve Body and Seat Zero leakage Zero leakage
Tightness should be should be
achieved achieved
5.0 All parts of valves coming in contact with Wear resistant Wear and
slurry shall be corrosion
resistant
6.0 Painting of Ferrous surfaces by VENDOR / PURCHASER shall be

as per Section C.
REV. NO. PPD. BY:DS/KS JOB NO. OWNER : BORL ; EPCC: BHEL
DATE CHD. BY:KG TCE.5178A
REV. BY DATE:23.05.08 PROJECT: 3 x 33 MW CPP BINA
FILE NAME : DA11660R6.DOC TCE FORM NO. 330 R1
DATA SHEET A
7.0 All valves shall be provided with operating

hand wheel and position indicator. Hand chain
shall be provided if the wheel is not reachable
from the operating platform.
8.0 For general inspection requirements TCE.M4-

185-01 shall be followed
9.0
REV. NO. PPD. BY:DS/KS JOB NO. OWNER : BORL ; EPCC: BHEL
DATE CHD. BY:KG TCE.5178A
REV. BY DATE:23.05.08 PROJECT: 3 x 33 MW CPP BINA
FILE NAME : DA11660R6.DOC TCE FORM NO. 330 R1
DATA SHEET - B
SR.NO. ITEM BIDDER
KNIFE GATE TAPER PLUG

VALVE VALVE
1.0 MANUFACTURER
2.0 NUMBER OF VALVES
3.0 LINE SIZE MM
4.0 ASH SLURRY FLOW RATE THROUGH

VALVE Cu.m/hr
5.0 VALVE BODY
5.1 Material
5.2 Hardness BHN
6.0 PLATE/PLUG
6.1 Material
6.2 Hardness BHN
7.0 SHAFT MATERIAL
8.0 IF REMOTE OPERATED TYPE, INDICATE
8.1 Type of Actuation
8.2 Quantity of Compressed Air Required if any Nm3/hr
8.3 Pressure of Compressed Air Required if any Kg/cm2(g)
8.4 Motor rating incase of electrically actuated valve
9.0 WHETHER CATALOGUES ENCLOSED? YES/NO

.
ASH DISPOSAL EQUIPMENT

DATA SHEET C

1.0 DRAWINGS / DOCUMENTS TO BE SUBMITTED FOR APPROVAL
1.1 Dimensional drawing indicating materials of construction and hardness of

various components.
1.2 QAP
2.0 DRAWINGS / DOCUMENTS TO BE SUBMITTED FOR REFERENCE
2.1 Manufacturers test certificates for the material supplied for various
components.
2.2 Hydrostatic test certificates
2.3 Operation and maintenance manuals.
ISSUE
R6

SPECIFICATION NO. TCE CONSULTING ENGINEERS SECTION D 11
TCE-M4 - 105 - 12
ENQ.SPEC.No. DATA SHEET - A
TCE.5178A SUMP PUMPS SHEET 1 OF 3
1.0 DESIGNATION BY BIDDER
2.0 QUANTITY No. One (1)
3.0 LIQUID PUMPED Bed Material Slurry
4.0 LIQUID TEMPERATURE C Ambient
5.0 SPECIFIC GRAVITY REFER SYSTEM DATA SHEET IN C-13
6.0 PERCENT OF SOLIDS % 25%
7.0 MAXIMUM SIZE OF SOLIDS mm REFER SYSTEM DATA SHEET IN C-13
8.0 PUMP AND SUMP DATA
8.1 Capacity cu.m/hr BY BIDDER
8.2 Total head m/c By BIDDER
8.3 Maximum speed rpm By BIDDER
8.4 Sump length and width mm REFER BHEL DWG NO. 0-381-01-00815
8.5 Depth of sump A mm REFER BHEL DWG NO. 0-381-01-00815
8.6 Maximum operating level C mm REFER BHEL DWG NO. 0-381-01-00815
8.7 Submergence level N mm REFER BHEL DWG NO. 0-381-01-00815
8.8 Bottom clearance D mm REFER BHEL DWG NO. 0-381-01-00815
8.9 Clearance from side wall L mm REFER BHEL DWG NO. 0-381-01-00815
8.10 Pipe terminal point H mm To ash slurry sump
9.1 Type of lubrication OIL/ GREASE/
9.2 Type of impeller SEMI-OPEN
9.3 Automatic float level switch for start/stop YES
9.4 Suction strainer YES
9.5 Companion flanges YES
9.6 Discharge point ABOVE BASE PLATE

FILE NO. M410512A.DOC
9.7 Location INDOOR IN TUNNEL

REV. NO. 00 PPD. BY DS/KS JOB NO. OWNER : BORL; EPCC: BHEL
DATE 26-05-08 CKD. BY KG 5178A
REV. BY DATE 26.05.08 PROJECT : 3x 33 MW CPP BINA
TCE FORM 330 R2
TCE-M4 - 105 - 12
10.1 Casing Cast iron
10.2 Impeller Cast Iron
10.3 Pump shaft EN8
10.4 Line shaft EN8
10.5 Shaft enclosing pipe
10.6 Discharge pipe
10.7 Strainer
10.8 Cover plate
10.9 Stuffing box
11.0 MOTOR BY VENDOR
12.0 INSPECTIONS AND SHOP TESTS
12.1 Visual inspection YES
12.2 Performance test YES
12.3 Hydrostatic test certificate YES
12.4 NPSH test NO
12.5 Type and routine test certificate YES
12.6 Material test certificates YES
13.0 NOTES
13.1 Material test certificates shall be furnished for

all components
13.2 The rating of the drive motor shall be at least

125% of the power required by the pump at
duty point
13.3 Hydrostatic test shall be conducted at twice the

total head or 1.5 times the shut off head,
whichever is greater.
13.4 If cooling water for line bearings is required

the same shall be drawn from the pump
discharge pipe. Vendor shall provide all the
TCE FORM 330 R2
TCE-M4 - 105 - 12
necessary pipes and fittings for supplying

water to the line bearings.
TCE FORM 330 R2
SPECIFICATION NO. TCE CONSULTING ENGINEERS SECTION D-11
TCE-M4-105-12
ENQ.SPEC.No. DATA SHEET - B
TCE. SUMP PUMPS SHEET 1 OF 2
SR.NO. ITEM BIDDER
1.0 MAKE
2.0 MODEL NUMBER
3.0 QUANTITY no.
4.0 GUARANTEED PERFORMANCE
4.1 Capacity cu.m/hr
4.2 Total head mlc
4.3 Shut-off head mlc
4.4 Speed rpm
4.5 Efficiency %
4.6 Pump input kW
4.7 Recommended motor rating kW
4.8 Sealing water (if required) cu.m/hr

quantity and pressure kg/sq.cm
(g)
4.9 Maximum size of solids mm
5.0 TYPE OF STUFFING BOX SEAL
6.0 TYPE OF PUMP LUBRICATION OIL/GREASE/EXTERNAL WATER/SELF

LUB
7.0 DISCHARGE PIPE mm
8.0 DISCHARGE PIPE END SCREWED/FLANGED
9.0 FLANGE DRILLING STANDARD
10.0 WEIGHTS kg (a) PUMP WITH COVER PLATE

(b) MOTOR
11.0 DIMENSIONS
(REFER DATA SHEET-A)
11.1 Pump setting length 'B' mm

FILE NO. M410512B.DOC
11.2 Minimum bottom clearance required D mm

BE
TCE FORM 294 R1
SPECIFICATION NO. TCE CONSULTING ENGINEERS SECTION D-11
TCE-M4-105-12
ENQ.SPEC.No. DATA SHEET - B
TCE. SUMP PUMPS SHEET 2 OF 2
SR.NO. ITEM BIDDER
11.3 Minimum side clearance required from centre line

of pump 'E'
11.4 Minimum submergence required from bottom of mm

sump 'N'
11.5 Minimum clearance required for removal of pump m

parts and motor (including height of slings on
lifting tackle used)
11.6 Sump dimensions required for the offered pump mm

(L x B x D)
11.7 Opening dimensions on cover slab mm

BE
TCE FORM 294 R1
.
DATA SHEET - C
SUMP PUMPS

AFTER THE AWARD OF CONTRACT
1.0 The Vendor shall submit the following key drawings/data having engineering
information to the Purchaser/ Engineer as listed below.
1.1 Detailed dimensioned general arrangement drawing of sump pump and motor
indicating important design data such as capacity, total head, efficiency, drive
motor, sealing water requirement (if any), (quantity and pressure), clearance of
sump required, base plate details, loads, weights of pump and motor, vertical
clearance required for removal of pump and motor etc.
1.2 Cross-sectional drawing of pump with complete bill of materials.
1.3 Performance characteristics curves of pump
1.4 Foundation drawings with details of fixing, grouting, plinth size, anchor bolts
etc. shown on the drawing.
1.5 Operation, erection and maintenance manuals.
ISSUE
FILE NO. M410512C.DOC R4
TCE FORM 329 R3

TCE.M4-113-50 TCE CONSULTING ENGINEERS SECTION : D-12
ENQ.SPEC.NO. DATA SHEET -A

TCE. CHAIN PULLEY BLOCK SHEET : 1 OF 2
1. DESIGNATION: CHAIN PULLEY BLOCK 20. TYPE OF TROLLEY:

FOR PUSH TYPE/ MANUAL GEARED
2. NUMBER REQUIRED: BY BIDDER 21. HAND CHAINS LOCATION: THE HAND-
3. TAG NOS.: BY BIDDER CHAIN FOR THE HOISTING AND
4. LOCATION IN HAZARDOUS AREA: TRAVERSING MECHANISM SHALL BE
YES/ NO WELL CLEAR OF THE HOOK AND
5. HAZARDOUS AREA CLASSIFICATION : BOTH CHAINS SHALL BE ON THE
AS PER IS 5572 ZONE 0/1/2 SAME SIDE
6. LOCATION : INDOOR/ OUTDOOR 22.
7. APPLICABLE STANDARD : IS 3832/ 23.
BS 3243 24.
8. DUTY CLASS : 1 / 2 25. CHAIN PULLEY BLOCK : AS PER
9. IS 3832/ BS 3243
10. TYPE : LUG OR HOOK OR TROLLEY 26. TROLLEY FRAME : ROLLED
SUSPENDED STRUCTURAL STEEL WITH SIDE
11. CAPACITY: BIDDET TO INDICATE Kg PLATES EXTENDED BEYOND WHEEL
12. RANGE OF LIFTING : FLANGES TO PROTECT WHEELS
ELEVATION FROM TO M 27. TROLLEY WHEELS : HEAT TREATED
13. OPERATING FLOOR ELEVATION: CARBON STEEL/ LOW ALLOY STEEL/
M GRADED CAST IRON. SINGLE
14.BOTTOM OF MONORAIL ELEVATION: FLANGED WITH TAPERED TREAD
M (NOTE 1)
15. MONORAIL TRACK: 28. LOAD CHAIN : ALLOY STEEL IS 3109/
STRAIGHT/CURVED IS 6216/ BS 1663/ BS 3114
16. RADIUS OF CURVATURE OF 29. LOAD CHAIN WHEEL AND MAIN ARM
:
MONORAIL: M HEAVY DUTY MALLEABLE CASTING/
17. MONORAIL BY: PURCHASER/ VENDOR PRESSED SHEET STEEL (NOTE 1)
18. SIZE OF MONORAIL ( IF PROVIDED BY 30. HAND CHAIN : AS PER IS 2429/ BS 6405
PURCHASER) : ISMB 31. HAND CHAIN WHEEL : PRESSED
19. TYPE OF CHAIN PULLEY BLOCK : SHEET STEEL (NOTE 1)
WORM/ SPUR GEAR 32. SHAFTS AND AXLES : CARBON STEEL
REV.NO. 00 PPD. BY DS/KS JOB NO. OWNER:BHEL; EPCC:BHEL

DATE CHD. BY KG TCE.
REV. BY DATE 23-05-08 5178A PROJECT:3X33MW CPP, BINA

FILE NAME: DA11350.DOC TCE FORM NO. 330 R1
TCE.M4-113-50 TCE CONSULTING ENGINEERS SECTION : D-12
ENQ.SPEC.NO. DATA SHEET -A

TCE. CHAIN PULLEY BLOCK SHEET : 2 OF 2
33. GEARS AND PINIONS : SPUR/ HELICAL 43. FINISH PAINT : EPOXY/ SYNTHETIC
AS PER IS 4460/ BS 436/ BS 721/ ENAMEL/
AGMA ATANDARDS (NOTE 1) 44.
34. LIFTING HOOK : HOOK WITH 45.
STANDARD DEPRESS SAFETY LATCH 46.
AND LOCK TO PREVENT HOOK FROM 47.
SWIVELING. HOOK SHALL BE FORGED 48. TCE.M4-904 AND TCE.M4-185-69 OR
ALLOY STEEL/ CARBON STEEL AS TCE. M4-186-11 ( STRIKE OUT WHAT
PER IS 8610/ BS 2903 IS NOT APPLICABLE ) (NOTE 2)
35. BEARINGS: BALL OR ROLLER AS PER 49. OVERLOAD TEST WITH 150 % OF
IS 5669/ IS 5692/ IS 5932/ IS 5935 SPECIFIED LOAD
36. BRAKE : SCREW AND FRICTION DISC 50.
TYPE SELF ACTUATING LOAD 51.
PRESSURE BRAKE 52.
37. LUBRICATION OF MOVING PARTS 53.
SHALL BE DONE MANUALLY BY 54.
HAND OPERATED GREASE PUMPS 55.
THROUGH RESPECTIVE GREASE 56.
NIPPLES 57.
38. 58.
39. 59.
40. 60.
41. 61.
42. 62.
NOTES:
1. MATERIALS OF CONSTRUCTION INDICATED ARE FOR CHAIN PULLEY BLOCKS
OPERATING IN NON HAZARDOUS AREA. FOR THE CHAIN PULLEY BLOCKS OPERATING IN
HAZARDOUS AREA, ALL CONTACT PARTS SHALL BE OF DISSIMILAR MATERIALS. FOR
EXAMPLE : BRONZE TO STEEL, BRASS TO STEEL ETC.
2. FOLLOWING ADDITIONAL TESTS INDICATED AS B IN TCE.M4-186-11 SHALL ALSO BE
CARRIED OUT WHEN TCE.M4-186-11 IS APPLICABLE.
3. BIDDER HAS TO FILL THIS DATA SHEET A ALONG WITH DATA SHEET-B
REV.NO. 00 PPD. BY JOB NO. OWNER:BHEL; EPCC:BHEL

DS\KS
DATE CHD. BY KG TCE.
REV. BY DATE 23-05-08 5178A PROJECT:3X33MW CPP, BINA
FILE NAME: DA11350.DOC TCE FORM NO. 330 R1

SPEC.NO.
TCE CONSULTING ENGINEERS SECTION: D-12
CHAIN PULLEY BLOCK
1.0 SCOPE

manufacture, shop inspection and testing at the manufacturers works, delivery
at site and performance testing at site of chain pulley block.

performance of chain pulley block 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. Nothing in this specification shall be construed to
relieve the VENDOR of this responsibility.
3.0 FEATURES OF CONSTRUCTION
Chain pulley block shall be complete with load chain, load chain wheel, hand
chain, hand chain wheel, necessary gearing, brakes for hoisting, hooks and
other accessories to make the equipment complete in all respects.
3.1 Load Chain And Load Chain Wheel
The total length of the load chain shall exceed the minimum length required to
give the prescribed range of lift by not less than three links per fall to ensure
that the slack end anchorage is not loaded. The load chain wheel shall be of
adequate strength and shall be suitably designed to ensure effective operation
of the chain and should be properly secured with shaft, preferably with splines.
3.2 Hand Chain And Hand Chain Wheel
The length of the hand chain shall be such that the lowest point of the
suspended loop shall hang 400 mm above the operating level. Hand chain
wheels shall be provided with flanges and designed to ensure effective
operation with hand chain.
3.3 Shafts And Axles
Shafts and axles shall have ample strength and rigidity and adequate bearing
surface for the intended duties.
3.4 Gears
ISSUE
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TCE FORM NO. 329 R3

FILE NAME : M411350.DOC
SPEC.NO.
TCE CONSULTING ENGINEERS SECTION: D-12
CHAIN PULLEY BLOCK
Gears shall be cut from solid cast or forged steel blanks or shall be of stress-
relieved welded steel construction or built-up from steel billets and welded
together to form a one piece gear section.
3.5 Brakes
Brakes shall be of automatic type that will stop and hold the load when hand-
chain pull is released and shall permit controlled lowering of the load when
hand-chain pull is applied in the lowering direction.
3.6 Pawls
Pawls shall be of sufficient strength to arrest the full load from lowering due to
gravity. The pawl and ratchet wheel shall be of steel, hardened and tempered
so as to attain required wear resistance and toughness.
3.7 Lifting Hook
Lifting hook shall be solid, forged, heat treated alloy or carbon steel of rugged
construction and provided with a standard depress type safety latch. Lifting
hook shall have swivels and operate on ball or roller thrust bearings with
hardened races. Lock to prevent the hook from swivelling shall be provided.
ISSUE
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TCE FORM NO. 329 R3

FILE NAME : M411350.DOC
SPEC.NO.
TCE CONSULTING ENGINEERS SECTION: D12
TCE.M4-113-50
SHEET 1 OF 1
CHAIN PULLEY BLOCK
DATA SHEET - C
DATA TO BE FURNISHED BY THE VENDOR AFTER THE AWARD OF

CONTRACT
1. Detailed dimensioned general arrangement drawing indicating various

clearances, lifts etc. Drawing shall also indicate all design data and
information furnished in data sheets A & B.
2. Part list of the chain pulley block and trolley along with materials and codes of
construction.
3. Calculations indicating effort required to lift the load.
4. Operation and maintenance manual with lubrication schedule.
Documents indicated at 1, 2 & 3 above shall be reviewed and approved, while

document indicated at 4 above shall be for information only.
ISSUE
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FILE NAME : M411350.DOC TCE FORM NO.329 R3

SPECIFICATION NO. TCE CONSULTING ENGINEERS SECTION : D12
TCE.M4-113-50 DATA SHEET - B

CHAIN PULLEY BLOCK SHEET : 1 OF 2

SL. BIDDER
NO. ITEM
1. DESIGNATION CHAIN PULLEY BLOCK FOR
2. NUMBER OFFERED
3. TAG NOS.
4. CAPACITY Kg
5.
6. MANUFACTURER
7. MAKE
8. MODEL NO.
9.
10.
11. MANUFACTURER
12. MAKE
13. MODEL NO.
14.
15. MONORAIL IF PROVIDED BY VENDOR :
INDICATE BEAM SIZE MINIMUM/ MAXIMUM mm ISMB / ISMB
SUITABLE FOR TROLLEY MOVEMENT
16. MONORAIL IF PROVIDED BY PURCHASER : YES/ NO
IS SIZE SPECIFIED IN DATA SHEET A SUITABLE IF NO INDICATE SUITABLE
FOR TROLLEY MOVEMENT SIZE ISMB
17. DISTANCE BETWEEN HIGHEST HOOK
POSITION
TO BOTTOM OF MONORAIL mm
18. IF MONORAIL IS CURVED, MINIMUM RADIUS
TROLLEY CAN NEGOTIATE mm
19.
20.
21.
NOTES TO BIDDER
SIGNATURE OF BIDDER
DATE
FILE NAME: DB11350.DOC TCE FORM NO. 294 R1

SPECIFICATION NO. TCE CONSULTING ENGINEERS SECTION : D12
TCE.M4-113-50 DATA SHEET - B

CHAIN PULLEY BLOCK SHEET : 2 OF 2

SL. BIDDER
NO. ITEM
22. IF CHAIN PULLEY BLOCK IS IN HAZARDOUS
AREA :
22.1 TROLLEY WHEELS
22.2 LOAD CHAIN WHEEL AND MAIN ARM
22.3 HAND CHAIN WHEEL
22.4 GEARS AND PINIONS
23.
24. WEIGHT OF COMPLETE CHAIN PULLEY BLOCK
AND TROLLEY ASSEMBLY Kg
25. WEIGHT OF CHAIN PULLEY BLOCK Kg
26. EFFORT REQUIRED TO LIFT THE LOAD Kg
27. WHEEL LOAD WITH IMPACT AND WITHOUT
IMPACT Kg /
28. PRELIMINARY DIMENSIONED GENERAL
ARRANGEMENT DRAWING OF CHAIN PULLEY WHETHER FURNISHED
BLOCK AND TROLLEY TO BE FURNISHED YES/ NO
ALONG WITH WHEEL STOP DETAILS
29.
30.
NOTES TO BIDDER
SIGNATURE OF BIDDER
DATE
FILE NAME: DB11350.DOC TCE FORM NO.294 R1

DATA SHEET - A
`TCE-3472-105-12 ASH SLURRY SUMP & ASH SLURRY PUMPS SHEET 1 OF 4
1.0 TYPE OF CONSTRUCTION :
1.1 ASH SLURRY SUMP RCC, PARTIALLY UNDER

GROUND
2.0 DETAILED DESIGN AND

CONSTRUCTION OF ALL CIVIL
WORKS OF
2.1 ASH SLURRY SUMP BY VENDOR
3.0 CAPACITY OF SUMP REQUIRED :
3.1 ASH SLURRY SUMP CAPACITY cu.m TO CATER FOR 10 MIN.

SLURRY GENERATION OF
BOTH FLY ASH & BED ASH
3.2 Complete Set of Sump Level YES (BY VENDOR)

Switches
3.3 Overflow Connection Sleeve YES (BY VENDOR)
3.4 Drain Connection Sleeve YES (BY VENDOR)
4.0 ASH SLURRY SUMP
4.1 Alloy Cast Iron Plates Having a YES

Minimum Hardness of 340 BHN
together with Fixtures to be
Fixed at Bottom of Ash Slurry
Sump
4.2 Alloy Cast Iron wear plates YES (BY VENDOR)

having a minimum hardness of
340 BHN together with fixtures
to be fixed on sump face which comes in
contact with ash slurry including
collecting channels.
4.3 Complete set of Bubbler Type/ YES ( BY VENDOR)

Float Operated Type sump level
control
5.0
6.0
DATA SHEET - A
7.0
8.0
9.0 NOTES
9.1 Alloy CI Used for Liners and Ni-HARD WITH 2.5% NICKEL and piping shall conform
to 340 BHN HARDNESS
9.2 Ash Slurry Sump and Ash Water Tank Covered with Suitable Gratings.
DATA SHEET - A
1.0 DESIGNATION **
2.0 NUMBER OF PUMPS ** 1 WORKING + 1 STANDBY
3.0 TYPE OF PUMP SUBMERSIBLE PUMP
4.0 LOCATION OF PUMPS AHEH ROOM
5.0 LIQUID PUMPED SLURRY
6.0 LIQUID TEMPERATURE AMBIENT
7.0 SPECIFIC GRAVITY BY BIDDER
8.0 PERCENT OF SOLIDS % 25% (ESTIMATED)
9.0 MAXIMUM SIZE OF SOLIDS mm 25
10.0 PUMP AND SUMP DATA
10.1 Capacity m3/hr BY BIDDER
10.2 Total Head mlc BY BIDDER
10.3 Maximum Speed rpm BY BIDDER
10.4 Sump Length and Width m BY BIDDER
10.5 Depth of Sump m BY BIDDER
10.6 Motor Mounting Height m (MIN.) 1000 MM FROM FLOOR

LEVEL
10.7 Sump Arrangement TWIN-PIT ARRANGEMENT
11.1 Type of Lubrication GREASE
11.2 Stuffing Box YES
11.3 Type of Impeller NON-CLOG, OPEN
11.4 Automatic Float Level Switch YES

for Start/Stop
11.5 Suction Strainer YES
11.6 Sump Cover Plate YES

DATA SHEET - A
11.7 Companion Flanges YES
11.8 Discharge Point REFER ATTACHED DRAWINGS
11.9 Seal Water NO
11.10 Location INDOOR
12.1 Casing C.I (210 BHN)
12.2 Impeller ALLOY C.I
12.3 Pump Shaft EN-8
12.4 Line Shaft EN-8
12.5 Shaft Enclosing Tube STEEL
12.6 Discharge Pipe STEEL
12.7 Strainer C.I
12.8 Cover Plate M.S
12.9 Stuffing Box MFG. STD.
13.0 MOTOR BY VENDOR
14.0 STARTER BY VENDOR
15.0 NOTES
15.1 Material test certificates shall be furnished for all components.
15.2 The rating of the drive motor shall be at least 125% of the power required
by the pump at duty point.
15.3 Hydrostatic test shall be conducted at twice the total head or 1.5 times
the shut off head whichever is greater. The duration of test shall be
minimum 30 minutes.
15.4 The strainer openings should be compatible with the size of solids that
can be handled by the pump impeller.
15.5 Sump pump motors shall be designed for frequent start-stops.
15.6 Out of two pumps, one pump will be operating
normally while the other pump will be a standby and will be operated
during emergency.
15.7 The total discharge head of each pump shall be selected by considering ash disposal
piping length of 1200mm, with a static lift of 6m to handle the ash with a characteristics
as indicated in System Data Sheet A-1 of this specification.
---------------------------------------------------------------------------------------------------------------
SPECIFICATION NO. TCE CONSULTING ENGINEERS LTD SECTION D 13
DATA SHEET - A
`TCE-3472-134-02 PIPES FOR GENERAL PURPOSES SHEET 1 OF 4
1.0 SERVICE ALL WATER SERVICES

INDICATED IN THE FLOW
DIAGRAM LIKE ASH
WATER,SEAL WATER,
COOLING WATER,FLUSHING
WATER,ETC.
2.0 FLANGE FACING SERRATED FINISH
3.0 LIMITS OF PRESSURE, NOMINAL * BIDDER TO DECIDE

SIZE AND THICKNESS
4.0 LINE JOINTS
a) For pipe sizes less than or SOCKET WELDED AS PER

equal to 50 mm ANSI B 16.11 UNLESS OTHER-
WISE INDICATED. FLANGED
CONNECTION SHALL BE
PROVIDED AT EQUIPMENT
b) For pipe sizes greater than BUTT WELDED ENDS WITH

50 mm size SPLIT PACKING
RINGS UNLESS OTHERWISE
SPECIFIED. FLANGED
CONNECTIONS SHALL BE
PROVIDED AT VALVES
AND EQUIPMENT.
5.0 PIPES TO CONFORM IS 1239, HEAVY CLASS/

IS-3589
6.0 FLANGES TO CONFORM ANSI 150 lbs FORGED STEEL

ASTM 105 TO B 16.5, FLAT
FACE
7.0 BOLTS & NUTS TO CONFORM FORGED STEEL BOLTS, NUTS

& STUDS TO IS 1367 CLAUSE
4.6 OR EQUAL.
8.0 GASKETS MIN. 3 MM THK. RED RUBBER

TO SUIT.
9.0 FITTINGS NB 15 TO NB 50 : 300 lbs

RATING FORGED CARBON
STEEL TO ASTM 105 OR) IS-
DATA SHEET - A
1875 CLASS II WITH SCREW

ENDS DIMENSIONAL
STANDARD : ANSI B 16.11
NB 65 & ABOVE : A 234 Gr

WPB MATERIAL WITH
FLANGED ENDS DIMENSIONAL
STANDARD : ANSI B 16.9
10.0 VALVES REFER VALVES DATA SHEET
11.0 NOTES
11.1 Piping system after installation shall be hydro-statically tested at pressure of 1.5
times the maximum working pressure.
11.2 Test certificates as required for relevant standards shall be furnished
1.0 SERVICE CONVEYING AIR FOR FLY ASH

CONVEYING AND
COMPRESSED AIR FOR
INSTRUMENTS & CONTROL
SERVICES UPTO VALVES,
OTHER SERVICES.
2.0 LIMIT OF TEMPERATURE AMBIENT
3.0 FLANGE FACING SERRATED FINISH
4.0 LIMITS OF PRESSURE kg/cm2(g) 9.0
5.0 NORMAL PIPE SIZE AND BIDDER TO DECIDE

THICKNESS
6.0 LINE JOINTS
a) For Pipe Sizes Less Than 65 mm SCREWED
b) For Pipe Sizes of 65 mm and FLANGED

Above.
DATA SHEET - A
7.0 PIPES TO CONFORM IS 1239, HEAVY CLASS/IS-

3589 ERW GALVANISED PIPE
8.0 FLANGES TO CONFORM ASA 150 lbs FORGED STEEL

ASTM A 105 TO ASA B 16.5
9.0 BOLTS & NUTS TO CONFORM FORGED STEEL BOLTS, NUTS

& STUDS TO SUIT IS 1367,
CLAUSE 4.6 OR EQUAL.
10.0 GASKETS RED RUBBER/ASA B 16.21,

3 MM THK.
11.0 FITTINGS ASA 3000 lbs RATING

FORGED STEEL TO IS 1875,
CLASS 2. FITTINGS TO ANSI
B 16.9 MATERIAL ASTM A
234 Gr NPB WITH SCREWED
ENDS FOR PIPES LESS THAN
OR EQUAL TO 50 MM
AND FLANGED CONNECTIONS
FOR PIPES EQUAL TO OR
GREATER THAN 65 mm.
12.0 NOTES
12.1 Piping system after installation shall be hydro-statically tested at pressure of 1.5

DATA SHEET - A
1.0 SERVICE COMPRESSED AIR FOR

INSTRUMENTS AND CONTROL
(PNEUMATIC SIGNAL LINE)
2.0 LIMIT OF TEMPERATURE AMBIENT
3.0 LIMIT OF PRESSURE kg/cm2(g) 9.0
4.0 NORMAL PIPE SIZE AND BIDDER TO DECIDE

THICKNESS
5.0 LINE JOINTS
6.0 PIPES
6.1 Normal Pipe Size Range LESS THAN 50 MM
6.2 MATERIAL SPECIFICATION SEAMLESS COPPER TUBING

TO ASTM 875 WITH PLAIN
ENDS
7.0 FLANGES COPPER ALLOY AS PER B 62

OR EQUIVALENT
8.0 BOLTS & NUTS FORGED STEEL BOLTS, NUTS

& STUDS TO SUIT IS 1367,
CLAUSE 4.6 OR EQUIVALENT
9.0 FITTINGS COPPER ALLOY AS PER B 62

OR EQUIVALENT WITH THREE
PIECES FLANGED ENDS.
10.0 GASKETS RED RUBBER/ASA B 16.21,

3 MM THICK WIRE INSERTED
TYPE
12.0 NOTES
12.1 Piping system after installation shall be hydro-statically tested at a pressure of 1.5

SPEC. NO. TCE CONSULTING ENGINEERS LIMITED SECTION: D
SUPPLY, SHOP FABRICATION AND TESTING OF

POWER PLANT PIPING
1.0 SCOPE
This specification covers the technical requirements and essential

particulars for the design (as applicable), supply, shop fabrication,
inspection, testing, cleaning, commissioning assistance and protection of
the piping systems as covered in the tender specification documents and
drawings. The CONTRACTOR shall demonstrate that the piping
satisfies the requirements of the specification and applicable codes. To
the extent design and engineering of piping systems are specified to be
in the CONTRACTOR scope in Section C of the tender documents and
hereunder, all references to the PURCHASER drawings and documents
in the subsequent clauses of this section shall be understood to imply
the CONTRACTOR's drawings and documents.
2.1 All piping systems including subcontracted items shall comply with all
currently applicable statutes, regulations and safety codes in the locality
where the system will be installed. The piping shall also conform to the
latest editions of the codes and standards listed under Clause 2.2 below.
Nothing in this specification shall be constructed to relieve the
CONTRACTOR of this responsibility.
2.2 The system and work under this contract shall conform to the following
standards/codes:
(a) Indian Boiler Regula tions
(b) Indian Regulations of Inspector of Explosives
(c) ASME Code Power Piping - ASME B 31.1 and all other
associated ANSI/ASME standards.
(d) Manufacturer's Standardisation Society (MSS), USA, Standard

Practices.
(e) American Society for Testing and Materials (ASTM)

Specifications.
(f) Pipe Fabrication Institute (PFI), USA, Standards
ISSUE
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TCE FORM NO. 329 R3


POWER PLANT PIPING
2.3 In case of conflict between the codes and standards referred to herein
and the requirements of this specification, the more stringent
requirement shall govern.
3.0 SCOPE OF WORK
3.1 The scope of supply of the CONTRACTOR under this contract shall be
as defined in Section C of this specification. For all the piping systems
included in this scope of supply, the CONTRACTOR shall supply all
materials except those items specifically excluded from his scope in
Section C, and render the piping systems complete as applicable. The
CONTRACTOR's scope of supply shall include but not be limited to the
following:
(a) Pipes, tubes, headers, manifolds, etc.
(b) Bends, elbows, returns, tees, laterals, crosses, reducers, caps

and closures, full and half couplings, plugs, sleeves and saddles,
stubs and bosses, unions and other similar fittings.
(c) Flanges
(d) Gaskets and fasteners
(e) Complete assemblies of hangers, supports, anchors, guides,

restraints, snubbers, shock absorbers, etc., including welded
attachments, springs and spring gauges, beam clamps, clips,
shoes, rollers, trapezes, trunnions, etc.
(f) Auxiliary steel, concrete foundations, pedestals, etc., as required

for hangers, supports, guides, restraints, anchors, snubbers,
shock absorbers, etc.
(g) All materials as required for providing anti-corrosive treatment to

buried pipes
(h) All paints, varnishes, primers, thinners and other painting

materials.
(i) Weather hoods fo r bare pipes crossing ceilings and walls.
ISSUE
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TCE FORM NO. 329 R3


POWER PLANT PIPING
3.2 Unless otherwise specified in Section C, the CONTRACTORs scope of

supply includes all instrument impulse piping and fittings upto the last
root valve. In the case of temperature measurement points, the
CONTRACTORs scope includes supply of thermowell stubs.
3.3 The CONTRACTOR shall supply all necessary drains and vents
including anti flash funnels as required for the safe and effective
draining/venting of the piping systems. It must be noted that the flow
diagrams may not indicate all the drains and vents that would be
required. As stated elsewhere, it is the CONTRACTOR's responsibility
to identify the requirements of drains and vents whether the same have
been shown in the flow diagrams or not and supply the necessary pipe
work, fittings, hangers, supports, etc. The drains and vents indicated on
the flow diagrams shall however be regarded as minimum requirements.
The drains and vents shall be led upto the nearest floor drain in case of
cold water systems and upto the flash tank in case of steam and hot
water systems, as directed by the PURCHASER.
3.4 In the case of pipes laid in trenches or on pipe racks, the

CONTRACTOR shall supply necessary steel members, cross beams
and other supporting accessories such as stools, saddles, base plates,
clamps, U-bolts, angles, clips, etc.
3.5 All concrete pedestals and foundations other then those specifically
indicated as excluded from the CONTRACTORs scope in Section C
shall be supplied by the CONTRACTOR.
3.6 Wherever uninsulated pipes cross walls or roofs, the necessary weather
hoods shall be designed, fabricated and supplied by the CONTRACTOR
as directed by the PURCHASER.
3.7 The CONTRACTOR shall design, fabricate and supply all hangers and
supports, anchors, guides, restraints, etc., including necessary welded
attachments and auxiliary steel based on data furnished by the
PURCHASER/ENGINEER. The data to be furnished by the
PURCHASER / ENGINEER would be from the systems point of view
and would typically include the overall configuration of the support
system, operating and design loads, cold to hot movements of pipe,
desired hanger/support spring constant, type of spring support, viz.,
constant load type or variable load type, etc. It is the CONTRACTORs
responsibility to design, engineer and select the individual components
of the hangers, supports, restraints, guides or anchors based on the
ISSUE
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TCE FORM NO. 329 R3


POWER PLANT PIPING
PURCHASERs data and in accordance with the requirements of this

specification.
3.8 The loads indicated in the PURCHASERs hanger/support sketches do

not include the weights of hanger components such as clamps,
turnbuckles, trapezes, spring cage assemblies, etc. The weights of these
components shall be considered by the CONTRACTOR in the design
and settings of hangers and supports under advice to the
PURCHASER/ENGINEER.
3.9 The CONTRACTOR shall perform necessary internal machining of pipes

for installing orifices, flow nozzles, straightening vanes, etc.
3.10 At all intersection joints, it is the CONTRACTORs responsibility to

design and provide suitable reinforcements as per the applicable codes
and standards taking into account the pressure, temperature and dead
weight loads.
3.11 Welding, nondestructive examination of welded joints and repair of weld

defect areas shall conform to TCE specification no. TCE.M4-134-04.
3.12 The CONTRACTOR shall prepare fabrication isometric drawings and

bills of material for piping NB 65 mm and larger based on the
PURCHASERs piping drawings except for Low Pressure (LP) piping
systems such as water and air. The PURCHASER/ ENGINEER will
review, prior to release for fabrication, all piping isometric drawings. The
PURCHASER/ENGINEER may request changes, if the
PURCHASER/ENGINEERs stress analysis or other considerations
require it. As the CONTRACTOR is responsible for the design and
adequacy of hanger components, no comments or approval may be
given by the PURCHASER/ENGINEER except in those instances where
it may appear that the CONTRACTORs work does not meet the
standard desired by the PURCHASER/ ENGINEER. In such cases, the
CONTRACTOR shall be guided by the PURCHASER / ENGINEER's
comments and the CONTRACTOR shall comply to the requirements at
no extra cost.
3.13 The CONTRACTOR's fabrication drawings shall take into account the
requirements of this specification as also all applicable codes and
standards including statutory regulations such as the Indian Boiler
Regulations. The CONTRACTORs fabrication drawings shall carry all
details of fabrication, welding, etc., as may be required for obtaining
ISSUE
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TCE FORM NO. 329 R3


POWER PLANT PIPING
necessary statutory clearances. It is the CONTRACTOR's responsibility

to obtain all such clearances, and fabrication shall commence only after
the necessary clearances have been obtained from the appropriate
authorities. All expenses incurred in obtaining these clearances shall be
to the CONTRACTORs account.
4.0 MATERIALS AND WALL THICKNESS
4.1 All piping materials to be supplied by the CONTRACTOR shall be in

accordance with the PURCHASERs piping material specification and/or
piping bill of materials.
4.2 The BIDDERs may offer if they so desire, alternate materials equal or
superior to those specified. However, no credit would be given to offers
containing materials superior to those specified. The responsibility for
establishing equality or superiority of the alternate materials offered to
those specified rests entirely with the BIDDER. The PURCHASER /
ENGINEER reserves the right to reject such alternate materials and
insist upon only those specified.
4.3 The BIDDERs shall note that equality or superiority of the materials
offered by them vis-a-vis those specified would be judged not only based
on a comparison of the material standards but also on the ease of
fabrication, shop and field welding, heat treatment, service record and
any other characteristic considered important by the ENGINEER.
4.4 BIDDERs shall indicate in their offer, reasons and justification for their
wishing to deviate from the materials specified.
4.5 Materials inferior to those specified will not be acceptable.
4.6 Where bending and forming allowances are excluded from the wall
thicknesses specified in the specification documents, the specified wall
thicknesses shall be increased in accordance with the CONTRACTOR's
standards to allow for the manufacturing process for bends and fittings.
In no case shall the wall thicknesses of fittings be less than those
specified for straight pipes.
4.7 For steam piping systems, all materials shall be procured directly from
the manufacturers. Materials procured from traders and stockists are not
acceptable. For LP piping systems, these can be procured from reputed
and approved traders or stockists.
ISSUE
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TCE FORM NO. 329 R3


POWER PLANT PIPING
4.8 All materials procured shall be new and specifically for the subject
contract.
4.9 All materials shall be certified by proper material test certificates. All
material test certificates shall carry proper identification number or other
acceptable references to enable identification of the certificate with the
material it purports to certify. The heat number shall also be indicated on
the material certified.
5.0 FABRICATION
5.1 Unless otherwise specified in Section C, all steam piping systems of size
NB 65 mm and larger shall be supplied fully prefabricated at works as
per the piping drawings. All piping, NB 50 mm size and smaller, shall be
supplied in straight lengths, with the pipe ends cut square to the axis.
5.2 Unless otherwise specified in piping drawings or piping materials

specification data sheets, all pipeline joints shall have welded
construction. Butt-welded joints shall be used for pipes NB 65 mm and
larger. Socket welded joints shall be used for pipes NB 50 mm and
smaller. The use of companion flanges to connect two pieces of pipe or
the use of odd or short pieces of pipes in making up long runs is
prohibited, except as noted on the PURCHASER's piping drawings.
5.3 Where welded pipes or fittings are used, longitudinal welds in adjoining
sections shall be staggered by minimum of 90o during fabrication. All
piping shall be fabricated true to lines and elevations as indicated in the
piping drawings.
5.4 Neither butt nor branch joints shall be closer than twice the pipe
diameter to any other joint in the same pipeline except where 'weldolet'
type fittings are used, in which case the branch weld will be made to the
'weldolet'.
5.5 The number of joints for field welding shall be kept as a minimum as
practicable and limited to accessible circumferential butt welds.
5.6 All pipe bends shall have a bend radius of five nominal pipe diameters
unless otherwise specified in the PURCHASERs piping drawings. The
pipe bends shall be true to angle and radius and shall maintain a true
ISSUE
R4
TCE FORM NO. 329 R3


POWER PLANT PIPING
circular cross section of pipe without deformity or undue stretching.

Crimping of pipes to form bends is not acceptable.
5.7 All pipe flanges and contact surfaces shall be concentric with the axis of
the piping. All flanges and fittings shall be accurately machined and
drilled true to template.
5.8 All threads on piping components shall be taper pipe threads as per
applicable standards. Threaded connections for insertion type fluid
temperature sensing and sampling devices shall be seal welded when
the service temperature exceeds 495oC or the service pressure exceeds
103.5 bar (g). The threads shall be entirely covered by the seal weld and
only qualified welders shall carry out such seal welding.
5.9 The CONTRACTOR shall cut the pipe short for cold spring for all hot
lines in accordance with the data furnished by the PURCHASER. In
addition to the cut for cold spring, a length of pipe must be cut to attain
slope when the line is in the cold or hot position. The additional cut must
not add to the cold spring in the system. In order not to add to the cold
spring, the pipe must be detailed and fabricated so that the affected
horizontal runs will be sloped to the proper angle when installed in the
field before the final weld is made. At the point of closure, the two pipe
ends should be separated by the required amount of cold spring only.
5.10 All welded attachments such as lugs, shoes, trunnions, etc., as required
for supporting, restraining or anchoring a pipe shall be welded to the
pipe at works and stress relieved as required. All welded attachments
and thermocouple pads shall be of the same material as the parent
pipeline and shall be subjected to the same fabrication and welding
procedures as the associated piping.
5.11 All welds between dissimilar materials shall be carried out at works.
Field welding of joints involving dissimilar materials shall be avoided.
5.12 The first circumferential weld joint after a pipe bend shall as far as
possible be after a minimum straight length of two times the pipe
diameter or 500 mm whichever is less.
5.13 All pipelines shall be pitched to low point(s) where drainage is indicated
on the PURCHASER's drawings. The pitch shall be sufficient to prevent
pockets of moisture collecting at low points between supports.
ISSUE
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TCE FORM NO. 329 R3


POWER PLANT PIPING
5.14 The CONTRACTOR shall fabricate the pipe assemblies in such a way
as to avoid any difficulty during field erection.
5.15 All branch connections shall be realised through the use of tees, crosses
and laterals to the extent such standards fittings are available as per
ANSI standards. Where intersection welds are employed due to non-
availability of a standard fitting, they shall be of suitable structural
adequacy by virtue of intrinsic weld connection, reinforcing pads or rings
or materials inherent in the branch. It is the CONTRACTOR's
responsibility to provide reinforcement, wherever necessary for branch
connections.
5.16 The CONTRACTOR shall machine welding ends of all pipes, bends and
fittings, to make sound welds. The welding rod shall be compatible with
the parent material.
5.17 The CONTRACTOR shall be responsible for determining the proper

bending procedure, including bending temperature, as well as the heat
treatment or stress relieving procedures to produce the desired end
product.
5.18 Cold bending may be performed on carbon steel, carbon molybdenum

and chromium molybdenum steel pipes with chromium content less than
1 % in a stress relieved, normalised and tempered or fully annealed
condition. Bending performed at temperatures below 900oC shall be
considered "cold bending".
5.19 Only hot bending at 900oC to 1200oC shall be performed on chromium -

molybdenum steel regardless of its heat treatment by full annealing. The
pipes shall be filled with free running, sulphur free silica sand or other
dry solid inert material, firmly tapped for the hot bending operations.
Optical pyrometry or other approved methods shall be used for
temperature control of these operations.
5.20 Oxyacetylene torches shall not be used for heating purposes during
bending operations.
5.21 Carbon steel, carbon molybdenum and chromium molybdenum piping

shall be bent hot if cold bends, free of cracks or buckles, cannot be
made.
ISSUE
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TCE FORM NO. 329 R3

SECTION: D14 VALVES DATA SHEET sh 1 of 2
GATE / GLOBE / CHECK VALVES
Sl. Description Water service Air service ( Globe & Check

No. valves only)
15 TO 50 NB 65 NB& 15 TO 50 NB 65 NB&
ABOVE ABOVE
1.0 BODY / BONNET Bronze as per CI as per IS Bronze as per Cast steel, as
ASTM B62 / 210 FG200 ASTM B62 / per ASTM
IS 318 LTB2 IS 318 LTB2 A216
Gr.WCB
DISC CI as per IS
-----do---- 210 FG200 -----do---- -----do----
STEM Manganese Manganese Manganese Alloy Steel as
( not applicable for check bronze IS320 bronze IS320 bronze IS320 per ASTM
valves) Gr.HT-2 Gr.HT-2 Gr.HT-2 A 479 Type
410-2
BODY SEAT / DISC SEAT Bronze as per Bronze as per Bronze as per
ASTM B62 / IS 318 Gr. ASTM B62 / -----do----
IS 318 LTB2 LTB2 IS 318 LTB2
END CONNECTION Screwed as Flat faced Screwed as Raised flange
per IS554 flanged to per IS554 as per
tapered ANSI B16.1 tappered ANSIB16.5
VALVE RATING 150 lb 125lb 150 lb 150lb
BALL VALVE
Sl. Description Water service Air service

No. 15 TO 50 NB 65 NB& 15 TO 50 NB 65 NB&
ABOVE ABOVE
1.0 BODY / BONNET Bronze as per CI as per IS Bronze as per Cast steel, as
ASTM B62 / 210 FG200 ASTM B62 / per ASTM
IS 318 LTB2 IS 318 LTB2 A216
Gr.WCB
DISC CI as per IS
210 FG200
STEM Manganese Manganese Manganese Alloy Steel as
bronze IS320 bronze IS320 bronze IS320 per ASTM
gr.HT-2 or gr.HT-2 or gr.HT-2 or A 479 Type
ASTM B312 ASTM B312 ASTM B312 410-2
Gr. A Gr. A Gr. A
BODY SEAT / DISC SEAT Bronze as per Bronze as per Bronze as per
ASTM B62 / IS 318 Gr. ASTM B62 / -----do----
IS 318 LTB2 LTB2 IS 318 LTB2
END CONNECTION Screwed as Flat faced Screwed as Raised
per IS554 fanged to per IS554 flanged as
tappered ANSIB16.1 tapered per ANSI B
16.5
VALVE RATING 150 lb 125lb 150 lb 150lb
General sh 2 of 2
1.0 For carbon steel valves Bolts and Nuts: ASTM A 193 Gr. B7, ASTM A 194 Gr.2H
2.0 Hand wheel / Lever ( for all valves) : Malleable Iron ASTM A 47 Gr.3251
3.0 For Bolts & nuts ( for CI & bronze valves) : ASTM A 307 Gr. B
BUTTER FLY VALVES
Body = CI, IS210 FG260
Disc = ------do-------
Shaft = SS410
Disc seal rings = neoprene rubber
Internal hardware = SS304
Pipes and fittings
SL. Description Water line Air line Ash line

NO 15 50NB 65NB & 15 50NB 65NB & 15 50NB 65NB &
above above above
1.0 LINE JOINTS Plain end Butt
as per welded Screwd Flanged
ANSI B ends.
16.11. Flanged
Flanged joints for
connection equpt.
for eqpt.
2.0 Pipes to confirm IS1239 / IS 3589 IS1239 / IS 3589 IS 1239 / 3589
3.0 Flanges ANSI 150lb forged ANSI 150lb forged steel Sleeve type with steel
steel ASTM 105 to ASTM 105 to B16.5 flat sleeve or CI flanges
B16.5 flat face. face.
4.0 Fittings 3000lb- A234 3000lb- A234
forged Gr.WPB forged Gr.WPB
carbon with Butt carbon with Butt Ni-Cr alloy CI as per IS
steel to welded to steel to welded to 4771 Type 1a 550 bhn
ASTM105 ANSI ASTM105 ANSI hardness
as per B16.9 as per B16.9
ANSI ANSI
B16.11 B16.11
5.0 MOC of piping ERW ERW GI pipe
MS ERW 9.5mm thk.

For I & II nd field and
7mm for other fieds
ISSUE NO.
DATA SHEET - B
TCE-M4-203-01 INDUCTION MOTORS SHEET 1 OF 2
ENQUIRY / SPECIFICATION NO.
SR.NO. ITEM BIDDER UNIT GUARANTEED PARTICULARS
1.0 Application
2.0 Manufacturer
3.0 Applicable Standards
4.0 Rated
(a) Output kW
(b) Speed RPM
(c) Frame size
5.0 Type of Duty (IS 325 or

equivalent)
6.0 Supply Conditions
(a) i) Rated Voltage V

ii) No. of Phases
iii) Frequency Hz
(b) Allowable Variations in
i) Voltage %
ii) Frequency %
iii) Combined %
7.0 Current
(a) Full Load Amps

(b) Starting % FL
8.0 Method of Starting
9.0 Class of Insulation
10.0 (a) Ref. Ambient Temp. deg.C
(b) Temp. rise of windings

by Res. Method
i) Stator deg.C
ii) Rotor deg.C
(c) Temp. rise of bearings deg.C
11.0 Degree of Protection

(IS 4691 or equivalent)
12.0 Suitable for Outdoor

Operation Yes/No
13.0 Normal winding connection Star/Delta
(i) Stator
(ii) Rotor

TCE FORM 294 R1
ISSUE NO.
DATA SHEET - B
TCE-M4-203-01 INDUCTION MOTORS SHEET 2 OF 2
ENQUIRY / SPECIFICATION NO.
SR.NO. ITEM BIDDER UNIT GUARANTEED PARTICULARS
14.0 Winding Suitable for 24V
Space Heating Yes/No
Space heater Rating 1 No.
15.0 Terminal box
i) Type & No. of Terminals
brought Out
ii) Fault withstand capacity
at rated voltage &
duration
17.0 Dimensional Dwg. Enclosed Yes/No

TCE FORM 294 R1
.
TCE-M4-203-01 TITLE
SHEET 1 OF 5
INDUCTION MOTORS
1.0 SCOPE
1.1 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 induction motors.
1.2 For motors of rated above 500 V, a separate specification (TCE.M4-203-02 -

Additional requirements for HV motors) covers the additional requirements, any or
all of which shall be complied with for motors rated 415V if specified in Data
Sheet-A.
2.1 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.
3.0 DRIVEN EQUIPMENT
3.1 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.
3.2 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.
4.0 PERFORMANCE AND CHARACTERISTICS
4.1 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
(a) Variation in supply voltage

from rated voltage +6% +10%
(b) Variation in supply frequency

from rated frequency +3% +5%
Supply Condition (contd.)
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00
.
TCE-M4-203-01 TITLE
SHEET 2 OF 5
INDUCTION MOTORS
I II
(c) Combined voltage and

frequency variation 9% 10%
4.2 Motors shall be suitable for the method of starting specified in the Data Sheet-A.
4.3 The minimum permissible voltage shall be 85% of the rated voltage during motor
starting
4.3.1 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.
4.4 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.
4.5 Motors shall be capable of developing the rated full load torque even if the supply
voltage drops to 70% of the rated voltage. If such operation is envisaged for a
period of one second, the pull out torque of the motor shall be atleast 205% of full
load torque.
4.6 Motors when started with the driven equipment coupled shall be capable of
withstanding atleast 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.
5.0 INSULATION
5.1 The insulation shall be given tropical and fungicidal treatment for successful
operation of the motor in hot, humid and tropical climate.
6.0 TEMPERATURE RISE
6.1 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.
6.2 For motors specified for outdoor installation heating due to direct exposure to solar
radiation shall be considered.
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.
TCE-M4-203-01 TITLE
SHEET 3 OF 5
INDUCTION MOTORS
7.0 CONSTRUCTIONAL FEATURES
7.1 Motors weighing more than 25 kg. shall be provided with eyebolts, lugs or other
means to facilitate safe lifting.
8.0 BEARINGS
8.1 Unless otherwise specified in data sheet-A, motor bearings shall not be subjected to
any external thrust load.
8.2 Unless otherwise specified, motor bearings shall have an estimated life of atleast
40,000 hrs.
8.3 The bearings shall permit running of the motor in either direction of rotation.
8.4 When forced oil lubrication or water-cooling is required, prior approval from the
purchaser shall be obtained.
8.5 When forced oil lubrication or water cooling is required, the machine shall be
suitable for starting & continuous operation for atleast 10 minutes, without the
availability of lubrication or cooling system
8.6 If the bearings are oil lubricated, a drain plug shall be provided for draining
residual oil & an oil level sight gauge shall be provided to show the precise oil
level required for stand still and running conditions.
8.7 It shall be possible to lubricate the bearings without dismantling any part of the
motor.
9.0 TERMINAL BOX
9.1 Terminal boxes shall have a degree of protection of atleast IP 55 for out door
applicable
9.2 Unless otherwise approved, the terminal box shall be capable of being turned
through 360o in steps of 90o.
9.3 Terminals shall be of stud type & the terminal box shall be complete with necessary
lugs, nuts, washers.
9.4 When single core cables are to be used the gland plates shall be of non-magnetic
material.
9.5 Sizes of terminal boxes and lugs shall be as given in Table-I, unless specified
otherwise in data sheet A or Section C.
ISSUE
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.
TCE-M4-203-01 TITLE
SHEET 4 OF 5
INDUCTION MOTORS
TABLE-I
415 V MOTORS - SIZES OF CABLES, STUDS, TERMINAL LUGS & TERMINAL BOXES
(TO BE PROVIDED ON MOTORS BY VENDOR)
SL. MOTOR 1100V Al. Stud Terminal lug size Minimum
NO RATING (kW) Conductor size of DOWELL Terminal Box
armoured PVC MAKE equivalent Size HXWXD mm
cable to DOWELLs X mm X mm
Cores x mm2 CAT NO.
1. Upto 3 3x4 M6 CUS/06 100 x 100 x 60
2. 3.1 - 7.5 3x6 M6 CUS/07 100 x 100 x 60
3. 7.6 - 15 3x16 M6 CUS/09 100 x 100 x 60
4. 16 - 25 3x35 M8 CUS/12 150 x 150 x 75
5. 26 - 40 3x70 M10 CUS/17 200 x 200 x 100
6. 41 - 55 3x120 M12 CUS/22 400 x 400 x 125
7. 56 - 70 3x185 M16 CUS/28 450 x 450 x 150
8. 71 - 85 3x240 M20 CUS/30 500 x 500 x 200
9. 86 - 110 3x400 M20 CUS/33 600 x 600 x 200
10. 111 - 175 3x1Cx500 M20 CUS/34 600 x 200 x 200
(3 separate cable
boxes for the 3
single core cables)
10.0 PAINT AND FINISH
10.1 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.
11.0 HEATING DURING IDLE PERIODS
11.1 For motors rated 30 kW and below, during idle periods, the stator winding will be
connected to a 24 V single phase, 50 Hz, AC supply for heating and elimination of
moisture. The supply will be connected between any two terminals.
11.2 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.
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.
TCE-M4-203-01 TITLE
SHEET 5 OF 5
INDUCTION MOTORS
12.0 ACCESSORIES
12.1 Two independent earthing points shall be provided on opposite sides of the
motor, for bolted connection of the PURCHASER'S earthing conductors as
specified in data sheet-A. These earthing points shall be in addition to earthing stud
provided in the terminal box.
12.2 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.
13.0 TESTS
13.1 Motor shall be subjected to all the routine tests as per applicable standard in the
presence of the PURCHASERS representative. Copies of test certificates of type
and routine tests shall be furnished as specified in the distribution schedule, for
the PURCHASER'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.
ISSUE
00
.
TCE-M4-203-02 TITLE
INDUCTION MOTORS SHEET 1 OF 4
ADDITIONAL REQUIREMENT FOR HV MOTORS
1.0 SCOPE
1.1 This specification covers requirements of HV induction motors. These are in

addition to the requirements of specification No.TCE.M4-203-01. Clauses of
this specification which are not applicable for any motor are mentioned in Data
Sheet-A of TCE.M4-203-01.
1.2 In case of conflict between TCE.M4-203-01 or applicable standard and this

specification, this specification shall govern.
2.0 PERFORMANCE AND CHARACTERISTICS
2.1 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 80% of the rated voltage.
2.2 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.
2.3 Motors shall withstand the voltage and torque stresses developed due to the
vector difference between the motor residual voltage and the incoming supply
voltage equal to 150% of the rated voltage, during fast change over of buses. The
duration of this condition is envisaged for a period of one second.
2.4 The locked rotor current of the motors shall not exceed the following values
which are inclusive of 20% tolerance.
2.4.1 600% of full load current for motors up to and including 1500 kW.
2.4.2 450% of full load current for motors above 1500 kW.
2.5 The locked rotor withstand time under hot conditions at 110% rated voltage shall
be more than the starting time at minimum permissible voltage (clause 2.1
above) by at least three seconds or 15% of the accelerating time whichever is
greater. Provision of speed switch shall be avoided to the extent possible. In case
the speed switch is required, it shall be indicated out by the bidder in his offer.
When a speed switch is mounted on the motor shaft , the same shall remain
closed for speeds lower than 20% and open for speeds above 20% of the
rated speed. The speed switch shall be capable of withstanding 120% over
speed in either direction of rotation. If the speed switch requires any auxiliary
voltage, it shall be suitable for the auxiliary voltage specified in Section-B -
Project Information of the specification
ISSUE
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TCE FORM 329 R3

.
TCE-M4-203-02 TITLE
3.0 INSULATION TREATMENT
3.1 Motors shall be given power house treatment. Additional treatments to withstand
heavily salt polluted or similar atmospheric conditions shall be given based on the
location indicated in Data Sheet-A.
4.0 ACCESSORIES
4.1 EMBEDDED TEMPERATURE DETECTORS (ETD'S)
Atleast six resistance type temperature detectors for the stator winding each
having D.C. resistance of 100 ohms at 0oC, embedded in the stator winding at
locations where highest temperatures may be expected, shall be provided. The
material of the ETD's shall be platinum. One ETD shall be provided for each of the
motor bearing & shall be wired up to the terminal box. The temperature detectors
shall be of 3 wire , duplex type.
4.2 BEARING THERMOMETERS
4.2.1 Each bearing shall be provided with a dial type thermometer. Each thermometer
shall consist of two potential free contacts. They shall be designed to close
independently at two different temperatures - one for 'Alarm' and another for 'Trip'.
4.2.2 The contact rating of the potential free contacts shall be 1A at 240V AC & 0.1A at
110V DC. Any auxiliary supply, if required shall be indicated by the bidder.
4.2.3 The thermometers shall be located at a convenient height for easy reading and
handling.
4.2.4 One bearing shall be insulated to prevent shaft currents.
4.3 DRAIN PLUGS
Motors shall be provided with drain plugs, so located to drain water, resulting from
condensation or due to other causes, from all pockets in the motor casing.
4.4 FLOW SWITCHES
Flow switches shall be provided for monitoring cooling water flow if CACW motors
are specified.
4.5 VIBRATION PADS
Vibration pads shall be provided when called for in the specification.
ISSUE
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TCE FORM 329 R3

.
TCE-M4-203-02 TITLE
5.0 TERMINAL BOX
5.1 Separate terminal boxes shall be provided for each of the following:
5.1.1 Stator Leads
5.1.2 Rotor leads (wound motors)
5.1.3 Space Heaters
5.1.4 Temperature Detectors
5.2 The three phases shall be segregated by barriers of metal or fibre glass.
5.3 The cable box design shall be suitable for any type of cable termination kits
available.
6.0 EARTHING PAD
The earthing pads shall be of non-corrodible metal welded or brazed at two

locations on opposite sides complete with suitable bolt and washers for
connecting the PURCHASER'S earthing flat.
7.0 RATING PLATE
7.1 The following details, in addition to those specified in applicable standards shall
be included on the rating plate.
7.1.1 Temperature rise of windings in degree centigrade at rated load, rated voltage,
frequency and ambient conditions and the method of measuring temperature rise.
(Thermometer/ Winding resistance).
7.1.2 Type of bearings, recommended lubricant, lubricating interval & re-lubricating

quantity.
8.0 TESTS
8.1 Type test certificates for similar motors shall be furnished with the Bid.
8.2 Extra price for performing type tests on the motor as per applicable standard shall
be quoted.
8.3 If specified in data sheet-A, for motors rated 3.3 kV and above, the induced
shaft voltage shall be measured at the manufacturer's works during shop
testing. The maximum value of induced voltage in the motor shaft shall not
exceed 250mV.
ISSUE
R8
TCE FORM 329 R3

.
TCE-M4-203-02 TITLE
8.4 The polarisation index test shall be carried out on all motors rated at 3.3 kV and
above. The minimum value of the polarisation index shall be 2 when determined as
per IS-7816.
8.5 Coils of HV motors shall be tested as per IEC-34-15.
8.6 Loss tangent measurement of coils for motors rated 6.6 kV & above shall be done
as per IS-13508.
8.7 All other routine tests shall be carried out as per applicable standards.
ISSUE
R8
TCE FORM 329 R3

ISSUE
R8
TCE FORM 329 R3

ISSUE NO. R8
SPEC. No. TCE CONSULTING ENGINEERS LIMITED SECTION D34
TCE. M4-203-01 DATA SHEET A
SL.NO. DESCRIPTION UNIT TECHNICAL PARTICULARS
1.0 GENERAL
1.1 APPLICATION
1.2 NUMBER OF UNITS
1.3 TYPE OF MOTOR SQUIRREL CAGE/

WOUND ROTOR
1.4 SUPPLY SYSTEM FAULT LEVEL MVA
1.5 SUPPLY NEUTRAL

TYPE OF EARTHING
1.6 COMPLIANCE WITH TCE.M4-

203-02 IS REQUIRED YES/NO
1.7 IF YES CLAUSES OF

TCE.M4-203-02 WHICH ARE
NOT APPLICABLE :
2.0 RATING
2.1 RATED OUTPUT : kW
2.2 RATED VOLTAGE : (415V for 132kW & below motors &
6.6kV for above 132kW motors )
V
2.3 NUMBER OF PHASES &
FREQUENCY
2.4 SUPPLY CONDITION (REF.

CL.NO.4.1 OF TCE.M4-
203-01) I/II
2.5 SYNCHRONOUS SPEED RPM
3.0 DUTY
3.1 TYPE OF DUTY (CLAUSE 9.2

OF IS:325 OR EQUIVALENT)
3.2 POWER REQUIRED BY LOAD kW
REV. NO. PPD. BY NP JOB NO. OWNER:BORL; EPCC:BHEL

DATE CKD. BY KG TCE. PROJECT : 3X33MW CPP BINA
REV. BY DATE 5178A
TCE.FORM NO.330R1
ISSUE NO. R8
4.0 METHOD OF STARTING D.O.L./STAR DELTA/

OTHER
5.0 INSULATION
5.1 CLASS OF INSULATION
5.2 REF. AMBIENT TEMPERATURE deg.C
5.3 TEMPERATURE RISE OF WINDING
5.3.1 BY THERMOMETER METHOD deg.C
5.3.2 BY WDG RESISTANCE METHOD deg.C
6.0 INSTALLATION
6.1 LOCATION Indoor/Outdoor
6.2 HAZARDOUS AREA DIVISION

(IS:5572 OR EQUIVALENT)
6.3 ATMOSPHERE CHEMICAL/DUSTY/SALT

LADEN
7.0 ENCLOSURE
7.1 TYPE OF COOLING (IS 6362)
7.2 DESIGNATION FOR DEGREE OF

PROTECTION (IS 4691)
8.0 MAIN TERMINAL BOX
8.1 LOCATION AS SEEN FROM NON-

DRIVE END: RIGHT/LEFT
8.2 RATINGS
(a) SHORT TIME

i. CURRENT : kA(RMS)
ii. DURATION : SECS. 0.25
(b) DYNAMIC : kA(PEAK)

REV. BY DATE 5178A
TCE.FORM NO.330R1
ISSUE NO. R8
8.3 EXTERNAL CABLE DETAILS
8.3.1 TYPE
8.3. 2 SIZE & NO OF CORES
8.4 EARTHING CONDUCTORS
8.4.1 MATERIAL
8.4.2 SIZE
9.0 MISCELLANEOUS REQUIREMENTS TO BE FILLED IF MOTORS ARE BOUGHT

SEPERATELY
9.1 SHAFT ORIENTATION HORIZONTAL/VERTICAL/

HOLLOW VERTICAL
9.2 MOUNTING SYMBOL (IS:2253

OR EQUIVALENT)
9.5 ROTATION AS SEEN FROM CLOCKWISE/ANTI-CLOCKWISE

NON-DRIVE END
9.6 TYPE OF BEARING
9.6.1 DRIVE END
9.6.2 NON DRIVE END
9.7 WHETHER BED PLATE REQUIRED YES/NO
9.9 COLOUR SHADES OF PAINT
9.10 WHETHER CTs FOR DIFFEREN-

TIAL PROTECTION REQUIRED
FOR MOTORS >1000 kW YES/NO

REV. BY DATE 5178A
TCE.FORM NO.330R1
ISSUE NO. R8
9.10.1 C.T. PARTICULARS :
a) 3 CTs, ONE IN THE

NEUTRAL LEAD OF
EACH PHASE
b) RATIO
c) CLASS PS
d) KNEE POINT VOLTAGE KPV
e) MAX. R.C.T. SECONDARY

WINDING RESISTANCE OHMS
f) MAX. EXCITING CURRENT

AT 1/2 KPV
g) CLASS OF INSULATION
9.11 WHETHER VIBRATION PADS

REQUIRED YES/NO
9.12 TEMPERATURE DETECTORS/

INDICATORS
9.12.1 EMBEDDED TEMPERATURE

DETECTORS FOR WINDING
REQUIRED YES/NO
9.12.2 EMBEDDED TEMPERATURE

DETECTORS FOR BEARINGS
REQUIRED YES/NO
9.12.3 BEARING THERMOMETERS

FOR DRIVING END & NON
DRIVING ENDS REQUIRED YES/NO
9.13 SPACE HEATERS FOR YES/NO

MOTORS REQUIRED

REV. BY DATE 5178A
TCE.FORM NO.330R1
ISSUE NO. R8
NOTES
DRAWINGS SHOULD BE SUBMITTED FOR REVIEW AS FOLLOWS:
1) GENERAL ARRANGEMENT WITHIN ___ WEEKS AFTER AWARD OF CONTRACT
2) DETAILS MARKED THUS (*) WILL BE DECIDED AND INTIMATED BY THE BIDDER BASED
ON DRIVEN EQUIPMENT CHARACTERISTICS.

REV. BY DATE 5178A
TCE.FORM NO.330R1
TCE. M4-203-01 DATA SHEET-A1
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 BS IEC
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 BS IEC-34-7

CONSTRUCTION AND MOUNTING
ARRANGEMENT OF ROTATING
ELECTRICAL MACHINES
6. TERMINAL MARKING & DIRECTION IS-4728 BS-4999 IEC-34-8

OF ROTATION FOR ROTATING -108
ELECTRICAL MACHINERY
7. DESIGNATION OF METHODS OF IS-6362 BSEN 60034 IEC-34-6

COOLING FOR ROTATING -6-1994
ELECTRICAL MACHINES
8. DEGREES OF PROTECTION PROVI- IS-4691 BS-4999 IEC-34-5

DED BY ENCLOSURE FOR ROTATING -105
ELECTRICAL MACHINERY
9. GUIDE FOR TESTING THREE PHASE IS-4029 BS IEC-34

INDUCTION MOTORS
10. MEASUREMENT AND EVALUATION OF IS-12075 BS-4999 IEC-34-14

VIBRATION OF ROTATING 142
ELECTRICAL MACHINES
11. CLASSIFICATION OF HAZARDOUS IS-5572 BS IEC-79

AREAS FOR ELECTRICAL
INSTALLATION
12. DIMENSIONS OF SLIDE RAILS FOR IS-2968 BS-4999 IEC

ELECTRIC MOTORS -141
13. PERMISSIBLE LIMITS OF NOISE IS-12065 BSEN 60034 IEC

LEVEL FOR ROTATING ELECTRICAL -9-1994
MACHINES
14. GUIDE FOR TESTING INSULATION IS-7816 BS IEC

RESISTANCE OF ROTATING
MACHINES

REV. BY DATE 5178A
TCE.FORM NO.330R1
TCE. M4-203-01 DATA SHEET-A1
SL.NO. BRIEF TITLE REFERENCE NUMBER OF STANDARDS
15. TANGENT DELTA & DELTA TANGENT IS-13508 BS IEC

DELTA TEST
16. IMPULSE VOLTAGE WITHSTAND TEST IS BS IEC-34-15
17. TEMPERATURE RISE MEASUREMENT IS-12802 BS IEC

OF ROTATING ELECTRICAL
MACHINES
18. TYPE OF DUTY AND CLASSES OF

RATING ASSIGNED TO ROTATING
ELECTRICAL MACHINES IS 12824 BS IEC
19. CBIP RECOMMENDATION FOR MOTORS
NOTES
1. EQUIPMENT, ASSOCIATED ACCESSORIES, COMPONENTS/PARTS, RAW MATERIAL AND

TESTS SHALL IN GENERAL CONFORM TO IS BS IEC
2. OFFERS CONFORMING TO OTHER AUTHORITATIVE STANDARDS MAY ALSO BE CONSIDERED/

MAY NOT BE CONSIDERED.

REV. BY DATE 5178A
TCE.FORM NO.330R1
SPEC. No. TCE CONSULTING ENGINEERS LIMITED SECTION D
TCE. M4-203-01 DATA SHEET-A

REV. BY DATE 5178A
TCE.FORM NO.330R1
TCE.M4-109-PLC TCE CONSULTING ENGINEERS LTD. SECTION D35
REV. 0
SPECIFICATION NUMBER PROGRAMMABLE LOGIC CONTROLLER
SH 1 OF 15
TCE-M4-126-IC-01 DATA SHEET
1 MANUFACTURER : SIEMENS LTD
2 MODEL NUMBER/SYSTEM TYPE *

3 MICRO PROCESSOR BASED PROGRAMMABLE LOGIC CONTROLLER (PLC)
4 CONFIGURATION : AS PER ENCLOSED DRAWING TCE-M4-126-IC-01
GENERAL FEATURES
}
5 FUNCTIONS : AS PER ENCLOSED LOGIC
6 AS PER SECTION-C WRITEUP (ALSO REFER NOTE 1)
7 AS PER I/O LISTS ENCLOSED
8 CAPACITY : BASED ON I/O LIST OF BIDDER
9 ADEQUATE TO MEET REQUIREMENTS AS PER LOGIC DRG. ENCLOSED }

10 TYPE OF INPUTS AND OUTPUTS : AS PER I/O LIST ENCLOSED AS PER LOGIC DWG. ENCLOSED
11 HARDWARE REQUIREMENTS : REFER NOTE 1
12 SOFTWARE REQUIREMENTS : REFER NOTE 1
13
14
15
16 PLC COMPLETE WITH PROCESSOR, I/O CARDS, MEMORY MODULES, RACKS, MOUNTING ACCESSORIES,
17 COMPLETELY WIRED & TESTED }

18 POWER SUPPLY MODULES YES NO (REF. SHEET NO. 5)
19 HAND HELD PROGRAMMER YES NO (REF. SHEET NO. 7)
EQUIPMENT TO BE SUPPLIED
20 PC BASED PROGRAMMER YES NO (REF. SHEET NO. 7)
21 PRINTER WITH THE PLC YES NO (REF. SECTION D )
22 OPERATING TILE YES NO (REF. SECTION D )
23 ILLUMINATED PUSH BUTTON YES NO (REF. SECTION D )
24 INTERPOSING RELAY YES NO (REF. SHEET NO. 7)
25 SYSTEM CABINET YES NO (REF. SECTION D )
26 SIGNAL DISTRIBUTION HARDWARE YES NO (REF. SHEET NO. 4)
27 CONTROL OPERATION PC PANEL

28
29
1 THE PLC SHALL MEET ALL THE FUNCTIONS LISTED HEREIN BUT NEED NOT BE LIMITED TO THE FOLLOWING.
ALL HARDWARES/SOFTWARES NECESSARY TO MEET THESE FUNCTIONS SHALL BE PROVIDED.
a) TO PROCESS THE FIELD SIGNALS/GENERATED SIGNALS AND DISTRIBUTE THE SIGNALS AS PER ENCLOSED I/O
LIST/LOGIC DRAWINGS
b) TO PERFORM PROTECTION, LOGIC, INTERLOCK AND SEQUENTIAL CONTROL FUNCTIONS AS SPECIFIED AND
GUARANTEE THE FUNCTIONAL REQUIREMENTS AS SPECIFIED UNDER GUARANTEE CLAUSES. THE CONTROL
FUNCTIONS OF PLC SHALL BE SUCH AS BINARY LOGIC OPERATIONS, SET/ RESET OPERATION, TIMERS,
COUNTERS, JUMP INSTRUCTION COMPARISON BLOCK, LOGICAL BLOCKS, MATH FUNCTIONS, BOOLEAN
FUNCTIONS, TIMER FUNCTIONS (ON & OFF DELAY TIMERS), COUNTER FUNCTIONS.
c) FAILURE OF ONE LOGIC SHALL NOT RESULT IN FAILURE OF OTHER LOGICS.
d) OTHER FUNCTIONS AS REQUIRED

NOTES
2. EACH LOOP IS A SUBSYSTEM AND CONSISTS OF PRIMARY SENSOR/INITIATING DEVICE, FUNCTION
MODULES, POWER SUPPLY CIRCUIT, LOGIC CIRCUIT MONITORING AND DETECTION.
3 EXECUTION TIME INCLUDES THE TIME FOR SCANNING ALL INPUTS AND OUTPUTS AND EXECUTION OF ALL
STEP/LADDER LOGICS WITH ALL INPUTS AND OUTPUTS CONNECTED TOGETHER. IF THE PLC OFFERED
CANNOT MEET THIS REQUIREMENT, BIDDER MAY DISTRIBUTE THE CONTROLS TO MORE THAN 1 PLC IN HIS
OFFER TO MEET THE REQUIRED RESPONSE TIME.
REV. NO. PPD. BY : CS JOB NO. OWNER : BORL EPCC : BHEL

DATE CKD. BY : KG TCE
5178 A PROJECT : 3X33 MW CPP, BINA

REV. BY DATE
P-PLC1
JAN 1994
REV. 0
REV.BY
DATE
REV. NO.
C. DIGITAL DISTRIBUTION AND SIGNAL CONDITIONING MODULE (REF. NOTE 7)*
TCE-M4-126-IC-01
SPECIFICATION NUMBER
TCE.M4-109-PLC
DISTRIBUTION MODULES SIGNAL CONDITIONING MODULES
TYPE OF NO. OF INPUTS MFR/
SL. SYSTEMS NO. OF INPUT SIGNALS NO. OF MODULES NO. OF INPUT SIGNALS NO. OF MODULES MFR/
No. SIGNALS ENVISAGED TYPE OF TYPE OF
PER MODULE PROVIDED PER MODULE PROVIDED
MODULE MODULE
DIGITAL DISTRIBUTION & SIGNAL CONDITIONING MODULES
TCE CONSULTING ENGINEERS LTD.

DATE
CKD. BY : KG
PPD. BY : CS
DATA SHEET
JOB NO.
5178 A
TCE
PROJECT : 3 X 33 MW CPP, BINA
OWNER :
BORL
SHEET
SECTION
EPCC : BHEL
10
D35
OF
15
P-PLC10
JAN. 1994
REV. 0
REV.BY
DATE
REV. NO.
D. DIGITAL INPUT / OUTPUT MODULE (REF. NOTE 7 ) *
TCE-M4-126-IC-01
TCE.M4-109-PLC
INPUT MODULE OUTPUT MODULE IPR
SL. NO. OF DIGITAL MAX. NO. OF MFR. NO. OF DIGITAL MAX. NO. OF MFR. NO. OF IPR NO. OF IPR
SYSTEMS NO. OF MODULES NO. OF MODULES
INPUTS INPUTS/ TYPE & OUTPUTS OUTPUTS/ TYPE & PROVIDED CABINETS
No. PROVIDED
ENVISAGED MODULE PROVIDED MOD. NO. ENVISAGED MODULE MOD. NO. (REF. NOTE 10) PROVIDED

DATE
CKD. BY : KG
PPD. BY : CS
DIGITAL INPUT/OUTPUT MODULES

DATA SHEET
JOB NO.
5178 A
TCE
OWNER :
BORL
SHEET
SECTION
EPCC : BHEL
11
OF
D35
15
P-PLC11
JAN. 1994
REV. 0
SPECIFICATION NUMBER PROCESSOR MODULE

DATA SHEET SHEET 12 OF 15
TCE-M4-126-IC-01
(REF. NOTE 3)
CAPACITY
AVAILABLE
PROVIDED & TYPE
PROCESSORS
NO. OF
PROCESSOR CAN
TOTAL NO. OF
SIGNALS ONE
HANDLE
INPUT & OUTPUT
TOTAL NO. OF
SIGNALS
OUTPUT SIGNALS
TOTAL NO. OF
INPUT SIGNALS
TOTAL NO. OF
E. PROCESSORS (SEE NOTES 3 & 7) *
SYSTEMS
LINE
No.
REV. NO. PPD. BY : CS JOB NO.
OWNER : BORL EPCC : BHEL
TCE
DATE CKD. BY : KG
5178 A PROJECT : 3 X 33 MW CPP, BINA
REV.BY DATE
P-PLC12
JAN. 1994
REV. 0
REV.BY
DATE
REV. NO.
F. RACKS AND CABINETS (SEE NOTES 2 & 7)*
TCE-M4-126-IC-01
TCE.M4-109-PLC
MAIN RACKS EXTENDED RACKS CABINTES
LINE NO. OF POWER NO. OF NO. OF BUS NO. OF NO. OF POWER NO. OF NO. OF NO. OF TOTAL NO. OF NO. OF
NO. OF TOTAL NO. OF
No. SYSTEMS SUPPLY I/O INTERF. MAIN SUPPLY BALANCE I/O COMMUNICATION EXTENDED MAIN & EXTD. RACKS PER
PROCESSORS CABINETS *
MODULES* MODULES* MODULES* RACKS* MODULES* MODULES* CARDS* RACKS * RACKS * CABINET *

DATE
CKD. BY : KG
PPD. BY : CS
RACKS & CABINET

DATA SHEET
JOB NO.
5178 A
TCE
OWNER :
BORL
SHEET
SECTION
EPCC : BHEL
13
D35
OF
15
P-PLC13
JAN. 1994
REV. 0
REV.BY
DATE
REV. NO.
NOTES:-
TCE-M4-126-IC-01
TCE.M4-109-PLC
1. THE DISTRIBUTION OF THE SIGNALS WHEREVER REQUIRED IS INDICATED. ANY CHANGES ON THE NUMBER OF DISTRIBUTION OF
SINGALS CALLING FOR ANY HARDWARE CHANGES SHALL NOT BE CONSIDERED AS SCOPE CHANGE.
2. THE RACKS IN SYSTEM CABINETS SHALL HAVE SPARE SLOT PROVISION ALONGWITH PLUGIN SOCKETS/ BACKPLANE TO HOUSE ATLEAST
10% ADDITION CARD OF EACH TYPE TO ACCOMODATE FOR ENGINEERING FLEXIBILITY OR FUTURE EXPANSION. THESE SPARE SLOTS SHALL
BE DISTRIBUTED TO DIFFERENT RACKS AND CABINETS.
3. THE PROCESSOR SHALL BE DESIGNED TO HAVE A MINIMUM OF 20% SPARE CAPACITY OVER AND ABOVE THAT REQUIRED
CONSIDERING HOT SPARE I/O MODULES (FUTURE) TO BE LOCATED AT SPARE SLOTS.
*4. BIDDER TO SUBMIT TYPICAL LOGIC SCHEMES (LOOP DRAWINGS) SHOWING THE SIGNAL PATH FROM SENSOR TO LOCAL/CUBICLE BUS
AND IDENTIFYING THE VARIOUS HARDWARES LIKE DISTRIBUTOR MODULES, SIGNAL CONDITIOING MODULES, INPUT MODULES,
PROGRAMMABLE LOGIC CONTROLLER

OUTPUT MODULES, PROCESSOR MODULES, COMMUNICATION CARDS, BUS INTERFACING CARDS, POWER SUPPLY MODULES, LIMIT

DATE
CKD. BY : KG
PPD. BY : CS
VALUE MONITORS ETC., CLEARLY BRINGING OUT THE REDUNDANT FEATURES.
*5. BIDDER SHALL SUBMIT A SCHEMATIC DRAWING TO SHOW THE POWER SUPPLY DISTRIBUTION TO VARIOUS MODULES IN DIFFERENT
RACKS IN A CABINET AND TO OTHER CABINETS.
6. BIDDER SHALL SUBMIT A SCHEMATIC DRAWING TO SHOW THE POWER SUPPLY DISTRIBUTION TO VARIOUS MODULES VIZ POWER SUPPLY MODULES,
SINGAL DISTRIBUTOR MODULES, SIGNAL CONDITIONING MODULES, INPUT MODULES, OUTPUT MODULES, PROCESSORS INTERFACING CARDS
DATA SHEET
ETC., IN THE RACKS AND CABINETS.
JOB NO.
7. BIDDER SHALL USE AS MANY SHEETS AS THEY NEED TO LIST OUT THE DETAILS CALLED FOR IN DATA SHEETS FOR
5178 A
TCE
PROCESS MODULES, PROCESSORS AND RACKS AND CABINETS. HOWEVER, THE INFORMATION SHALL BE PRESENTED IN THE
SAME FORMAT.
8. CONCEPT FOR I/O ASSIGNMENT (GROUPING)

OWNER :
(i) NO TWO IDENTICAL/ SIMILAR EQUIPMENT SHALL BE GROUPED IN THE SAME INPUT MODULE/ OUTPUT MODULE.
GENERAL NOTES
(ii) ANY ONE CARD SHALL HAVE I/O RELATED TO ONLY ONE EQUIPMENT AND ASSOCIATED AUXIUARIES, IF ANY EQUIPMENT AND
AUXILIARY REQUIRES MORE THAN ONE CARD, I/O RELATED AUXILIARIES (EG. LOP-À' & LOP-`B') SHALL BE
IN DIFFERENT CARDS.
BORL
(iii) INPUTS AND OUTPUTS CANNOT BE COMBINED IN SINGLE MODULE.
(iv) WHENEVER, 2/3 LOGIC IS INVOLVED, EACH OF THESE INPUTS WILL BE CONNECTED TO DIFFERENT INPUT CARD AND THE ALL
THE CORRESPONDING CONDITIONED OUTPUTS WILL BE TAKEN TO ONE PROCESSOR OR MORE THAN ONE PROCESSOR DEPENDING
SHEET
SECTION
EPCC : BHEL
ON THE GROUPING FOR PERFORMING 2/3 LOGIC IN THE PROCESSORS.
14
OF
D35
15
JAN. 1994
P-PLC14
REV. 0
REV.BY
DATE
REV. NO.
(v) ALL COMMON INPUTS TO IDENTICAL EQUIPMENT (SAY 3 BFP) SHALL BE INDIVIDUALLY CONNECTED TO THE RESPECTIVE
TCE-M4-126-IC-01
TCE.M4-109-PLC
PROCESSORS OF THE EQUIPMENT THROUGH INDIVIDUAL INPUT MODULES. ALL SUCH INPUTS ARE INDICATED WITHIN BRACKET.
(vi) I/O ASSIGNMENT SHALL BE IDENTICAL FOR SIMILAR/ REDUNDANT EQUIPMENT. FOR EXAMPLE IF ID FAN À' RUN IS ASSIGNED
CHANNEL 4 OF A CARD, ID FAN `B' RUN SHALL ALSO BE ASSIGNED CHANNEL 4 OF ANOTHER CARD. ALSO THESE CARDS
SHALL BE LOCATED IN IDENTICAL SLOTS OF DIFFERENT RACKS.
(vii) I/O MODULES OF ONE EQUIPMENT AND ASSOCIATED AUXILIARIES SHALL BE LOCATED IN THE SAME RACK.
IN DIFFERENT RACKS OR EVEN AT DIFFERENT CABINETS TO INCREASE THE AVAILABITY
9. * BIDDER TO FUNISH DETAILS.
10. TWO NOS. OF INTERPOSING RELAYS SHALL BE PROVIDED FOR EACH DRIVE
PROGRAMMABLE LOGIC CONTROLLER GENERAL NOTES

DATE
CKD. BY : KG
PPD. BY : CS
DATA SHEET
JOB NO.
5178 A
TCE
OWNER :
BORL
SHEET
SECTION
EPCC : BHEL
15
OF
D35
15
JAN. 1994
P-PLC15
REV. 0
SH 2 OF 15
1 SUB SYSTEM - REF. NOTE No. 2
2 WATCH DOG TIMER
3 SCAN TIME FOR DIGITAL INPUTS : > 60 mSEC.
4 SCAN TIME FOR PULSE INPUTS : > 60 mSEC.
SYSTEM FEATURES
5 SCAN TIME FOR ALL ANALOG INPUTS : > 500 mSEC.
6 EXECUTION TIME : > 120 mSEC. (REF. NOTE 3)
7 SYSTEM LOADING : MAX. 60% UNDER WORST LOADING CONDITIONS
8 MEASUREMENT CIRCUIT : INDEPENDENT FOR EACH MEASUREMENT
9 GROUPING OF SIGNALS IN CARDS : REFER NOTE 14
10 GROUPING OF CONTROL LOGICS : REFER NOTE 15
11 OVERALL ACCURACY OF MEASUREMENT SIGNALS : 0.5% S T *

12 SYSTEM DESIGN : ENERGISE TO COMMAND BASIS AND ON FAULTS TO DEENERGISE CONDITION
13 IMPLEMENTATION OF FUNCTIONAL REQUIREMENTS TO BE INDEPENDENT FOR EACH PROTECTION
14 INTERLOCK AND SEQUENTIAL CONTROLS }

15
16
17 PROCESSOR REDUNDANCY :- 1:1 :- YES NO
18 POWER SUPPLY REDUNDANCY :- 1:1
REDUNDANCIES
YES NO
19 COMMUNICATION MODULES :- 1:1 :- YES NO
SYSTEM 20 INPUT MODULES :- 1:1 :- YES NO *

21 OUTPUT MODULE :- 1:1 :- YES NO *
22
23
24 EACH SUBSYSTEM FAILURE ALARM
25 EARTH FAULT ALARM FOR EACH SUBSYSTEM
26 POWER SUPPLY FAILURE ALARM
}
27 ISOLATION FACILITY FOR GROUND DETECTION AT SUB SYSTEM WITHOUT REMOVING ANY HARDWARE
28 (POWER SUPPLY ISOLATION)
}
29 ISOLATION FACILITY FOR GROUND DETECTION OF INDIVIDUAL SIGNAL WITHOUT REMOVING FIELD
30 WIRING (ISOLATION OF SIGNAL AT BOTH TERMINALS)

SYSTEM MONITORING
31 MTBF (BIDDER TO FURNISH SUPPORTING DATA FOR CALCULATIONS) *

32 MTTR (BIDDER TO FURNISH SUPPORTING DATA FOR CALCULATIONS) *
33 POWER SUPPLY MONITORING : REQD.
34 LEDS FOR FAULT INDICATION ON EACH TYPE OF CARD
35 LED FOR WATCH DOG TIMER FAILURE
36 AUTO OPERATION TO BE MONITORED AND ALARMING OF AUTO FAILURE.
37 FUSE PROTECTION AND FUSE FAILURE
38 COMMUNICATION MONITORING
39 SELF CHECKING FEATURES
40 CRITICAL FAULTS TO FREEZE THE FINAL CONTROL ELEMENT TO CHANGE TO MANUAL POSITION WITH ALARM
41
42
4. THE INTERFACING REQUIREMENT WITH SYSTEMS SUPPLIED BY OTHERS, SHALL BE THROUGH A (i) POTENTIAL
NOTES
FREE CONTACT WITH 220 V DC, 0.2 A RATING FOR DIGITAL SIGNALS AND (ii) 4-20 mA AT 24 V DC FOR
ANALOG SIGNALS.
5. ALL FUNCTIONAL CARDS INCLUDING POWER SUPPLY SHALL BE MOUNTED IN CABINETS AND PRE-WIRED.


REV. BY DATE
P-PLC2
JAN 1994
REV. 0
SH 3 OF 15
1 OPTICAL ISOLATION OF ALL DIGITAL INPUTS AND OUTPUTS
2 GALVANIC ISOLATION/OPTICAL ISOLATION FOR ALL ANALOG INPUTS AND OUTPUTS
}
3 POWER SUPPLY TO SENSOR TRANSMITTER AT 24 V DC
4 FROM STATION BATTERY FROM INTERNAL POWER PACK
5 INRUSH CURRENT LIMITER TO DRIVING CIRCUIT
6 CIRCUITS : SHORT CIRCUIT PROOF AND VOLTAGE SURGE PROOF
DESIGN FEATURES OF HARDWARE

7 PROTECTION AGAINST CONTINUOUS PRESENCE OF POWER SUPPLY OR SIGNAL
8 MODULAR TYPE OF CARDS
9 PCB : EPOXY FIBRE GLASS
10 PLUG IN TYPE PCB WITH GOLD PLATED CONTACTS (BOTH AT PLUG & SOCKET)
11 RELIABILITY AND AVAILABILITY

*
12 I/O MODULE LOCATION IN SYSTEM CABINETS
13 CARD TYPE OR FUNCTION DESIGNATION TO BE INSCRIBED ON EACH CARD
14 CARD PROTECTION : TROPICALISATION
15 CONSTRUCTIONAL DETAILS AND SPECIAL FEATURES OF CARDS *

16 LOGIC DEVICES : INTEGRATED CIRCUITS
17 MAXIMUM RESISTANCE OF FIELD CABLE PER INPUT/OUTPUT *

18 RECOMMENDED FIELD CABLE SPECIFICATION *
19 STATUS (CHANNEL HEALTHY) INDICATING LEDS FOR EACH INPUT AND OUTPUT
20 FILTERS FOR NOISE REJECTION
21 POWER SUPPLY HEALTHY LED IN MODULES
22
23
24 MAXIMUM TEMPERATURE 50C

ENVIRONMENT
25 RELATIVE HUMIDITY 95%
26
27
28
29 TYPE OF INPUT CONTACT : NO/NC - FIELD SELECTABLE CHANGE OVER CONTACT *

30 TIME DELAY OF 5-10 mSEC. FOR CONTACT DEBOUNCE TIME
INPUTS/OUTPUTS
}
31 OUTPUTS - RELAY OUTPUTS FOR DRIVING MCC STARTER COILS, DRIVING SOLENOID VALVES
DIGITAL
32 (REF. NOTE 12)
33 SIGNAL DISTRIBUTION (REF. NOTE 6)
34 COMMON MODE NOISE REJECTION
35
36
6. SIGNAL DISTRIBUTION OF INPUT SIGNALS TO VARIOUS DEVICES WITHIN THE VENDOR'S SYSTEM SHALL BE
THROUGH SOLID STATE DEVICES WITHOUT ANY SOFTWARE BEING USED FOR THE SAME.
7. NON VOLATILE MEMORY IS REQUIRED TO STORE PROGRAMMES, STANDARD SOFTWARE TO PERFORM LOGIC
FUNCTIONS, DATA ACQUISITION AND DIAGNOSTIC FUNCTIONS.

NOTES
8. THE INTERNAL POWER PACK SHALL BE REDUNDANT AND ACCEPT TWO (2) NUMBERS OF FEEDERS OF _ _
_ _ FROM UPS. THE INTERNAL POWER PACKS GENERATE ALL DIFFERENT VOLTAGES REQUIRED BY THE
SYSTEM AND A BUS WILL BE FORMED FOR EACH OF THESE VOLTAGES WITH DIODE AUCTIONEERING AT
THE OUTLET OF THE INTERNAL POWER PACK. EACH POWER PACK SHALL BE RATED FOR 110% OF
MAXIMUM REQUIREMENTS. IN CASE THESE VOLTAGES ARE PROVIDED AT INDIVIDUAL CARD, THEN POWER
PACK ARE NOT APPLICABLE. HOWEVER THE SYSTEM SHALL BE DESIGNED TO ACCEPT SUPPLY FROM TWO
FEEDERS.


REV. BY DATE
P-PLC3
JAN 1994
REV. 0
SH 4 OF 15
1 CONTACT MONITORING
MONITORING FUNCTIONS
2 FIELD CABLE MONITORING
3 POWER SUPPLY FAILURE
DIGITAL SIGNAL
4 FUSE PROTECTION AND FUSE FAILURE
6 SELF CHECKING FEATURES FOR DETECTING FAULTY OPERATIONS
9 GALVANIC ISOLATION OF INPUT AND OUTPUT SIGNALS
10 INPUT FILTERING FOR NOISE LEVEL
CONDITIONING FUNCTIONS
11 NON LINEAR FILTERING FOR ATTENUATION OF NOISE LEVEL
ANALOGUE SIGNAL
12 AMPLIFICATION OF LOW LEVEL SIGNALS
13 SIGNAL DISTRIBUTION : REFER NOTE No. 6
14 TRANSMITTER POWER SUPPLY
15 COLD JUNCTION COMPENSATION FOR THERMOCOUPLES
16 20% OVER RANGE PROTECTION
}
17 CAPABILITY TO WITHSTAND CUSTOMER POWER SUPPLY VARIATION SPECIFIED UNDER POWER
18 SUPPLY SPECIFICATION
}
19 POWER SUPPLY FAILURE DUE TO LOOSE PLUG CONNECTION, SHORT CIRCUIT, WIRE BREAK AND
ANALOGUE SIGNAL MONITORING 20 VOLTAGE INTERRUPTION
21 TRANSMITTER MONITORING FOR PARITY, WIRE BREAK, LINE ZERO AND END LIMIT VALUES
22 MONITORING OF A/D CONVERSION
23 CABLE MONITORING FOR OPEN CIRCUIT

FUNCTIONS
24 FUSE PROTECTION AND FUSE FAILURE DETECTION
26 WIDE DEVIATIONS BETWEEN ADJACENT SCANS
27 SELF CHECKING FEATURES FOR DETECTING FAULTY OPERATION
28 DETECTION OF OPEN CIRCUIT OF THERMOCOUPLES
29
30
31
9. THE I/OS FOR IDENTICAL SERVICES/EQUIPMENTS LIKE FD-A AND FD-B SHALL BE LOCATED ON DIFFEREDNT RACKS.
10 PLC SHALL SUPPORT THE ADDITION/DELETION OF INPUTS FROM SCANNING/PROCESSING, ALARM INHIBIT.
11 THE PURCHASER RESERVES THE RIGHT TO RE-GROUP THE INPUTS TO PLC AFTER AWARD OF CONTRACT.
ANY INCREASE IN PROCESSORS ON ACCOUNT OF THE ABOVE, UPTO 10% SHALL NOT HAVE ANY PRICE
IMPLICATION TO PURCHASER.
12. PLC OUTPUTS SHALL BE TRANSISTOR OUTPUT OR TRIAC OUTPUTS ONLY AND THESE SHALL DRIVE THE
INTERPOSING RELAYS. PCB MOUNTED RELAYS ARE NOT ACCEPTABLE. RELAYS SHALL BE SUPPLIED
NOTES
ALONGWITH PLC.
13. THE POWER SUPPLY AND OTHER HARDWARE SHALL ALSO BE PROVIDED WITH EXCESS CAPACITY TO ADD
ON THESE ADDITIONAL MODULES. ALL SPARE MODULES SUPPLIED SHALL BE MOUNTED WIRED & KEPT
WITH POWER SUPPLY ON AT ALL TIMES. THE POWER SUPPLY SHALL BE DESIGNED TO MEET THE
REQUIREMENT OF ADDITIONAL I/O MODULES FOR WHICH THE SPARE LOTS ARE MADE AVAILABLE.
14. GROUPING OF SIGNALS IN EACH CARD IS SUBJECT TO PURCHASER'S APPROVAL AT THE TIME OF
DETAILED ENGG. ANY CHANGE RESULTING IN INCREASE OF CARDS UPTO 5% WILL NOT BE CONSIDERED
AS SCOPE CHANGE.


REV. BY DATE
P-PLC4
JAN 1994
REV. 0
SH 5 OF 15
1 DATA ACQUISITION
2 PROVISION OF TIME SYNCHRONISATION WITH MASTER CLOCK (REF. NOTE No. 18)
3 LOGIC FUNCTIONS
PROCESSOR FUNCTIONS AND CAPABILITY

4 GENERATION OF BOOLEAN FUNCTIONS.
5 DIAGNOSTIC FUNCTIONS PERFORMANCE : REQD.
6 MONITORING ADC/DAC PERFORMANCE AND ALARMING (FOR ANALOG INPUTS)
7 DIGITAL FILTERING
8 VALIDATION OF ALL INPUTS AND OUTPUTS
9 POINT IDENTIFICATION : BY TAGS, UPTO 8 CHARACTERS LONG : REQD.
10 POINT DESCRIPTION : MINIMUM 24 CHARACTERS
11 FACILITY TO DELETE OR RETURN OF ANY POINT FROM SCAN/PROCESSING (REF. NOTE No. 10)
12 COMMUNICATION WITH I/O MODULES
13 COMMUNICATION CONTROL AND MONITORING
14 BATTERY BACKUP OF NOT LESS THAN 72 HRS.
15 PROCESSOR 32 BIT WITH FLOATING POINT CAPABILITY
16 PROCESSOR CAPABILITY :- REF. NOTE 3 OF I/O LIST
17 CAPACITY OF VOLATILE MEMORY OF EACH PROCESSOR (REF. NOTE 7)
18 VOLATILE MEMORY TO STORE DYNAMIC PLANT DATA, CONTROL PROGRAMMES AND SELF DIAGNOSTIC ROUTINES
19
20
21
22 POWER SUPPLY VARIATION: *

23 POWER SUPPLY SCHEME : REF.. DWG. No. TCE. -580-SK-
POWER SUPPLIES
(REF. NOTE 13)
24 INTERNAL POWER PACK : REF. NOTE 8
25 SEPERATE FUSES AND CIRCUITS FOR EACH SUBSYSTEM
26 POWER REQUIREMENTS *
*
27 HEAT DISSIPATION
28
29
30
}
31 SYSTEM CABINETS
32
}
(REF. NOTE 5)
ARRANGEMENT
33 PREFABRICATED PLUG IN CABLES WITH IN PLC EX. RACK TO RACK, RACK TO POWER SUPPLIES ETC. AND
34 BETWEEN OTHER CABINETS SUPPLIED BY VENDOR
35 ARRANGEMENT OF CARDS/PROCESSOR CARDS IN SYSTEM CABINET (REF. NOTE 9)
36 PROTECTION CLASS : IP-55 (FOR NON A/C AREA) IP-32 FOR A/C AREA.
37
38
39
15. THE PURCHASER RESERVES THE RIGHT TO RE-GROUP ANY OF THE CONTROL LOGICS IN A PLC AFTER
THE AWARD OF CONTRACT. ANY INCREASE IN NUMBER OF PLCS UPTO 10% SHALL NOT HAVE ANY
COST IMPLICATION. FOR ANY REDUCTION IN THE NUMBER OF PLCS THE COST REDUCTION SHALL APPLY
NOTES
BASED ON THE UNIT PRICE.
16. BIDDER SHALL FURNISH IN HIS PROPOSAL THE TEST FACILITY AND DETAILS OF SIMULATION TEST
AVAILABLE IN THEIR FACTORY INCLUDING THEIR PREVIOUS EXPERIENCE.
17. ALL TESTS SHALL BE WITNESSED BY PURCHASER/PURCHASER'S REPRESENTATIVE.

REV. BY DATE
P-PLC5
JAN 1994
REV. 0
SH 6 OF 15
1 ALL CARD REPLACEMENTS ON POWER ON CONDITIONS
MAINTAINABILITY
ISOLATION FACILITY FOR EACH SUBSYSTEM WITHOUT AFFECTING OTHER SYSTEMS
}
3 ALL CARD MOUNTED INTEGRATED CIRCUIT CHIPS SHALL BE MOUNTED THROUGH IC SOCKETS FOR
4 EASE OF MAINTENANCE
5 PROGRAMMING DEVICE
8 ISA
9 IEEE
CODES/STDS
10 ANSI
11 BS
12 NEMA
13
14
15
16 SPARE CHANNELS - 10% OF THE I/O MODULES SUPPLIED. (WIRED TO THE CABINET TERMINALS)
}
17 SPARE MODULES - 10% OF EACH TYPE OF MODULE OR 1 MUNBER MIN. (WIRED TO THE CABINET
SPARES
18 TERMINALS)
19 WIRED SPARE SLOT - 10% FOR FUTURE EXPANSION (WIRED TO THE CABINET TERMINALS)
20
21
22
23 FACILITY FOR INJECTING INPUT SIGNALS - ON LINE SIMILATION

FACILITY
TESTS
24 FACILITY FOR BLOCKING OUTPUT DURING TESTING
25 FACILITY FOR FORCING ON/OFF OF INPUTS.
26 EXTENSION CARDS FOR CHECKING/TESTING OF CARDS ON LINE
27
28
29 FUNCTIONAL TESTS (SIMULATED) FOR COMPLETE SYSTEM
30 SYSTEM PERFORMANCE & TESTS FOR MONITORING FUNCTIONS
31 DAMP HEAT CYCLING TEST AS PER IS-2106 PART-II 1962 OR EQUIVALENT.
}
32 DIELECTRIC STRENGTH TESTS (HIGH POT TEST) AS PER NEMA ICSI PART-I ICS-109/ANSI 39.51/
33 UL 508
34 RFI TEST AS PER SAMA PMC 33.1

TESTS
35 IMMUNITY TO NOISE TEST AS PER IEEE SWC TEST 587
36 BURN IN TEST & TEMPERATURE RISE TEST FOR 120 HRS.
37 UNDER VOLTAGE TEST & SHORT CIRCUIT TEST (AT 10% OF RATED VOLTAGE)
38 SURGE WITHSTAND CAPABILITY TEST AS PER ANSI C 37.9A/IEEE 4721 BE MMA 219
39 CONTINUITY TEST AND SHORT CIRCUIT TEST
40 FACTORY ACCEPTANCE TEST (REF. NOTE 17)
41 SIMULATION TEST FOR ALL LOGICS/LOOPS (REF. NOTE 16 & 17))
42 VENDOR TO SUBMIT ALL TEST CERTIFICATES FOR PURCHASER/CONSULTANT'S REVIEW
43
44
18 TIME SYNCRONISATION SHALL BE PROVIDED WHERE PLC IS PROVIDED WITH A PRINTER OR PLC IS A
NOTES
PART OF DCS i.e PLC IS PROVIDED ALONG WITH DEVICES HAVING REAL TIME CLOCK.


REV. BY DATE
P-PLC6
JAN 1994
REV. 0
SH 7 OF 15
1 HAND HELD PROGRAMMER UNIT WITH LED/LCD DISPLAY PC BASED PROGRAMMER
PROGRAMMING
2 PROGRAMMING IN LADDER LOGIC
UNIT
}
3 KEY PAD WITH DISPLAY FOR CHANGING TIMING SETTINGS, COUNTER SETTINGS, JUMPING/BYPASSING
4 SEQUENCES WITH LOCK FACILITY
7 DATA SHEET FOR VARIOUS MODULES : I/O LIST INDICATING GROUPING OF VARIOUS SIGNALS IN
}
8 EACH MODULE, CONFIGURATION DWG.; TRANSMISSION SCHEME, IDENTIFYING VARIOUS HARDWARES
DRAWING TO BE
9 INDICATING FLOW OF SIGNAL PATH, INTERNAL AND EXTERNAL WIRING DIAGRAMS, POWER SUPPLY
FURNISHED
10 SCHEME-TO VARIOUS PANELS/CUBICLES AND DISTRIBUTION OF SENSORS AND OTHER HARDWARES
11 IN SIGNAL PATH INCLUDING POWER SUPPLY, TERMINAL NUMBER, PIN NUMBER AT THE VARIOUS
12 CARD LEVEL, RACK NUMBER, CABINET NUMBER, ETC., EARTHING DIAGRAMS, LAYOUT OF VARIOUS
13 MODULES ON RACKS AND DETAILED WRITE UP OF CONTROL SYSTEMS FOR PURCHASER/
14 CONSULTANTS APPROVAL.
15 DETAILED INSTRUCTION MANUAL
16
}
17 NO SPURIOUS OPERATION OR UNSAFE PLANT CONDITION DUE TO FAILURE/CHANGE OVER - ON
SECURITY
SYSTEM
18 RESTORATION OF POWER SUPPLY AND/OR MALFUNCTION OF COMPONENTS/LOOPS AND/OR THE RELATED
19 EQUIPMENT SHALL TAKE PLACE
20 PLC SOFTWARE CHANGE : SHALL BE POSSIBLE THROUGH KEYBOARD LOCK
21
22
23 FOLLOWING DESIGN AND CONSTRUCTION REQUIREMENT SHALL BE FULFILLED.
24 a) PROVEN DESIGN
25 b) REPUTED MAKE
26 c) SHOCK PROOF DESIGN

GENERAL DESIGN FEATURES
27 d) VIBRATION PROOF DESIGN
28 e) MAXIMUM INTERCHANGEABILITY OF PARTS
29 f) USE OF COMPONENTS WHICH HAVE HIGHER RATING THAN REQUIRED FOR OPERATING CONDITIONS
30 g) DESIGN OF EQUIPMENT TO AVOID OVERHEATING OF ELECTRONIC COMPONENTS
31 h) RUGGEDNESS OF EQUIPMENT/COMPONENTS
32 i) MINIMUM USE OF ELECTROLYTIC CAPACITORS
33
34
35
36
37
38
39
40
41
42
44
19. LEGEND : INDICATES THE SPEC CLAUSE IS REQUIRED AND APPLICABLE.
*
NOTES
INDICATES BIDDER TO FILL IN DATA/DETAILS
* INDICATED SPEC CLAUSE IS APPLICABLE; HOWEVER BIDDER SHALL INDICATE
HIS SYSTEM'S PERFORMANCE/SPEC DATA AGAINST THE CLAUSE


REV. BY DATE
P-PLC7
JAN 1994
REV. 0
A. ANALOG DISTRIBUTION AND SIGNAL CONDITIONING MODULES. (REF. NOTE 7) *
REV.BY
DATE
REV. NO.
TCE-M4-126-IC-01
TCE.M4-109-PLC
TYPE OF NO. OF INPUT DISTRIBUTION MODULES SIGNAL CONDITIONING MODULES
SL. SIGNALS ENVISAGED NO OF INPUT SIGNALS NO. OF MODULES MFR/ NO OF INPUT SIGNALS NO. OF MODULES MFR/
SYSTEMS
PER MODULE PROVIDED MOD. PER MODULE PROVIDED MOD.
No. 4-20MA RTD T/C 4-20MA RTD T/C 4-20MA RTD T/C 4-20MA RTD T/C TYPE 4-20MA RTD T/C 4-20MA RTD T/C TYPE
ANALOG DISTRIBUTION & SIGNAL CONDITIONING MODULES

DATE
CKD. BY : KG
PPD. BY : CS
DATA SHEET
JOB NO.
5178 A
TCE
PROJECT : 3X33 MW CPP, BINA
OWNER : BROL
SHEET
SECTION
EPCC : BHEL
D35
OF
15
JAN. 1994
P-PLC8
REV. 0
REV.BY
DATE
REV. NO.
B. ANALOG INPUT/OUTPUT MODULES. (REF. NOTE 7) *
TCE-M4-126-IC-01
TCE.M4-109-PLC
INPUT MODULES. OUT PUT MODULES
NO. OF INPUTS MAX. NO. OF NO. OF MODULES MFR/ NO. OF OUTPUTS MAX. NO. OF NO. OF MODULES MFR/
SL. SYSTEMS
ENVISAGED INPUT MODULES PROVIDED TYPE OF ENVISAGED OUTPUT/MODULE PROVIDED TYPE OF
No.
4-20MA RTD T/C 4-20MA RTD T/C 4-20MA RTD T/C MODULE 4-20MA DIGITAL 4-20MA DIGITAL 4-20MA DIGITAL MODULE

DATE
CKD. BY : KG
PPD. BY : CS
ANALOG INPUT/OUTPUT MODULES

DATA SHEET
JOB NO.
5178 A
TCE
OWNER :
BORL
SHEET
SECTION
EPCC : BHEL
D35
OF
15
JAN. 1994
P-PLC9
PC
PROGRAMMER
UNIT
PROGRAMMABLE LOGIC CONTROLLER

PLC
PROCESSOR B
(PS)
LOCAL BUS
INPUT A OUTPUT
MODULE (PS) MODULE
A B
INTERPOSING POWER
RELAY SUPPLY
SWGR/ PSDB
MCC
)
(
(
)
FIELD SWITCHES ( E
FIELD
FAN VALVE SV
PUMP
DO NOT SCALE
REV DR CH DT
TCE CONSULTING ENGINEERS PLC CONFIGURATION
MUMBAI SCALE APPROVED
OWNER BORL EPCC : BHEL
DIV
PROJECT : 3 X 33 MW CPP, BINA DR

CH
TCE FORM 034

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SPEC NO. TCE CONSULTING ENGINEERS LIMITED SECTION: D36

SUPPLY AND FABRICATION OF STRUCTURAL

2.0 APPLICABLE CODES AND SPECIFICATIONS

In case of discrepancy between this specification and those referred to

1. IS : 808 - Dimensions for Hot Rolled Steel Sections.

2. IS : 814 - Covered Electrodes for Metal Arc welding of

3. IS : 1363 - Black Hexagonal Bolts, Nuts and Lock Nuts

4. IS : 1367 - Technical Supply Conditions for Threaded

5. IS : 1852 - Rolling and cutting tolerance for Hot Rolled

6. IS : 1977 - Structural Steel (Ordinary Quality)

7. IS : 2016 - Plain Washers.

8. IS : 2062 - Weldable Structural Steel.

9. IS : 2074 - Ready mixed paint, Air drying, Red Oxide Zinc

SUPPLY AND FABRICATION OF STRUCTURAL

10. IS : 3757 - High strength friction grip bolts.

11. IS : 5372 - Taper washers for channels.

12. IS : 5374 - Taper washer for I beams.

13. IS : 6610 - Heavy washers for steel structures.

14. IS : 6639 - Hexagon bolts for steel structures.

(b) CODES OF PRACTICE

1. IS : 800 - Code of practice for general construction in

2. IS : 816 - Code of practice for use of metal arc welding for

3. IS : 817 - Code of practice for training and testing of

4. IS : 818 - Code of practice for safety and health

5. IS : 822 - Code of procedure for inspection of welds.

6. IS : 1182 - Recommended practice for radiographic

7. IS : 1200 - Method of measurement in building and civil

8. IS : 1204 - Code of practice for use of welding in bridges

9. IS : 1477 - Code of practice for painting of ferrous metals

10. IS : 2595 - Code of practice for radiographic testing.

11. IS : 2598 - Safety code for industrial radiographic practice.

SUPPLY AND FABRICATION OF STRUCTURAL

12. IS : 3016 - Code of practices for fire protection in welding

13. IS : 3600 - Code of practice for testing fusion welded joints

14. IS : 3657 - Radiographic image quality indicators.

15. IS : 3658 - Code of practice for liquid penetrant flaw

16. IS : 3664 - Code of practice for ultrasonic testing by pulse

17. IS : 4000 - Code of practice for assembly of structural

18. IS : 4225 - Recommended practice for ultrasonic testing of

19. IS : 4260 - Recommended practice for ultrasonic testing of

20. IS : 5334 - Code of practice for magnetic particle flaw

21. IS : 7215 - Tolerances for fabrication of steel structures.

22. IS : 7310 - Approval test for welders working to approved

23. IS : 7318 - Approval tests for welders when welding

24. IS : 9595 - Recommendations for metal arc welding of

25. IS : 823 - Code of procedure for manual arc welding of

26. IS : 1181 - Qualifying tests for metal arc welders (engaged

SUPPLY AND FABRICATION OF STRUCTURAL

3.0 STEEL MATERIALS

Steel materials shall comply with IS:2062 or IS:1977. Usage of steel

Steel conforming to IS:1977 shall be used only for the following :

Fe310-0(St 32-0) : For general purposes such as door/window

Fe410-0(St 42-0) : For structures not subjected to dynamic

Platform roofs, foot over bridges, office

Fe410-0(St 42-0) : Grade steel shall not be used :

(a) If welding is to be employed for

(b) If site is in severe earthquake zone.

(c) If plastic theory of design is used.