Nit 132 KV

TURNKEY TENDER DOCUMENT
for
Planning, Design, Engineering, Construction, Fabrication,
Supply, Erection, Trial Run and Commissioning of 2x 40/50
MVA, 132/33 kV substation which includes all the
electrical outdoor and indoor equipment, lighting system,
earthing system, lightning protection system, signalling and
control system, DG set, fire fighting system, structural and
civil works, drinking water supply system etc. on Turnkey
Basis at Kusmunda OCP,SECL
(KUSMUNDA AREA)
SOUTH EASTERN COALFIELDS LIMITED
(A MINI RATNA COMPANY)
NIT No. : GM(CMC)/SECL/BSP/132 kV Kusmunda SS/Turnkey/2014/688

Date : 17.09.14
VOLUME II
(TECHNICAL )
Job No.- 502255

NIT for 132/33 kV Substation at Kusmunda OCP
INDEX
PARA PARTICULARS PAGE

NO. NO.
2.1.0 INTRODUCTION 1-2
2.2.0 SYSTEM DESCRIPTION 3 - 22
2.3.0 SCOPE OF WORK 23 - 36
2.4.0 SPECIFICATIONS OF EQUIPMENT 37 - 162
2.4.1 DISCONNECTING SWITCH ISOLATOR 37 -42
2.4.2 LIGHTINING ARRESTER- 132 kV and 33 kV 43-46
2.4.3 CURRENT TRANSFORMER 47-55
2.4.4 POTENTIAL TRANSFORMER 56-62
2.4.5 132 kV SF6 CIRCUIT BREAKER 63-82
2.4.6 33 kV VCB 83-99
2.4.7 132/33 kV TRANSFORMER 100-109
2.4.8 CONTROL AND RELAY PANEL 110-112
2.4.9 STATION TRANS FORMER 113-115
2.4.10 AC POWER DISTRIBUTION BOARD 116-119
2.4.11 LIGHTING DISTRIBUTION BOARD 120-121
2.4.12 110 V DC SUPPLY ARRANGEMENT 122-127
2.4.13 METAL HALIDE FLOOD LIGHT FITTING 128
2.4.14 FLOURESCENT TUBE LIGHT FITTINGS 129
2.4.15 POWER,LIGHTING, CONTROL AND SPECIAL CABLES 130-131
2.4.16 LIGHTING MAST 132-133
2.4.17 POST/ DISC INSULATORS 134-137
2.4.18 FIRE FIGHTING EQUIPMENT 138-162
2.5.0 CIVIL SPECIFICATIONS 163-315
2.5.1 TECHNICAL SPECIFICATION FOR SOIL INVESTIGATION WORK 163-166
TECHNICAL SPECIFICATION FOR PREPARATION OF SITE AND 167-171
2.5.2
EARTH WORK IN FOUNDATION AND TRENCHES
TECHNICAL SPECIFICATION FOR FABRICATION OF 172-187
2.5.3
STRUCTURAL STEEL WORKS
TECHNICAL SPECIFICATION FOR ERECTION OF STRUCTURAL 188-191
2.5.4
STEEL WORKS
TECHNICAL SPECIFICATION FOR EXCAVATION OF HARD 192-195
2.5.5
ROCK
TECHNICAL SPECIFICATION FOR CEMENT CONCRETE ( PLAIN 196-219
2.5.6
AND REINFORCED )
2.5.7 TECHNICAL SPECIFICATION FOR BRICK WORK 220-224
TECHNICAL SPECIFICATION FOR FINISH TO MASONRY AND 224-229
2.5.8
CONCRETE
Job No.- 502255 Vol-II

PARA PARTICULARS PAGE

NO. NO.
TECHNICAL SPECIFICATION FOR SUPPLY AND LAYING OF 230-231
2.5.9
RCC PIPES
TECHNICAL SPECIFICATION FOR PAINTING, WHITE WASHING, 232-236
2.5.10
POLISHING ETC.
TECHNICAL SPECIFICATION FOR DRAINAGE AND SANITARY 237-249
2.5.11
FIXTURES
TECHNICAL SPECIFICATION FOR PLANT AREA ROADS AND 250-259
2.5.12
DRAINS
TECHNICAL SPECIFICATION FOR FLOOR FINISHES AND ALIED 260-277
2.5.13
WORKS
TECHNICAL SPECIFICATION FOR METAL DOORS , WINDOWS, 278-282
2.5.14
VENTILATORS, LOUVERS ETC.
2.5.15 TECHNICAL SPECIFICATION FOR GLASS AND GLAZING 283-284
TECHNICAL SPECIFICATION FOR ROLLING STEEL 285-287
2.5.16
SHUTTERS/GRILLS
2.5.17 TECHNICAL SPECIFICATION FOR SUSPENDED CEILING 288-290
TECHNICAL SPECIFICATION FOR ROOF WATER PROOFING, 291-298
2.5.18
INSULATION AND ALIED WORKS
2.5.19 TECHNICAL SPECIFICATION FOR WATER SUPPLY 299-306
2.5.20 TECHNICAL SPECIFICATION FOR CARPENTARY AND JOINERY 307-312
2.5.21 TECHNICAL SPECIFICATION FOR MICELLANEOUS METALS 313-315
2.6.0 LIST OF APPROVED VENDORS 316-327
2.7.0. SCHEDULES, DATA AND PRICE BID 328-379
COVERING LETTER 328
SCHEDULE- I, Qualification Information 329
SCHEDULE- II, Work Completion Schedule 330
SCHEDULE- III, Acceptance of Terms & Conditions 331
SCHEDULE- IV, Performance Guarantee 332
SCHEDULE- V, System Description 333
SCHEDULE- VI, Technical Deviations 334
SCHEDULE- VII, Additional provisions included in offer 335
SCHEDULE- VIII, Instruments for conducting performance & 336
efficiency
SCHEDULE- IX, List of spares, tools & tackles 337
SCHEDULE- X, Technical information and data of major equipment 338-378
SCHEDULE- XI, Price Bid 379

List of Drawings
SL SUBJECTS DRAWING NO.

NO.
1 Single Line Diagram for 132/33 kV, 2 x 40/50 MVA Substation RV-ELC-200278
2 GA Drawing of the Sub-Station RV-ELC- 200279
3 Substation / Control Room Building RV-ELC- 200280

Introduction NIT for 132/33 kV Substation at Kusmunda OCP
2.1.0.0 INTRODUCTION
2.1.1.0 PREAMBLE
2.1.1.1 It is proposed to construct on turnkey basis a 132/33 kV substation of

2x40/50 MVA capacity at Kusmunda OCP for supplying power at 33kV to the
quarry substations,CHP substation and other load centers. The substation will
receive power through two numbers of 132 kV Overhead Transmission lines
from CSPTCL. Drawing of 132 kV overhead lines , provision of wave trap ,
coupling capacitor,48 V Batteries and 132 kV meter is not included in the
scope of work.
The substation will consist of Isolators, Lightning Arresters, Current
transformers, Potential transformers, Circuit Breakers, Main Power
Transformers, Control units, Station/Lighting Transformers, AC/DC power
supply, cables, substation building, sheds for DG set and transformer oil
filtration machine, watch tower, car parking shed, out door yard with path
ways , boundary wall with gate, drain, security guard room, diesel generator
set, fire fighting system, earthing & lightning protection system, illumination
system, pump house with water supply system, safety equipment, testing
equipment, transformer oil filtration machine etc.
2.1.1.2 Necessary technical parameters have been given in the subsequent

clauses/chapters of this document for design of the substation. Tenderers
/Bidders are required to carry out checks and ensure guaranteed performance
of the substation. In case of any change from the tender requirements, the
same are to be brought out clearly giving advantages and disadvantages.
2.1.1.3 Tenderers/Bidders are requested to get themselves acquainted with the

various provisions of this document before submitting their offers. Tenderers
may visit site at their own cost to have the details of site condition.
2.1.1.4 Tenderers/Bidders are required to furnish the information in the schedules/

performa given in this document in the first instant itself for evaluation of the
tenders/bids. In case of insufficient information, the offers may be passed
over.
2.1.1.5 The scope of work shall be read along with Basic data, Plant description and
Specifications of the equipment/items, civil and structural works etc. which are
elaborated in subsequent clauses/chapters.
2.1.2.0 LOCATION AND COMMUNICATION
2.1.2.1Kusmunda opencast expansion project (50 Mty capacity) of Kusmunda Area

of South Eastern Coalfields Ltd (SECL) forms south central part of Korba
Coalfields. The project is located in the Korba District of Chhattisgarh State.
2.1.2.2 The project is at a distance of 10 km from Gevra Road Railway station and
15 km from Korba Railway station. These stations are on the branch line of
Champa and Gevra Road Railway Station. The Gevra Road Railway Station
is about 100 km from Bilaspur and 708 km from Howrah by rail.
NIT 688 dtd 17.09.14 Job No. 502255 (VOL II) Page no- 1
Introduction NIT for 132/33 kV Substation at Kusmunda OCP
2.1.2.3 The project is well connected by all weather metal Road. It is about 105 km
from Bilaspur, the head quarters of SECL and about 15 km from Korba.
2.1.3.0 PHYSIOGRAPHY
2.1.3.1 The general topography of the project is gently undulating with elevations
ranging from 280 m to 300 m above mean sea level. The drainage is mainly
by Hasdeo River which marks the south western boundary of the block .
2.1.4.0 CLIMATIC CONDITIONS
2.1.4.1 The climate of the area is dry to moist tropical with well defined summer from
April to June, rainy season from July to September and winter season from
October to March.
2.1.4.2 The average annual rainfall is about 1456 mm. The highest rainfall recorded
within a period of 24 hours over the last 20 years is 278 mm in September
1991
2.1.4.3 The relative humidity varies from 70 to 100% during monsoon and 17 to 78%
during summer.
2.1.4.4 The ambient temperature rises to maximum of 50 degrees centigrade in

summer and drops to minimum of about 4 degrees centigrade in winter.
2.1.4.5 The wind direction is generally westerly to south westerly with wind velocity
varying from 0.57 to 13.38 km/h.
2.1.5.0 This substation will feed power initially to 3 nos. of 33 kV substations of

Kusmunda OCP. The two numbers quarry substations (33/6.6 kV) will feed
power to Shovels, Rotary Blast Hole drill machines, In pit conveyor system,
Mine pumps etc. The CHP substation (33/6.6 kV) will meet the power
requirement of CHP.
System Description NIT for 132/33 kV substation at Kusmunda OCP
2.2.0.0 SYSTEM DESCRIPTION
2.2.1.0 Incoming Power Supply Arrangement
The proposed 132/33 kV substation at Kusmunda Open Cast project

will receive power at 132 kV through two numbers of over head lines
from CSPDCL. A single line diagram showing the incoming lines and
the proposed equipment in the substation out door yard/ building are
shown in the drawing no. RV/ELC/200278 & RV/ELC/200279
respectively. The schematic layout of control room is shown at drawing
no. RV/ELC/200280.
2.2.2.0 Brief Description of the Proposed Substation
2.2.2.1 In the out door yard of the Substation one number of 132 kV
sectionalised over head strung bus will be provided. Two numbers of
over head lines will feed power to the sectionalised over head strung
bus through pole mounted motorised 132 kV Isolators and 132 kV SF6
circuit breakers. The incoming Isolators will be provided with earthing
switch and station class Lightning Arrestor. Power will be supplied from
the bus to the primary side of the 132 /33 kV Transformer through
Isolator, Current Transformer (CT) and SF6 Circuit Breaker. Tapping
will be provided on each side of the132 kV side sectionalised bus for
feeding power to 132kV/3 / 33kV/3 Potential Transformer (PT)
through Isolator. One 132 kV station class Lightning Arrestor will be
provided before each Transformer. The 132 kV current Transformer,
Lightning arrestor, SF6 Circuit Breaker, 132kV/33kV Transformer will
be kept in one line as shown in the GA Drawing RV/ELC/200279. The
132 kV strung bus shall have two nos. 132 kV isolators, one number
SF6 circuit breaker and one number CT for sectionalizing.
2.2.2.2 Two overhead sectionalised strung buses (Main and Auxiliary) each of
33 kV and circuit breaker of 33kV will be provided on the 33kV side of
the 132/33kVtransformer (40/50 MVA rating each). Required number of
Isolators, Vacuum Circuit breaker and CT will be provided for
sectionalising the buses and to avoid Parallel operation of transformers
as shown in the Drawing RV/ELC/200279. From the secondary side of
the 132kV/ 33 kV Transformers, power will be fed to the respective
sections of the 33kV over head sectionalised strung Main bus through
out door type 33kV Vacuum Circuit Breakers, Current Transformer,
Lightning arrestor, Isolator etc. The Main bus will be coupled with 33 kV
auxiliary bus through Isolators and Vacuum circuit breaker for
energising auxiliary bus. Normally power will be supplied to the out
going feeders from the main bus through 33 kV, Vacuum Circuit
Breakers, CTS, Isolators (with earth blade) etc. The out going feeders
are also connected with auxiliary bus through isolators. These isolators
will normally be in OFF position. If VCB of a particular feeder is out of
order or is required to be shut off for maintenance purpose, then the
Isolator between this feeder and auxiliary bus will be made ON to avail
power from auxiliary bus for which auxiliary bus will be energized.
Total of 16 nos. 33kV out going feeders will be provided.

Number of feeders Purpose
2 nos. Feeders Kusmunda OCP quarry sub
station-1
2 nos. Feeders Kusmunda OCP quarry sub
station-2
2 nos. Feeders Kusmunda CHP substation
2 nos Feeders Kusmunda Washery Feeders
4 nos Feeders Korba Area (proposed)
4 nos Feeders Reserve
From both the sections (I &II) of the 33kV sectionalised bus, power will
also be tapped through Isolators and HG fuses for feeding power to
Potential Transformers (PTs) and 200 kVA, 33kV/0.44-0.23 kV ( L-L)
Transformers. The 200 kVA Transformers will meet the requirement of
both lighting loads (at 230 V, L-L) and other industrial loads (at 415V)
of the substation. The Potential Transformers will be required to meet
the needs of measurements and instrumentation.
2.2.3.0 Power Transformers ( 2x40/50 MVA,132 /33 kV)
2.2.3.1 Two numbers of Power Transformers will be provided at this

substation. The Transformers will be 40 MVA (ONAN) / 50 MVA
(ONAF),132kV/ 33 kV ,YN- yn -0, oil immersed, double wound ,core
type, on- load-tap changing device with all necessary protective
elements as per I.S. and as given in the detailed specifications
provided in the document. Both the transformers shall be fitted with
individual nitrogen injection system for fire fighting. Both the
transformers will be identical.
2.2.3.2 The transformer will be mounted on a trolley so that it can be moved on

a rail track. Proper foundations will be made so that transformers can
be kept over it. Proper locking arrangement shall be provided to keep
the transformers in position over the foundations.
2.2.4.0 Isolator / Disconnecting Switches
2.2.4.1 Motorised cranking type OFF load isolator shall be provided on the132
kV side and manually operated cranking type OFF-Load Isolators shall
be provided in 33 kV side. The location of isolators is shown in the GA
drawing RV/ELE/200279
2.2.4.2 All the Isolators will be triple pole, double break, centre post rotating,
out door, gang operated type. Suitable inter locking arrangement shall
be provided between the respective Isolators and Circuit Breakers so
that required operational safety can be achieved.
2.2.5.0 Potential Transformer
2.2.5.1 Required number of Potential Transformers (PT) shall be provided in

the switch yard of 132 kV and 33 kV system as shown in the GA
drawing. All the PTs will have two core only and is used for
measurement purpose. The PTs will be of out door type.
2.2.6.0 Current Transformer
2.2.6.1 Out door type Current Transformers (CT) of required quantity will be
provided in the switch yard of 132 kV and 33kV system for protection
and metering. The CTs will be provided for restricted earth fault
protection, over current and earth fault protection, transformer
differential protection, bus bar protection, distance protection and for
metering. The accuracy class, burden, CT ratio, accuracy limit factor,
Knee point voltage etc. shall be duly selected based on the system
requirement. The CTs shall conform to IS2705 and IS4201.
All 132 kV CTs shall have five cores(1-1-1-1-1 A) with 15 VA burden.

Core-1 is for metering (Class 0.5). Core-2 for over current and Earth
fault current (Class 5P10). Core-3 for bus bar differential protection
(Class-PS). Core-4 for Transformer differential protection (Class-PS).
Core- 5 spare (Class- PS).
All incoming 33 kV CTs shall have 3 cores (1-1-1 A) with 15 VA

burden. Core-1 is for metering (Class 0.5). Core-2 for over current
and Earth fault current protection (Class 5P10). Core-3 for bus bar
differential protection (Class-PS). The outgoing CTs shall have 2
cores(1-1 A). Core-1 is for metering (Class 0.5). Core-2 for Over
current and Earth fault current protection (Class 5P10).
2.2.7.0 132 kV SF6 Circuit Breaker & 33 kV Vacuum Circuit Breakers
2.2.7.1 Required number of SF6 and Vacuum Circuit Breaker as shown in the
single line diagram (RV/ELE/200278) shall be provided in the switch
yard of 132 and 33 kV side for protections.
2.2.7.2 All the Circuit Breakers on 132 kV and 33 kV sides will be of out door
type with indoor control and relay panel.
2.2.7.3 132kV and 33kV Circuit Breakers shall be single pole. The
simultaneous operation of all three poles for close, open and trip shall
be required and ensured through required relays.
2.2.7.4 All the Circuit Breakers will be operated remotely from control room,
however facility for local electrical operation will also be provided.
2.2.8.0 Control and Relay panel for 132 kV SF6 CBs and 33kV VCBs,
Transformers etc.
2.2.8.1 The out door Circuit Breakers both on 132 kV and 33 kV side will be
controlled remotely from the control panels located in the control room
of the sub station. The control panels will meet the requirements of
control, protection, metering, signaling and annunciation needs of
Circuit Breakers and Transformers. All the relay panels for various
protections on 132 kV and 33 kV side will also be located in the
respective control panels. Various relays for different protection
schemes will be judiciously selected so that their reliability,
effectiveness and quality are of highest order and are suitable for
continuous satisfactory performance over the years. Relays of latest
and improved design and proven quality and reliability will be preferred.
Arrangement for remote tripping by protective relays will be provided.
Automatic indication of operating switches will also be provided.
The transformer protection shall include following ;
(i) High speed biased numerical differential protection in 132 kV

side
(ii) Numerical over fluxing protection in 132 kV side
(iii) Numerical non-directional IDMT relay on both sides
(iv) Protection for over load and back up numerical over current and
earth fault (O/C and E/F) protection
(v) Trip circuit supervision relay on both sides
(vi) DC auxiliary 110 V supply voltage monitoring relay to be
installed at both sides of transformers and feeders.
(vii) Gas pressure type and winding and oil temp. protection to give
alarm and tripping
High speed differential bus bar protection along with local breaker back
up protections under provision of regulation of CEA,2010 is to be
provided.
All the auxiliary circuits of the protective system will be operated by

110 V DC supplied from storage Battery / Rectifier.
2.2.9.0 Signaling arrangement:
The following system of signaling (audio and visual) shall be provided

in the substation.
i) Signaling for automatic tripping of circuit breaker due to fault.
ii)Warning signal about occurrence of abnormality in any particular
device.
2.2.10.0 Interlocking arrangement:
2.2.10.1 Various interlocking systems will be provided to prevent
- Simultaneous supply to a bus bar from two sources

- Making OFF an Isolator when its associated Circuit Breaker is ON
- Suitable interlocking between Circuit Breakers and Isolators to
facilitate maintenance of the equipment
- Electrical interlocks for switching operation and other necessary
functions in order to ensure correctness and safety
- Suitable mechanical / Electrical interlocks to ensure the safety of
equipment, operating personnel and to prevent un-authorised/
inadvertent operation of the equipment.
2.2.11.0 Protection to Main Transformer and SF6 Circuit Breakers
2.2.11.1 The following protections will be provided
i) The Transformers will be provided with protections for Through

faults and internal faults through over load (O/L), earth fault (E/F),
differential protection, Buccholz relay protection, winding
temperature protection, oil temperature protection, explosion /
pressure relief device etc along with aforesaid protections.
ii) The 132k V and 33kV strung bus will be protected with high speed
differential bus bar protection scheme along with local breaker back
up protections.
iii) The outgoing 33kV transmission line feeder will be protected for
O/L, E/F and distance protection.
2.2.12.0 Metering arrangement / Instrumentation:
Digital microprocessor based power meter shall be provided on

132kV, 33kV side of this substation for measurement, monitoring
and management of different electrical parameters. The incoming
metering in 132 kV side shall be provided by CSPDCL. The different
parameters to be displayed in regular intervals are as shown below:
i) Values of current (RMS), Voltage (RMS), frequency.

ii) Current and Voltage demand parameters
iii) Power Factor
iv) Average power values
v) Power demand parameters
vi) Total Energy
vii) Minimum / maximum log
viii) Real time current, voltage and frequency
ix) Real time power values
x) Phase rotation
xi) Counters
xii) Remote Relay control
xiii) Self diagnostic tests
2.2.12.3 All the meters will be of preferred standard size and of required
accuracy class.
These will be flushed in the front panel of respective control panels.
2.2.12.4 Fault annunciation with visual and audible alarm will be provided for
different types of tripping of Circuit Breakers, auxiliary power supply
(AC &DC), air pressure, SF6 gas pressure fall, winding and oil
temperature rise etc. Facility for acceptance of audible alarm will also
be provided.
2.2.12.5 Lamp indictors and semaphore indications with mimic diagrams will
also be provided for various Circuit breakers and Isolators.
2.2.12.6 Lamp indications (Green, Red, Yellow) for power supply (AC/DC) and
other equipment will also be provided.
2.2.12.7 Condition Monitoring & Self Diagnostic Facilities as required will also
be provided.
2.2.12.8 Any other meters and indications other than the above mentioned, if
necessary, for safety and effective operation of the substation will also
be provided.
2.2.13.0 Auxiliary power supply:
2.2.13.1 Two numbers of 200 kVA, 33 kV/0.44 kV - 0.23 kV (L-L)

Station/Lighting Transformers, out door type, plinth mounted will be
installed in the out door yard of the substation for supplying power to
lighting loads at 230 V (L-L), auxiliary and misc. loads of the
substation. 33kV power supply will be tapped from 33kV bus through
33kV pole mounted OFF load Isolator and HG fuse.
2.2.13.2 Two nos. 3 Ph-N, 415 V sectionalised Power Distribution Boards will be
installed in the AC/DC room of the substation and this will receive
power from the secondary side of the Station Transformers. Each
power distribution board will consist of two numbers of 400 A , MCCB
acting as an incomer controller, one number MCCB as sectionaliser of
the bus, required number of out going panels with 3 pole MCCB s and
3 and 2 poles MCB s. This switch board will be of industrial type, dust
and vermin proof. From the switch board power will be supplied to the
following:
i) On load tap changer
ii) Cooler control cubicle of transformers
iii) Float cum charging unit
iv) Circuit Breakers
v) On line oil monitoring unit
vi) Transformer oil filtration machine
vii) Other industrial loads
A separate 3 ph- N , 415 V switch board with change over switch shall
be provided at the pump house.
2.2.13.3 The incomer MCCBs will receive power from the secondary of the
Station Transformers through PVCSWA, 1100 V grade, stranded,
copper conductor cable of suitable size.
2.2.14.0 110V DC Supply:
2.2.14.1 One set of sealed maintenance free type lead acid batteries along with
two numbers (one working and one standby) float and boost charger
will be provided for supplying power to the following:
-closing and tripping coils of Circuit Breaker

-indicating lamps, holding coils, relays
-motor spring charging device of Circuit Breaker
-signaling and protective circuits
-interlocking
- any other load, as required
2.2.14.2 The batteries will be installed in the wooden racks located in the battery
room of the substation building. The battery will be of minimum 200 AH
capacity. The room will be properly ventilated by exhaust fan. The
batteries will receive power from the float charger.
2.2.14.3 The DC power will be supplied normally through the rectifier cum float
charger and in case of AC power supply is OFF, DC supply will be
affected through the battery. The rectifier / charger will receive from the
3 Ph-N, 415 V Power Distribution Board. Two nos DC Power
Distribution Board ( 110 V) with required MCCBs/MCBs shall be
installed at control room.
2.2.15.0 Illumination system:
2.2.15.1 Main lighting distribution boards 230 V ( L-L) with suitable number of
panels will be provided in the AC/DC room of the substation.
2.2.15.2 The out door substation yard will be illuminated with the help of
luminaries fitted with 400W metal halide lamps on 15m lighting masts
to achieve illumination level as per IS 3646 part-II. Minimum eight
numbers of lighting mast each of at least 15 m height with six numbers
luminaries with 400 W metal halide lamps will be provided for
illuminating the substation out door yard. Twelve numbers of 11 m
height steel tubular poles with 250 W HPSV lamps will be provided
along the road for illumination purpose. Luminaries with 250 W HPSV
lamps will be mounted on the substation building with brackets for
illuminating the area around substation building to achieve the required
illumination level. All the light fittings will receive power from the 230 V
(L-L) lighting distribution boards through 2 core PVC insulated copper
conductor cables. Required number of out going circuits will be

provided for supplying power to luminaries.
2.2.15.4 The indoor substation building will be illuminated with the help of
required number of energy efficient decorative recessed lamps light
fittings to achieve an illumination level of 200 lux (as per IS 3636 part
II). Corridors, toilets, testing rooms etc will be illuminated by suitably
rated compact fluorescent lamps. All the lamps will be placed suitably
to achieve uniform level of illumination. These lamps will also receive
power from the lighting distribution board. DC light fixtures with 40 W
GLS lamps shall also be fitted
2.2.15.5 One number inverter-cum- battery charger along with battery will be
installed in the substation building for emergency lighting in the
substation building in case of failure of power supply.
2.2.15.6 Supply and installation of one no. 63 kVA, 3 ph, 415 V, 50 Hz diesel
generator set (silent type) in the generator shed along with cabling and
change over switch as per requirement.
2.2.15.7 Required number of 1200mm sweep ceiling fans with double ball
bearings and electronic regulators shall be provided in control room,
battery room, testing room, PLCC room, Engineer in charges room,
Engineers room and other rooms. Exhaust fans of 375 mm sweep will
be provided in toilets, battery room, store, DG room, transformer oil
filteration room, oil storage room. Required number of 2 ton capacity
split type air conditioners with 5 star rating including servo stabilizer
shall be provided in the control room, Engineer in charges room.
These will get power from the power distribution board through 2 cores,
PVC insulated copper conductor cables. Required number of switches,
ceiling roses, sockets etc will be provided. For control of air
conditioners, MCBs with industrial type plug and sockets shall be
provided.
2.2.16.0 Power, Lighting, Control Cables:
2.2.16.1 All the LT power cables( 3 / 4 core, 1.1 kV grade) will be PVCSWA of
suitable size not less than 10 sq mm stranded copper conductors cable
as per requirement.
2.2.16.2 All internal wiring for illumination, ceiling fans, exhaust fans, misc.
items will be done by 1.5 sq mm - 6 sq mm PVC insulated cables of
1100/660V grade with copper conductor cable.
2.2.16.3 All out door illumination circuits will be of PVCSWA, 1100 V grade, 2
cores of required size cables with stranded copper conductors.
2.2.16.4 Internal wiring for air conditioners, power sockets will be carried out by
insulated 660 V grade, of suitable size copper wires/cables.
2.2.16.5 All internal control wiring of control cubicle , Circuit breakers , Isolators,
CTs etc will be carried out by PVC insulated 660 V grade , 2.5 sq mm
copper wires of suitable no. of cores.
2.2.16.6 All out door control cables will be PVCSWA, 660 V grade, 2.5 sq mm
(min), multi core copper conductors. However in case higher size
cables are required as per the design, the same is to be provided.
2.2.16.7 Cables used with CTs and PTs will be PVCSWA, 2.5 sq mm(min)
multi core copper conductors.
2.2.17.0 Bus system:
2.2.17.1 132 kV bus will be single sectionlised (with two nos. isolators, one no.
SF6 Circuit Breaker and one no. CT) overhead strung bus with single
ACSR Zebra conductor. The 33 kV bus will be two (Main & Auxiliary)
overhead strung bus. The main bus will be by twin ACSR Zebra
conductor and auxiliary bus will be by single ACSR Zebra conductor.
2.2.18.0 Earthing System
2.2.18.1 The touch and step potential at substation shall be maintained within
acceptable limit as per relevant IS/ IEEE standards. Earthing of the
complete 132kV/33kV substation will be done strictly in accordance
with the latest revision IS 3043 and Central Electricity Authority
Regulation-2010, IEEE standards & Electricity Act-2003(current). The
specific requirements of earthing in respect of some equipment in the
substation as indicated in IS 3043 are reproduced below for ready
reference:
Clause 17.8 Earthing of lightning arresters
Clause 17.8.1The base of lightning arresters shall be directly

connected to the earth by conductors as short as straight as
practicable to ensure minimum impedance. In addition, these shall be
as direct a connection as practicable from the earth side of the lightning
arresters to the frame of the apparatus being protected.
Clause 17.8.2 Individual earth electrodes should be provided for each

station type lightning arresters while for distribution type lightning
arresters one earth electrode may be provided for a set of lightning
arresters. Separate earth electrodes for lightning arresters are provided
for the reason that large Earthing systems in themselves may be of
little use for lightning protection. These earth electrodes should be
connected to the main earth system.
Clause 17.8.3 For lightning arrestors mounted near Transformer,

Earthing conductors will be located clear of the tank and coolers in
order to avoid possible oil leakage caused by arching.
Clause 17.8.4The earth connection should not pass through iron pipes
as it would the impedance of the connection.
Clause17.9. Earthing of miscellaneous, substation and generating

station Apparatus.
Clause 17.9.1 Disconnecting Switches
Clause 17.9.2.1 Current Transformers
Clause 17.9.2.2 Voltage Transformers
Clause 17.9.3 Circuit Breakers
2.2.18.2 Out door switch yard will have mat Earthing system. While designing
mat grid system, due care will be taken to keep touch potential, step
potential and mat potential within allowable limits as per statutory
requirements. The mat Earthing system will consist of earth grid made
of suitable size galvanised steel strips/flats buried at a depth of
approximately 700 mm below the ground. The size of the grid will be as
per requirements. Sufficient number of earth pits shall be provided in
the substation out door yard and will be connected to earth grid suitably
to keep the earth resistance below 1 ohm or to the specified level
required for EHV substation which ever is low. The earth pits shall be
constructed as per Indian Standard (IS-3043). Two separate earth pits
for each Transformer will be constructed very close to them to which
the neutrals of the Transformers will be connected. Similarly , for each
lightning arrester( LA) set, two numbers of earth pits will be constructed
very close to the LAs to which the LA shall be connected. All other
earth pits shall be distributed suitably over the earth mat. The metal
bodies of the out door equipment shall be connected to the earth mat.
2.2.18.3 Required number of earth pits will be provided along the fencing and
will be inter connected with the help of suitable size galvanised steel
strips / flats buried below the ground at a depth of 700 mm. The fencing
will be connected to this earth grid
2.2.18.4 Required number of earth pits will be provided around the substation
building and will be inter connected with the help of suitable size
galvanised steel strips / flats buried below the ground at a depth of 700
mm. The control cubicles and other equipment will be connected to this
earth grid.
2.2.18.5 Required number of earth electrodes will be provided and connected to

over head earth wire (shield wire) provided for direct lightning stroke
shielding protection through suitable size of insulated conductor.
2.2.18.6 Suitable arrangement for watering the earth pits shall also be provided.
2.2.18.7 The Tenderer/Bidder is to provide the design calculation for complete

Earthing system along with drawing.
2.2.19.0 Lightning Protection System:
2.2.19.1 Metal Oxide Lightning arrester of station class shall be provided on the
structures of 132kV incoming lines, primary side of the 132/33 kV
Transformers and 33kV outgoing feeders for protection against
traveling waves due to lightning. The 132kV lightning arresters `shall
be provided with surge monitor/ counter.
2.2.19.2 All the 132kV and 33kV structures will be extended by 2m high over the
conductors. At the top of these structures, horizontal shield wires will
be drawn for protection against direct lightning strokes. The shield
wires will be connected to earth by separate earth pits. In addition three
15m high lightning masts is to be erected in such a way that the entire
substation area is protected against lightning. Separate earth pit will be
provided for each lightning mast.
2.2.19.3 The lightning protection system will be as per relevant Indian

Standards and IE rules.
2.2.20.0 Fire Protection System:
2.2.20.1 Suitable fire fighting system (consisting of hydrant points, electric and
diesel pumps, portable fire extinguishers, sand buckets etc) to quench
electric fires in the out door switch yard, diesel gen. shed, transformer
oil filter/purification shed, oil storage shed, pump room and the
substation building will be provided as per the IER rules. Fire/ smoke
detectors and alarm system will be provided to warn the people
working at the substation. Each control panel (132kV &33kV) shall be
provided with individual fire extinguisher with sensor inside the panel.
The Tariff advisory committee and National Building codes will also be
considered for designing the fire fighting system. Along with these,
CO2 fire extinguisher and chemical powder type ( trolley mounted) are
to be provided.
2.2.20.2 Individual Nitrogen injection system for fire fighting shall be provided
with both the Power transformers (40/50 MVA,132/33 kV).
2.2.21.0 Misc. items:
2.2.21.1 The following will be provided inside the substation for safety and
education on safety:
i) Danger Plates Danger plates as per IE rules will be hanged on

the equipment indicating the voltage of operation.
ii) Safety charts Paper charts showing the shock treatment to a
person who gets shock.
iii) Safety belts
iv) Discharge rod.
2.2.22.0 Compliance with Standards:
All equipment and installations covered under this document shall

conform to the latest relevant Indian standards. However, equipment
confirming to other equivalent international standards may also be
accepted in the absence of Indian standards subject to approval from
the customer.
All equipment and installations shall conform to the following

rules/regulations amended up to date.
The Indian Electricity Rules.

The Indian Electricity Act.
The Indian Electricity (Supply) Act.
Coal Mining Acts and Rules.
Central Electricity Authority(CEA) Regulation 2010
Equipment complying with any other authoritative standard such as

IEC, British, USA, German etc. will also be considered if it ensures
performance equivalent or superior to Indian Standard. In that case,
however the Bidder shall supply copies of specifications adopted by the
standard and shall clearly mention in what respect such standard
specifications differ from the corresponding Indian standard mentioned.
The salient features of comparison shall be brought out and furnished
along with the offer.
The specifications, codes and standard referred to in this specification

shall govern in all cases where references there to are made. In case
of conflict between the referred specifications, the code or standard
and this technical specification, the later shall govern to the extent of
such difference.
The following Indian standards will be followed for selection and

commissioning of the different equipment. In case of absence of Indian
Standards Foreign Standards may be adopted after getting the
approval from the Owner.
1) IS: 2531 : Specification of Danger/Caution Boards
2) IS: 398 : Aluminum conductors, galvanized steel

reinforced
3) IS: 5561 : Specification of electric power connectors
4) IS: 802 : Code of practice for use of structural steel on

Transmission towers.
5) IS: 226 : Specification for structural steel (standard quality)
6) IS: 6639 : Specification for hexagonal bolts for steel
structures
7) IS: 6610 : Specification of heavy washers for steel
structures
8) IS: 2016 : Specification of plain washers
9) IS: 3063 : Specification for spring washers for bolts, nuts

and Screws
10) IS: 4795 : Specification for hot dip zinc coatings on

Structural steel and allied products
11) IS: 2629 : Recommended practice for hot-dip galvanizing of

iron and steel
12) IS: 3043 : Code of practice for Earthing
13) IS: 731 : Porcelain insulators for overhead power lines with
A nominal voltage greater than 1000 V
14) IS: 486 : Insulator fittings for overhead power lines with a
nominal voltage greater than 1000V.
15) IS: 808 : Rolled steel, beams, channel and angle section.
16) IS: 961 : Specifications for high tension structural steel
17) IS: 12063 : Classification of degrees of protection provided

by enclosures of electrical equipment
18) IS: 325 : Specification of 3 phase induction motor
19) IS: 4379 : High pressure cylinder in which SF6 gas is

transported IS: 7311 and stored at site.
20) IS: 2099 : Specification for high voltage porcelain bushings
21) IS: 2071 : Method of high voltage testing
22) IS: 2165 : Insulation co ordination of highest voltages for

equipment of 100 kV and above.
23) IS: 3202 : Code of practice for climate proofing of electrical

equipment
24) IS: 375 : Specification for marking and arrangement for

switchgear, bus-bar, main connection and
Auxiliary wirings.
25) IS: 5621 : Specification of large hollow porcelain for use in

electrical installations.
26) IS: 6071 : Specification for synthetic separators for lead

acid batteries
27) IS: 366 : Specification for sulphuric acid
28) IS: 1069 : Specification for water for storage batteries.
29) IS: 3116 : Specification for sealing compound for lead acid
batteries.
30) IS: 3895 : Specification for rectifier equipment in general .
31) IS: 9224 : Specification for HRC fuses.
32) IS: 1248 : Specification for indicating instruments

IS: 2419
33) IS: 13947 : Specification for AC contactors for voltage not

exceeding 1000 V
34) IS: 13947 : Specification for air break switches and fuse
combination units
35) IS: 5 : Specification for colour for ready mix paints
36) IS: 6619 : Specification code for semiconductor rectifier

equipment
37) IS: 4237 : General requirement for switchgear and control

gear for voltage and not exceeding 1000V
38) IS: 3231 : Specification for electrical relays for power

System protection
IS 255
39) IS: 8686 : Specification for static protective relays
40) IS: 722 : Specification for AC electricity meters

IS: 13010
IS: 8530
41) IS: 1554 : Specification of PVC insulated cables upto

Including 1000 V
42) IS: 6600 : Guide for loading of oil immersed transformers
43) IS: 10322 : Particular requirements for flood light luminaries

(Parts1, 2, 5/ 5)
44) IS: 4691 : Degrees of protection provided by enclosure for

rotating electrical machinery
45) IS: 335 : Insulation oils
46) IS: 2026 : Power transformers
47) IS: 2147 : Degree of protection provided by enclosures for

low voltage switch gear and control gear
48) IS: 2418 : Fluorescent lamps for general lighting service
49) IS: 2516 : Circuit breakers
50) IS: 2705 : Current transformers
51) IS: 2309 : Code of practice for protection against lighting
52) IS: 2997 : Air circulator type electric fans and regulators
53) IS: 3070 : Lightning arrester for AC system
54) IS: 3156 : Voltage transformers
55) IS: 3427 : Metal enclosed switch gear and control gear
56) IS: 3480 : Flexible steel conduits for electrical wiring
57) IS: 3639 : Fittings and accessories for power transformers
58) IS: 4710 : Switches and switches isolators
59) IS: 110118 : Code of practice for selection, installation and

maintenance of switch gear and control gear
60) IS: 2148 : Junction boxes

Indian electricity Act
Indian electricity (supply) Act
Mining Act and Rules
Safety codes, rules and regulations
Indian electricity rules 1956
CIVIL AND STRUCTURAL ENGINEERING
2.2.23.1 The Civil and structural works covered under this document will
consists of substation building, security room, underground water
storage reservoir, Room for D.G set, transformer oil filteration machine
and oil storage , Galvanized steel structures (Gantries, Towers,
Stools), equipment foundations, rail track for transformer and
transformer foundation, cable trenches, bore well with submersible
pump, sump with pump house, soak pit, septic tank, drainage system,
path ways, boundary wall with gates, drains. car parking shed, watch
tower chain link fencing with gates, anti grass treatment, spreading of
crushed stone in the outdoor yard, drinking and industrial water supply
etc. The design of steel and RCC structures will be as per standard
code of practices for industrial structural/buildings in the absence of
which international standards can be used. Along with this soil
investigation and surface dressing shall also be covered.
During the design of structures, the effect of dead loads, live loads,
dynamic loads, effect of blasting, seismic load etc. wherever applicable
shall be considered. The effect of blasting (maximum charge per delay
of 20,000 kg at a distance of app. 1000 m) will be considered. The
topography factor for design calculations will be considered and shall
not be less than 1.05.
2.2.23.2 Substation building:-
The plinth area of the substation building will be 29 m x 23 m. The

internal arrangement of the various rooms shall be as shown in the
drawing no RV/ELC/200280. The plinth level of the building shall be
about 450 mm above final accepted ground level around the building.
The details of the rooms provided in the substation building will be as
given below:
i) Control Room Air conditioned to house control and relay

panels, Instrumentation panel for CBs and
transformers.
ii) Battery Room To house lead acid batteries in wooden

racks.
iii) Auxiliary units For storage of transformer oil drums,

filtration machine and DG set to be
constructed seperately
iv) Testing room 1&2 For conduction of tests on relays, meters,

transformer oil etc.
v) Engineers room For accommodation of Engineers.
vi) Engineer in charge room For accommodation of Engineer-in-

charge with a provision of Air conditioner
vii)Tool & Store room Tool room will have locker facilities for
storage of tools.
viii)AC/DC room To accommodate rectifier, battery, float

charger, 415V switch board and lighting
switch board.
ix) Security room 2 Nos.
x) PLCC room 1 No.
xi) PLCC Battery room 1 No.
xii) Toilet Two nos. of toilet will be located at the

space indicated in the drawing along with
required sanitary fittings and water pipe line.
The substation building shall be of RCC framed structure with brick

walls and RCC roof. The roof height shall be minimum 4.5 m. The
plastered internal surface shall be finished with plastic emulsion paint
of approved shade or any other finish depending on functional need.
Outer surface is to be plastered and finished with water proofing
cement based paint. Required doors with steel frames, paneled
aluminum windows, rolling shutters (one for control room and second
for transformer filtration machine room) will be provided. The wall
facing the outdoor yard will be provided with windows having double
glass for full length and 2 m height (glass will be laid 1 m above floor).
All windows will be protected by grills of suitable pattern. The doors
shall be of flush door shutters with proper locking arrangement. The
main control room and Engineer In charges room will be air
conditioned so proper leak proof arrangement will be provided. If
required control room may be provided with double doors. For effective
air conditioning the walls of the control room will be extended up to the
roof. The doors of the above rooms shall be provided with suitable door
closures. The noise level in the control room shall be kept below 60
db. The Engineer in charges room shall be provided with false ceiling.
The floor of stores, transformer oil filtration machine unit, DG room, oil
storage room shall be of I.P.S flooring followed by150 mm thick RCC of
M-20 grade over the base course. The floor finish of Battery room will
be anti acidic. The Engineers room, AC/DC room, testing room will be
glazed tiled. Engineer In charges room shall be glazed tiled. Other
floorings will be I.P.S flooring over suitable base course.
The battery room and toilets will be provided with 375 mm sweep
exhaust fans. Required number of light fittings, fans, sockets, ceiling
roses etc. will be provided. The toilet will be provided with required
sanitary fittings, wash basin etc. Dado in toilet up to height of 1.5 m
above finished floor level and skirting of standard height is to be

provided in all utility buildings. Plinth protection of 1.5 m wide shall be
provided all around the substation building.
2.2.23.3 Sump and Pump house:
One number sump of suitable capacity (minimum 1,35,000 litres

capacity) will be provided to meet the requirement of fire-fighting
system. The sump will of RCC construction. A ladder shall be
provided in the sump for getting down into the sump for cleaning. The
sump will be fully covered leaving a manhole cover with steel lid.
Arrangement will be provided for supplying water through
establishment of bore well with submersible pump which is within the
scope of this work.
The pump house will be of brick masonry construction with RCC roof.
The plastered internal surface will be finished with plastic emulsion
paint of approved shade, while outer surface shall be plastered and
finished with water proofing cement based paint. The plinth area of the
pump house will be such that a clearance of 1.5 m (min.) on all sides
after installation of pumps (both electric and diesel) will be available.
The floor of the pump house will be IPS over suitable base course
preferably RCC. Required steel windows with square bars and glass
panels, steel door frames of suitable width and 2 m height with flush
door shutters will be provided. The door will be provided with proper
locking arrangement. Required light points, ceiling roses, sockets,
switches etc. will have to be provided.
2.2.23.4 Substation out door yard:
The ground area in the outdoor yard of the substation switch yard
portion will have to be leveled, suitably conditioned with anti grass
treatment before providing crushed stone. The crushed stones will be
of 25 mm x 25 mm size and will be spread uniformly to reduce shock
hazard. The thickness of crushed stone will be as per design
consideration and approval of DGMS.
2.2.23.5 Units for Diesel generator, transformer oil filtration and oil
storage:
Diesel generator unit of required size along with flooring to

accommodate and install 63 KVA generator is within the scope of this
contract along with separate units for transformer oil filteration plant
and oil storage. Required paneled aluminum windows, rolling shutters
will be provided. All windows will be protected by grills of suitable
pattern. The floor of the rooms shall be of I.P.S flooring followed by150
mm thick RCC of M-20 grade over the base course. Necessary light
fittings, fans and exhaust fans electrical connections are to be provided
within the room.
2.2.23.6 Soak pit:
A soak pit of 25 kl or oil capacity of one power transformer which ever

is more will be provided at the far end of the transformer (at suitable
location) as shown in the drawing to store spilled transformer oil. GI
pipe of suitable diameter with valves will be provided from the
transformer up to soak pit for drainage of spilled over transformer oil.
Soak pit will be of Brick masonry construction, plastered and finished
with a coat of neat cement punning to avoid any seepage. Soak pit will
be covered with a RCC lid of required thickness and will have a
suitable size manhole.
2.2.23.7 Drinking and Industrial water system:-
Two nos. of PVC tanks each of 2000 lit capacity will be provided on the
roof of the substation building. One tank will be for supplying drinking
water and the other for supplying water for industrial use. Arrangement
will be provided for connecting the inlet water pipe from water supply
system. Out let pipes from the water tank for industrial use will be laid
up to various earth pits in the outdoor yard of the substation and to
toilets. Required valves, taps etc shall be provided. Drinking water
tank will be connected to water cooler etc.
2.2.23.8 Cable Trenches
All the power /lighting cables, control cables will be laid on separate
cable hangers in the cable trenches provided inside the sub station
building and out door yard as shown in Drg. No. RV/ELC/200279. The
cable trenches will be of desired size. The floor of the cable trench will
be provided with a gradient for easy flow of water to a place out side
the substation yard. The trenches provided in the out door yard will be
covered by means of pre-cast RCC covers supported on steel frame
which can be lifted easily. The indoor cable trenches will be covered by
means of aluminum cover of at least 3mm thick and properly stiffened
to avoid bending.
2.2.23.9 Development:-
Site grading/leveling will be done within the boundary limit of the

substation. The HFL, bed level water floor etc. will be considered for
designing the drainage system. Suitable path ways along the
boundary wall inside the substation with brick flat soling shall be
provided. Path ways (3 m wide) shall also be provided in the yard to
reach the transformers, circuit breakers on tripper trucks/crane etc.
2.2.23.10 Sewerage system:
A septic tank of suitable size will be provided near the Substation

building and connected to sanitary outlet provided in the toilet.
2.2.23.11 Rail track:
Rail track with 45 kg/m rails or of required size will be provided on the
transformer foundations and in front of the transformer so that the
transformer can be taken out for under taking repair in case of
requirement. Diamond crossing is to be provided for easy
transportation of power transformers.
2.2.23.12 Boundary wall, Fencing and gate:
The boundary wall will be of brick masonry construction of 2 m height

between plinth beam and a top beam. The wall length shall be divided
into suitable sections /Panels. The wall shall be plastered on both
sides. Above the wall concertina coil shall be provided for safety. Two
steel gates will be provided in the boundary wall. The gates will be of 6
m width and 1.8 m height, structural steel framed of suitable design.
Locking arrangement shall be provided. The outdoor yard is to be
fenced (as shown in the drawing) with chain link fencing in between
RCC pre-cast poles of 2.4m height. The height of the fencing will be
1.8 m.
Scope of work NIT of 132/33 kV substation at Kusmunda OCP
2.3.0.0 SCOPE OF WORK
2.3.1.0 General
2.3.1.1 The construction of a 132 kV/33 kV substation on turnkey basis

requires good technical background and high skills. The design,
drawings, manufacture, fabrication, erection, testing/inspection
etc. shall be carried out strictly as per Indian Electricity rule,
latest BIS code of practices, prevailing mining acts, CEAR etc.
In absence of Indian standards, British, American, German,
Russian, Japan or International Standards may be adopted after
getting the approval from the Employer/ Owner.
2.3.1.2 The parameters furnished are subject to scrutiny/approval at the

design stage which may undergo minor changes keeping in view
the system requirements/code of practice/regulations by
statutory bodies. The parameters not mentioned in the
document will be decided at the time of detailed engineering
subject to Owners approval.
2.3.2.0 Basic Scope
The scope of work shall be read with system requirements and

technical specifications given in this document. The basic scope
of work shall include the following:
i) Design and Engineering

ii) Surveying, soil testing
iii) Procurement, supply of equipment at site
iv) Civil and structural works
v) Erection and Installation of equipment including Diesel
Generator, obtaining the approval of statutory bodies
vi) Inspection, trial run, commissioning and handing over
vii) Performance guarantee
viii) Training of Personnel
ix) Supply of manuals, tools, office furniture and fittings etc.
x) Critical spares
xi) First fill of oil, gas and grease
xii) Any other items not mentioned but are required for the
success full commissioning and operation of the substation
2.3.3.0 Design Engineering
The design engineering shall consist of the following:
2.3.3.1 E&M Engineering
i) Single line diagram showing the details of all the equipment in

the substation (outdoor and indoor)
NIT 688 dtd 17.09.14 Job No.502255 (VOL II) Page no- 23
ii) Preparation of detailed layout drawing of the substation

outdoor yard, Indoor control room, AC/DC room and other
rooms for DG set, transformer oil filtration unit and oil storage
giving dimensions, clearances
iii) Sectional elevations of the layout in outdoor yard showing

dimensions, clearances and load date wherever necessary
iv) Single line diagram showing the size and length of cables for
feeding power to various equipment
v) Plan showing the cable trenches in the outdoor yard along

with the location and size of soak pit.
vi) Drawing showing shield wire arrangement (to protect the

outdoor equipment from direct lightning strokes) showing the
size of GI wires, elevation at which they are provided and other
required details
vii) Drawing showing the Earthing system provided with

dimensions.
viii) General arrangement showing the layout of indoor

equipment in the control room, AC/DC power supply room
alongwith sheds for diesel generator, transformer oil filtration
and oil storage with dimensions, clearances, cable trench
details etc.
ix) Plan, elevation showing the position of various luminaries

(specifications), cable layouts, location of lighting main and sub
distribution boards.
x) Single line diagram showing the control scheme along with

details
xi) Emergency lighting system details along with single line

diagram
xii) Details of signaling system along with single line diagram
xiii) G.A. drawing of fire fighting system provided indicating the

details of equipment provided
xiv) Calculations in support of selection of cable sizes, number

of luminaries
xv) Calculations in support of number of earth pits, conductor

size etc. used for Earthing system
xvi) Calculations in support of number of pumps, capacity of

pumps, size of the pipe, sump capacity to be used for fire
fighting
xvii) Calculations in support of requirement of air conditioner for

air conditioning the control room.
xviii) Drawings as specified in the technical specifications of the

equipment
2.3.3.2 Civil Engineering
i) G.A. drawing of the substation building, D.G room, transformer

oil filtration machine room, oil storage room showing all the
dimensions, location of windows, doors, rolling shutters, cable
trenches, utility rooms etc.
ii) Detailed design drawings showing foundations, roof slab,

walls etc. of the substation building, D.G and other rooms,
boundary wall, Oil overflow chamber, security room, Car parking
area, drain, watch tower etc. along with relevant calculations.
iii) Detailed design calculations and drawings for sump and

pump house used for fire fighting system.
iv) Detailed drawings showing the drinking and Industrial water

supply & distribution system.
v) Details of soak pits, cable trenches in out yard, pathway,

boundary wall, chain link fencing, gate, WBM road within
substation premises etc.
vi) Design calculations and drawing showing the structural and

RCC foundation, equipment foundations, details of gantries,
towers, stools, Transformer foundation etc.
vii) Drawing showing the site development, drainage system etc.
2.3.4.0 Surveying and Soil Testing
The successful Tenderer shall undertake the detailed survey of

the area. All works related to survey shall be conducted as per
standard practice and also as per system requirement.
2.3.4.1 The successful Tenderer shall undertake soil investigation

wherever required and submit a report. The soil testing is to be
carried out through any Govt. approved laboratory and the same
must be submitted though authorized signatory of the successful
bidder. The report shall be comprehensive and shall contain
recommendations for type of foundations, bearing pressure,
method of deep excavation, probable settlement for foundations,
earth resistivity for designing earthing system etc. A report shall

be submitted for approval of Employer. The soil investigation
(collection of samples) etc. shall be carried out in the presence
of the Employer or his representative.
2.3.5.0 Supply of Equipment
The brief specifications and quantity of equipment to be supplied

under this Contract are as given below. Equipment not
mentioned below but required for the completion of the job shall
also be supplied by the Bidder. The scope of supply of
equipment shall be read in conjunction with the system
description and Technical specifications of the Equipment given
in this document
2.3.51. Equipment on 132 kV side

Sl Item Particulars Qty
no.
1 Isolators, outdoor type, motorised, 132 kV 12
(nominal), 3pole, pole mounted, 800 A (10 nos.), sets
31.5 kA ( 2 nos with earth switch), 2 nos. of
1600 A for sectionalisers
2 Lightning arresters, station class, 120 kV, 10 kA, 4
suitable for 132 kV effectively earthed (each set sets
consists of 3 nos.) along with surge
monitor/counter
3 Current transformer (CT), single phase, outdoor 5
type, oil cooled, 132 kV, 5 cores, 250-125 A/ sets
(1A-1A-1A-1A-1A ) for metering and protection:
(each set consisting of 3 sets)
4 Potential Transformer (PT), out door type, 132 2
kV/3 / 110V/3, 2 core for metering and sets
protection ,100VA each for 132kV ,3 phase
system(each set consisting of 3 sets)
5 SF6 Circuit breaker, outdoor type, gang 5 nos
operated spring charge mechanism 132 kV,
1250 A, 31.5 kA, 7500 MVA
6 Power Transformer, outdoor, plinth mounted, 40 2 nos
MVA/50 MVA ,132 / 33 kV, ONAN/ONAF, YN-
yn-o with on load tap changer, HV and LV
neutrals effectively earthed with all accessories
7 Indoor type control and relay panels including 6
instrumentation for 132 kV feeders, 132 kV side sets
of power transformers, bus coupler & busbar
protection
8 Indoor type control panel for on load tap 2
changer(RTCC Panel) for 132/33 kV transformer sets
(on HV side)
2.3.5.2 Equipment on 33 kV side

no.
1 Isolator, manually operated, 3 pole, pole 12
mounted, with earth switch & Cranking type sets
mechanism 33 kV (nominal), 25 kA with
arrangement for interlocking with VCB circuit
breakers - 1250 amps
2 -Do but , - 800 amps (isolators with 54
outgoing feeders are to be fitted with earth sets
blade and cranking type mechanism)
3 33 kV HG Fuse unit 4 sets
4 Lightning arresters, station class, 30kV, 10 kA, 20
suitable for 33 kV solidly earthed (each set sets
consists of 3 nos.)
5 Current transformer, (CT), single phase, 4 sets
outdoor type, oil cooled with CT ratio 800-
400/1-1-1 A, 33 kV, 3 cores (1A-1A-1A) (Each
set consists of 3 nos.) for metering and
protection
6 Current transformer, (CT), single phase, 16
outdoor type, oil cooled with CT ratio 400- sets
200/1-1 A, 33 kV, 2cores (Each set consists of
3 nos.) for metering and protection
7 Potential Transformer (PT), out door type, 33 2 sets
kV/3/ 110V/3, 100VA each for 33 kV, 3
phase system (Each set consisting of 3 nos.)
for metering and protection
8 Vacuum Circuit breaker, outdoor type, 33 kV, 20
1250 Amps , 25 kA, having IDMT relay for O/L sets
and E/F protection , ammeter etc.
9 Indoor type control and relay panel including 20
instrumentation for 33 kV circuit breakers Sets
10 Indoor type control and relay panel including 1 set
instrumentation for 33 kV bus coupler
2.3.5.3 Substation out door yard:-

no.
1 Insulators for 132 kV & 33 kV Lot
2 132 kV strung bus bar system complete with Lot
suitable insulators (Post, disc), steel towers,
beams, hardware etc.
3 33 kV strung bus bar system (main and Lot
auxiliary/ transfer bus) complete with ACSR
Zebra conductors suitable insulators (Post,
disc), steel towers, beams, hardware etc.
4 ACSR conductors and suitable insulators for Lot

making inter connections between different
equipment on 132 kV and 33 kV side.
2.3.5.4 Earthing system

no.
1 Mat earthing system for earthing of switch yard As per
equipment, complete with earth pits, Design
electrodes, grid conductors (Galvanised steel
flats), saddles, required hard ware (washers,
nuts, bolts) etc.
2 Earthing of boundary fencing consisting of As per
earth pits, electrodes, grid conductors Design
(Galvanised steel flats), saddles, required
hardware (washers, nuts, bolts), earthing
conductors etc.
3 Required earth pits, electrodes, Galvanised As per
steel flats, saddles, required hardware etc. for Design
Earthing of Transformer neutrals.
4 Required earth pits, electrodes, Galvanised As per
steel flats, saddles, required hardware etc. for Design
earthing of Lightning arrestors.
5 Earthing arrangement consisting of earth pits, As per
electrodes, grid conductors (Galvanized steel Design
flats), saddles to be provided around the
substation building, earth conductors from the
equipment.
6 Required piping, pipe fittings, valves, overhead As per
tank etc. for arranging watering arrangement Design
at earth pits.
2.3.5.5 Lightning protection system
In addition to the station class lightning arrestors provided for

protecting the equipment, the following shall also be provided.

no.
1 Lightning protection of out door yard As per
equipment from direct lightning stroke Design
consisting of steel towers, insulators, steel
wires, down earth conductors, earth pits
(Independent of earth pits provided for
earthing) electrodes, GI flats for connecting
earth pits hardware etc.
2 Lightning protection system for substation As per

no.
building consisting of suitable number of Design
spikes, interconnecting galvanized steel flats,
down earth conductors, earth pits
(Independent of earth pits provided for
earthing), electrodes, earth pit interconnecting
galvanized flats, saddles, hardware etc.
3 Required piping, pipe fittings, valves etc. for As per
arranging watering arrangement at earth pits. Design
4 15 m lightning mast for shield wire 3 nos.
2.3.5.6 Fire fighting system

no.
1 Fire fighting system consisting of Nitrogen As per
injection system (2 nos.) for power Design
transformers (2X40/50 MVA), hydrant system
(hydrant points, fire hose cabinets along with
fire hose, electric & diesel pumps, pipes , pipe
fittings etc), portable Co2 and dry type
chemical powder fire extinguishers, trolley
mounted dry type chemical powder fire
extinguishers, sand buckets, power supply
arrangement for pumps etc.
2.3.5.7 Lighting system

no.
1 Lighting distribution board, 230 V (L-L) 2 nos
consisting of MCCBs and MCBs for control of
various lighting circuits
2 Lighting mast, 15 m height, along with 6 nos. 8 nos
luminaries with 400 W metal halide lamps,
control gear etc. for outdoor yard lighting
3 11 m height steel tubular poles along with 12
luminaries with 250W HPSV lamps along with Nos.
control gear, brackets etc for outdoor yard
illumination..
4 Lighting of substation building As per
- Energy efficient recessed light fittings Design
- 20 W compact fluorescent lamps complete
with the fittings, DC light fixtures with 40W
GLS Lamps.
5 Accessories such as sub distribution boards, Lot
junction boxes,250 W HPSV flood light fittings

no.
with brackets, individual control cables, PVC
conduits/casings, back up HRC fuses,
switches sockets, ceiling roses, single core
PVC cable with copper conductors (for internal
connections) , flexible wire etc.
6 Inverter cum battery charger along with battery 1 no
for emergency lighting suitable for operation at
230V AC inside substation building
2.3.5.8 Auxiliary Power supply system

no.
1 Transformer, outdoor type, plinth mounted, 200 2 nos
kVA , 33 kV/415V- 230 V (L-L), Dy-11, 3-
phase & neutral Copper wound, ONAN cooled,
OFF load tap changer conforming to IS-
2026(current)
2 Power distribution board, 415V, 3 ph N with 2 Nos
MCCBs/MCB for control and distribution of AC
supply.
3 110V rechargeable sealed maintenance free 1 Set
battery (SMF), lead acid type (200 AH.
Capacity minimum) complete with two float
cum boost charger (one working and one
standby), wooden rack etc.
4 DC Power distribution board, 110V, with all 2 Nos
protections for supplying power to various
installations.
2.3.5.9 Cables and accessories:-

no.
1 LT Power cable, 3 / 4 core PVCSWA, stranded Lot
copper conductors, 1100 V grade of suitable
sizes, (not less than 10 sq mm size)
2 Lighting cable, PVCSWA, copper conductors, 2 Lot
core, 1100 V grade of suitable sizes
3 Control cable, PVCSWA, copper conductors, Lot
1100 V grade of suitable size (not less than 2.5
sq mm)
4 Wires for internal wiring of 1.5 sq mm to 6 Lot
sq.mm size, PVC insulated copper conductor
660V grade
5 Cable trays, cable racks, binding material, Lot

no.
cable glands, cable terminal lugs, nuts, bolts,
washer, cable jointing and termination kit etc.
2.3.5.10 Misc. items

no.
1 63 kVA Diesel Generator (silent type), 3 ph, 50 1 no.
hz, 415 V output supply with cable & change
over switch with earthing to be installed in the
DG room of the substation
2 Split type room air conditioners (5 star rating) , 2 As
ton capacity including servo stabiliser of rated Reqd
capacity with digital indicator for input and out
put voltage, industrial type plug sockets, fuses,
control MCBs
3 Exhaust fan 375 mm sweep in battery room, oil Lot
filtration unit room, toilet
4 Ceiling fans, 1200 mm sweep along with lot
electronic regulators in Engineer in charge
room, testing room, battery room, control room,
Engineers room, other rooms etc.
5 Two stage high vacuum transformer oil purifier 1 no
cum filtration M/c , on line, tyre mounted, 2400
lph capacity, heavy duty flexible hose pipe of
required length, associated electricals suitable
for operation on 415V, 3 phase 50 Hz, required
flexible cable of 4 core copper conductors,
coupler etc
6 Automatic transformer oil Dielectric strength 1 no
testing equipment, 3 kVA, 0-100 kV, adjustable
gaps, protective fuses, pilot lamp, oil testing
cup, double pole control MCB, suitable for
operation on 230V, single phase, 50 Hz supply
7 Transformer Ratio Meter 1 no
8 Meter and relay testing kit (Range 0-100 amps) 1 no
Secondary injection 230 V AC
9 Primary injection kit (Range 0-2000 amps), 230 1 no
V AC
10 Earth resistance testing equipment / Megger 1 no
with galvanized steel prods
11 Motorized oil pump1.1 lps, 5 m head, electrical 1 no
suitable for operation on 230 V, 1 ph, 50 Hz
supply, along with suitable cable coupler etc
12 Vacuum cleaner, domestic type, 35 lps, 2100 1 no
mm water gauge, wheel mounted, electricals

no.
suitable for operation on 230V, 1 Ph, 50 Hz
supply, hose pipe, other accessories, suitable
flexible cable etc
13 High voltage detector (for 33 kV & 132 kV), 1 2 no
no. each
14 Testing equipment for testing such as
a) Contact Resistance Measurement Kit 1 no
b) Circuit Breaker time trial kit 1 No
15 Tools , Tackles , safety items , measuring LS

instruments etc
2.3.5.11 (i) Mandatory spares- list with specifications to be given
(ii) Any other equipment which have not been specifically

mentioned but are necessary for efficient operation of the
substation, shall also be supplied. The list of such items to be
provided.
2.3.6.0 Civil and Structural Works
The civil and structural works are related mainly to following (but
not limited to)
i) Providing all labour, supervision, materials, scaffoldings,

construction equipment, tools, plants, supply, transportation,
construction etc.
ii) Substation building , D.G room & other associated structures

(as indicated in General arrangement drawing), car parking area
of RCC framed structure with RCC roof, brick walls, windows,
doors, shutters, false ceiling in sub-station building only, cable
trenches with aluminum covers, PVC flooring in control room
etc. The overall plinth area of the substation is around (29 m x23
m, 4.5 m height), 667 sq m
iii) Supply of galvanized steel, fabrication of gantries/ towers/

supporting stools for CTs, PTs, lightning arrestor, circuit
breakers and other associated electrical equipment structures
etc.
iv) Foundation for the above equipment, station & power

transformers, steel structures etc.
v) Construction of bore well with submersible pump, RCC water

reservoir of 135 cum capacity along with pump house for
firefighting system.
vi) Boundary wall with concertina coil on top, Chain link fencing
between the substation and outdoor yard, required gates,
Security rooms, watch tower etc.
vii) Drinking and Industrial water distribution system.
viii) Development works such as leveling / land filling, drainage,

cable trenches with RCC covers on steel frame, concrete
pavement, drainage pipe for draining transformer oil to soak pit,
soak pit of minimum of 25 k lit or capacity of one transformer
which ever is higher. Septic tank, anti grass treatment, supply
and spreading of crushed stones (25x25 mm size) in the outdoor
yard.
ix) Removal of debris and disposing of at a distance of at least

1km.
x) Supply and laying of suitable rail track with diamond crossing

up to transformer foundations and in the yard up to maintenance
bay.
xi) Drainage system along the periphery of the sub-station area

and its disposal to the outside drainage system.
xii) Construction of bituminous top metallic road within

substation premises.
xiii) Any other installation of equipment/ services which are not

specially mentioned but required for successful operation of the
substation.
Note: - All works are to be executed in accordance to BIS provisions & CPWD
specifications
2.3.7.0 Erection and Installation
The installation of equipment shall be done under the direct

supervision of qualified and experienced personnel, if possible,
by the personnel from original equipment manufacturer. The
installation shall be as per standard code of practice, Indian
electricity rules/relevant BIS/mine acts
The following shall include under erection of equipment
i) Erection of the outdoor equipment on 132 kV side such as

132 kV sectionalized strung bus, isolators, current transformers
(CTs) , potential transformers (PTs), station class lightning
arrester (LA), SF6 circuit breakers, power transformers (132/33
kV) etc.
ii) Erection of the outdoor equipment on 33 kV side such as 33

kV sectionalized strung bus (Main & Auxiliary) , isolators,
current transformers, potential transformers, station class
lightning arrestor, VCB , station transformer (33 kV /415 V-230 V
( L-L)) , signaling system (in the control room of the substation
building) etc.
iii) Installation of indoor control panels for control of ON load tap

changer for 132/33 kV transformers and SF6 & VCB circuit
breakers (132kV & 33kV) etc in the control room of substation
building.
iv) Installation of AC/DC power supply arrangement, 415 V

power distribution board, 230 V (L-L) lighting distribution board,
emergency lighting system, Batteries etc. in the substation
building.
v) Installation of various luminaries, poles, masts etc.
vi) Installation of 63 kVA Diesel Generator, oil filtration machine
vii) Installations of ceiling fans, exhaust fans, air conditioners.
viii) Installation of fire fighting system (consisting of pumps,

pipes fire hydrants, landing valves, hose cabinets along with
hoses, branch pipes, nozzle),fire and smoke detectors,
annunciator panels, Nitrogen injection plant for power
transformers, portable and trolley mounted fire extinguishers ,
sand buckets etc and Nitrogen injection system for power
transformers.
ix)Laying, jointing, termination of power cable, lighting cables

and control cables etc.
x) Construction of required number of earth pits and their inter

connection to form earthing grid, Independent earth pits for
earthling of transformer neutral and lightning arresters, earthling
grid for fencing, independent earthling system around substation
building etc.
xi) Erection of shield wires interconnecting the towers/gantry to

protect from direct lightning strokes, spikes and their
interconnection over the out door yard, required earth pits and
interconnection etc.
xii) Installation of drinking water and industrial water supply,

laying and termination of GI pipe from the OH tank in the
substation building to various earth pits, required valves etc.
xiii) Any other installation of equipment which are not specifically

mentioned but required for successful operation of the
substation.
2.3.8.0 Inspection, Trial run, commissioning
2.3.8.1 These will be carried out as specified elsewhere in the Tender

document
2.3.9.0 Performance Guarantee
2.3.9.1 Performance guarantee will be as specified in volume I of this

Tender document
2.3.10.0 Training of personnel
2.3.10.1 Training of personnel will be minimum 100 man days however

Tenderer has to specify the time.
2.3.11.0 Manuals and Tools
2.3.11.1 Manuals and final drawings shall be submitted by the Contractor
2.3.11.2 The tools, safety items, tackles, measuring instruments shall be

as given below.
i) Multi meter for measuring AC & DC (Voltage, Current,

Resistance etc.) (avometer). 1 no
ii) Tong tester (Digital), 0-1000A, 0-600 V 1no
iii) Motorised Meggers 0-5000V, 1no

0-10000V, 1no
iv) Hand operated crimping tools (0-95 sq mm) 1no
v) Hydraulic crimping tools (10-400 sq mm) 1no
vi) Spanners 1 set

Full range of D spanners (each)
- Full range of ring spanners
- Full range of box spanners
vii) Full range of screw drivers 1set
viii) Slide wrenches of required size. 1set
ix) Discharge rods, 3 m long along with the hook, cable etc. 2set
x) Hand gloves, 33 kV grade. 4sets
xi) Insulating mats of required length x 0.8 m wide x 8 mm thick
(for control room & AC/DC room) Lot
xii) Safety Belts 4nos
xiii) Manual winch operated 12 m long telescopic FRLS

ladder mounted on big wheels. 1 no
xiv) Extensible platform ladder up to 4.5 m long, FRLS 1 no
xv) All special tools as detailed in the technical

specifications of equipment As required
xvi) Wooden testing bench As required
xvii) Providing and fixing of Danger plates, caution boards as per

IE rules at strategic locations, safety charts, bay identification
marks etc.
As required
2.3.12.0 Critical spares
2.3.12.1 List of critical spares along with prices shall be as supplied by
(separately) by the Tenderer, however Owner will scrutinize the
list and order will be placed separately.
2.3.13.0 First fill oil ,SF6 gases and grease
2.3.13.1 The first fill oil, gas and grease shall form part of supply
2.3.14.0 Other items
i) All the construction equipment, testing instruments, tool and
tackles required for installation and testing shall be brought by
the Contractor
ii) The Contractor shall prepare a safety code of practice for
these operations and obtain the approval of Owner
iii) Obtaining the approvals from various Govt. departments for

establishment of 132/33 kV substation.
Equipment Specifications NIT of 132/33kV Substation at Kusmunda OCP
2.4.0.0 TECHNICAL SPECIFICATIONS OF EQUIPMENT
2.4.1.0 SPECIFICATION OF DISCONNECTING SWITCH ISOLATOR
2.4.1.1 General:
i) Twelve nos. 132 kV and sixty six nos. 33 kV isolators have been
proposed in the substation at various points where isolators are
intended for control as well as maintenance. These have been
indicated in drawing number R5/ELC/200278 ( single line diagram).
ii) The isolators which are required to have earthing switches will also
be combined in one unit. Interlock shall be provided between the
isolator and the earthing switch to ensure proper operation and safety.
2.4.1.2 Technical Parameters:
The specific technical requirements/parameters of isolator with or

without earthing switch are indicated below:-
i) Nominal voltage 132kV - 33kV
ii) Nominal current rating 1600/800 A - 1250 A/800 A
iii) Highest system voltage 145kV - 36kV
iv) One minute power frequency 275 kV (rms) - 70kV ( rms)

withstand voltage
v) Lightning impulse 650 kV (peak) - 170kV (peak)

withstand voltage
vi) Rated frequency 50Hz - 50 Hz
vii) No of posts per phase Three - Three
viii) No of breaks per phase Two - Two
ix) Short time fault current 31.5kA - 25kA

withstanding cap. for 3 sec. (r.m.s.) (r.m.s.)
x) Operating mechanism :
For 132 kV : Motorized as well as manually operated. The motorized

operation shall be both by local panel as well as by
remote panel.
For 33 kV : Manually operated cranking type
xi) Type : OFF-LOAD, three phase, gang operated,

horizontal double break with centre post
rotating type
xii) Installation Outdoor suitable for horizontal

up right mounting on steel/
civil structures
xiii) Earthing switch As required As required
xiv) Interlock with circuit breaker as standard

practice, requirement.
xv) Control operation Local manual/ Local manual

Remote
xvi) Clearances between earthing to be indicated by the Tenderer

blade and live part at any point
when in operation (Isolator with
earthing blades only)
xvii) Disconnecting and earthing as required as required

blade operating cubicle
xviii) Auxiliary NO/NC contacts of as required as required

required rating in cubicle
xix) IS to be followed
a) IS: 1818 Specification for Alternating current

isolators (Disconnectors) with Earthing
switches (with latest amendments)
b) IS: 9921 Alternate current isolators
c) IS: 2544 Insulators
d) IS: 12063 Degree of protection provided by

enclosures
e) IS: 2629 Recommended practice for hot dip
galvanising of iron and steel.
f) IS: 1573 Electroplated coating of zinc on iron

and steel.
xx) The following list of drawings shall be submitted by the tenderer

after placement of order.
a) GA drawings of 132kV and 33 kV isolators including weight
b) Base assembly details of 132 kV and 33kV isolator
c) Details of porcelain insulators
d) Details showing arrangement for operating mechanism
e) Details of earthing blade and operating mechanism
f) Details of sectional view, clearances etc

g) Details of name plate
xxi) All the type test and routine test certificate as recommended in
relevant IS shall be submitted by the Tenderers along with the
offer.
2.4.1.3 Current Carrying Part
The materials for moving blades and contacts of main switch and
earthing blades and contacts of earthing switch shall be the same.
Cross sectional area of earthing blades and contacts shall not be less
than 50% of cross sectional area of main blade and contacts.
2.4.1.4. Insulators
i) The insulators shall be with solid core insulators only. The insulators
shall be provided with galvanised steel base design for mounting on
the support. The mounting arrangement shall be rigid and self
supporting and without any cross bracing between phases. The
insulators shall be made of homogeneous and vitreous porcelain of
high mechanical and dielectric strength. The glazing of porcelain shall
be of uniform brown or dark brown with a smooth surface to be
arranged to shade away rain water. The porcelain shall be free from
lamination and other flaws or imperfections that might affect the
mechanical or dielectric quality.
ii) A cap shall be provided on top of the insulator and shall be of high
grade cast / malleable steel casting or aluminum alloy. It shall be
machine faced and hot dip galvanised.
2.4.1.5 Operating Mechanism
i) Motorised operating as well as manual operating mechanism shall be

provided for 132 kV isolators. The motorized operation shall be both by
local panel as well as remote panel. The 33 kV rated isolator shall be
with manual operating mechanism and gang operated through a crank
and reduction gear shall be provided for main switch.
ii)The main switch shall be completely closed or opened with about 20

revolutions of cranking. Manual operating mechanism gang operated
through a lever /handle on operating shaft shall be provided for earth
switch.
iii) The operating mechanism shall provide quick, simple and effective
operation. The design shall be such that one person shall be able to
operate the isolator without undue effort. The earth switch shall close
or open by rotation of lever through 90 degrees. The operating
mechanism shall be suitable to hold the main switch or earth switch in
closed or opened position and shall not change due to gravity, wind,
short circuit, vibration, seismic acceleration, shock, accidental touching

etc.
2.4.1.6 Gear
i) The disconnecting switches may be required to operate occasionally

with considerably long idle intervals. Special care shall be taken for
selection of materials for gear and lubrication of gears to meet this
requirement .The gears shall be lubricated with graphite or better
quality non-draining and non-hardening grease.
2.4.1.7. Gland Plate and Glands
A removable gland plate with double compression type brass cable

glands shall be provided with each operating mechanism for
terminating all cables.
2.4.1.8 Auxiliary Contact
i) Each operating mechanism shall be equipped with sufficient number

of reliable NO and NC contacts for use with interlock and protection
schemes. The contacts shall be rated for 10 A continuous current
carrying.
ii) The requirement of auxiliary contacts of the isolators shall be that
they should close before the main contact (primary) closes and shall
open after the main contact opens. A full- proof operation to this effect
shall be carried by actuation through a cam directly mounted on the
isolation shaft.
2.4.1.9 Control Cabinet
The control cabinet of each operating mechanism shall be made out of

12 SWG sheet steel or 10 mm thick aluminum in the form of plate or
casting. Control cabinet shall be provided with hinged door along with
pad-locking arrangement. Suitable gasket shall be provided to ensure
degree of protection of IP 55 or better as per IS 12063. The cabinet
shall be suitable for fixing on support structure with adjustment for
vertical, horizontal and longitudinal alignment.
2.4.1.10 Interlocking
The main switch and main switch with earth switch are required to be
interlocked with associated switch gear and protection schemes
through auxiliary contacts. Mechanical interlocking shall be provided
between main switch and earth switch. Electrical interlocking shall be
suitable for 110V DC supply. It shall be possible to lock isolator when in
de-energised condition. It shall also be possible to engage the crank for
operation by energising the device through a push button, only when all
interlocking contacts are through.
2.4.1.11 Accessories
Following accessories shall be provided with each isolator:
i) Position Indicator: A position indicator at site to show whether the

isolator is in ON or in OFF position
ii) Counter Balancing Spring: Counter balance springs, cushions etc

shall be provided to prevent impact at the end of travel both on
openings and closing of the isolator. The springs shall be made of long
durable and non rusting type alloy.
iii) Name Plate: Each isolator shall be provided with a name plate
which is weather proof and corrosion proof. Name plate shall be
provided for the isolator and for operating mechanism with the following
data:
a) Isolator: Name of the manufacturer, type, serial number, rated

voltage, rated current, rated short time current with duration in
seconds.
b) Operating Mechanism: Name of the manufacturer, type, motor

power, reduction gear ratio, number of revolutions for one CLOSE or
OPEN operation, quantity of auxiliary contacts with ratings, quantity of
terminal blocks with rating.
iv) Padlocking Device: Each isolator and earthing switch shall be

provided with padlocking of the isolator and earthing switch in both fully
OPEN and fully CLOSE position.
2.4.1.12 Signaling
i) Signaling of the close position shall not take place unless the
movable contact has set in position in which the rated normal current,
the short time withstand current and the peak withstand current can be
carried safely.
ii) Signaling of open position shall not take place unless the movable
contact has reached the position such that the clearance between the
contacts is at least 80% of the isolating distance.
2.4.1.13 Tests
i) Type Test
The equipment/material offered shall be type tested successfully in line

with standards and Technical Specifications.
ii) Routine Tests & Acceptance Tests
All routine tests and acceptance tests as stipulated in relevant Indian

Standards shall be carried out by the Tenderer in presence of
Employers representative.
Mechanical operation test (routine test) shall be conducted on the

complete isolator at manufacturers works. The certified test report
shall be furnished by the Tenderer along with the offer.
Power frequency voltage withstand test on insulators shall be

conducted by the Tenderer along with the offer.
iii) Special Tests
Special tests on insulators and operation tests on operating

mechanism and interlock as per relevant Standards shall be carried out
by the Tenderer at manufacturers works free of cost and in presence
of Employers representative.
2.4.1.14 Inspection
The inspection may be carried out by the Employer at any stage of

manufacture at manufacturers works. The Tenderer shall make
arrangement for grant of free access to Employers representative at
reasonable time.
2.4.2.0 SPECIFICATION OF 132 kV/33 kV LIGHTNING ARRESTER
2.4.2.1 The parameters of the lightning arrester /Surge Arrestor are as given
below:
132 kV 33kV
i) Type : outdoor installation, single phase, single

column construction,station-class,heavy duty
ii) Mounting : Self supporting, mounting on pedestal
iii) Nominal system voltage: 132kV 33kV
iv) Highest system voltage: 145kV 36kV
v) Phase : 3 phase 3 phase
vi) Frequency : 50Hz 50Hz
vii) System neutral earthing : Effectively earthed neutral
viii) Connection Phase to Earth
ix) Ratio of switching impulse 2:1 2:1

residual voltage to rated
voltage of arrester
x) Minimum prospective symmetrical: 31.5 kA 25 kA

fault current for pressure relief test
xi) Take off Horizontal Horizontal
xii) Rated arrester voltage 120 k 30 kV
xiii) Minimum power frequency 228kV 66kV

spark over voltage
xiv) Nominal discharge current (peak) 10 kA 10 kA

for 8/20 micro sec wave
xv) Maximum residual voltage with 400 kV 108 kV

8/20 micro sec. wave at 10 kA
discharge current
xvi) Pressure relief valves Required Required
xvii) High current impulse 4 / 10 100 kA 100 kA

micro seconds in amps
xviii) Surge monitor/ counter required not required
xviii) Fittings and accessories All necessary fittings and accessories

as per IS are to be provided
xix) IS to be followed:
a) IS: 3070(Part I) Specification for lightning arrester for

alternating current system
b) IS: 4004 Application guide for non-linear

resistor type lightning arrester for
alternating current system
c) IS: 2070 Method of Impulse voltage testing
d) IS: 5621 Specification for large hollow

insulators for use in electrical
installation
e) IS: 12063 Classification of degree of protection

provide by enclosures electrical
equipment.
xx) The following drawings shall be submitted by the Tenderer after

placement of order.
a) GA drawing of 120 kV Lightning Arrester with weight
b) GA drawing of 30 kV Lightning Arrester with weight
c) Base assembly details of 120 kV and 30 kV Lightning Arrester
d) GA and sectional view of porcelain insulations
e) Details of grading rings
f) Details of recommended minimum clearances
g) Details of pressure relief arrangement
h) Details of terminal plate for Lightning Arrester
xxi) The following test certificates shall be submitted by the tenderer along
with the supplies
a) Wet power frequency voltage test for 120 kV and 30 kV Lightning

Arrester
b) Lightning impulse voltage withstand test for 120 kV and 30 kV Lightning

Arrester
c) Switching surge voltage withstand test for 120 kV LA
d) Residual voltage test for 120 kV and 30 kV LA
e) Long duration current impulse withstand test
f) Operating duty test for 120 kV and 30 kV LA
g) High and low current pressure relief test for 120 kV and 30 kV LA
h) Artificial pollution test
2.4.2.2 Requirements
i) The specification given above, cover design, manufacture, assembly,

testing at manufactures works for the referred surge arresters. Surge
arresters shall conform in respect of highest standard of design and
workmanship. The arresters offered shall be complete with all parts and
accessories necessary for their effective and trouble free operation over
the years.
ii) The surge arrester shall be fitted with pressure relief devices and diverting
ports and shall be tested as per the IS provisions for minimum
prospective symmetrical fault current of 31.5 kA and 25 kA r.m.s. for 132
kV and 33 kV lightning arresters respectively.
iii) A grading ring shall be provided, if necessary, on each complete arrester

for proper stress distribution.
iv) Each individual unit of surge arrester shall be hermitically sealed and fully
protected against ingress of moisture. The hermetic seal shall be
effective for the entire life time of the arrester and under specified service
conditions.
v) The surge arrester shall be suitable for hot line washing.
vi) The corresponding units of arresters of the same rating shall be inter
changeable without adversely affecting the performance.
vii) The surge arrester shall be suitable for pedestal type of mounting
viii) The 132kV lightning arrester shall be provided with surge monitor/
counter
2.4.2.3 Polymeric Housing
i) Polymeric housing shall be free from lamination cavities or other flaws

affecting the mechanical and electrical strengths.
ii) The polymeric shall be thoroughly vitreous and non-porous.
iii) The grounding terminals shall be suitable for connection to earth mat/
earth electrode.
2.4.2.4 Tests
i) All the type tests as per IS shall be carried out by the Tenderer at
manufacturers works at the cost of Tenderer. Employer may like to
depute his representative for the tests. If already type tested, certified
copies of type tests shall be submitted by the Tenderer along with the
supplies.
ii) The certified pollution test shall be carried out as per IS provisions.
iii) All routing and acceptance tests as stipulated in the IS shall be carried
out by the Tenderer at manufacturers works in presence of Employers
representative at the cost of Tenderer.
2.4.3.0 SPECIFICATIONS OF CURRENT TRANSFORMERS
2.4.3.1 General
The specification covers design, manufacture, assembly, testing

at manufacturers works, packing and delivery of outdoor
Instrument Transformers for protection and metering services in
132/33 kV substation. All 132 kV instrument transformers shall be
out door type, single phase, oil immersed , self cooled and shall
be supplied with first filling of insulating oil and 33 kV instrument
transformers shall be out door type, single phase, oil immersed
type.
It is not the intent to specify completely herein all details of the

design and construction of equipments. However the
equipment shall conform in all respects to high standards of
engineering, design and workmanship and specifications
mentioned in and shall be capable of performing in continuous
commercial operation up to the Contractors guarantee in a
manner acceptable to the Employer, who will interpret the
meanings of drawings and specification and shall have the
power to reject any work or material which, in his judgment, is
not in accordance with their specifications. The equipments
offered shall be complete with all components necessary for
their effective and trouble free operation. Such components
shall be deemed to be within the scope of Contractors supply,
irrespective of whether those are specifically brought out in this
specification or not.
2.4.3.2 Technical Parameters for 132 kV and 33 kV Current Transformers

(CT)
132kV 33 kV
i) Nominal system voltage : 132 kV 33kV
ii) Highest system voltage : 145 kV 36 kV
iii) No. of phases and frequency : --- 3 phase, 50 Hz ---
iv) System neutral Earthing : - effectively earthed neutral
v) Type : - outdoor type, outdoor type,

single phase, oil single phase,
immersed, self oil immersed
cooled, dead tank, self cooled
hermetically sealed
vi) Cores : 5 core 3 core & 2 core
vii) Ratio selection : ------------ on secondary -------------
viii) Type of mounting : Pedestal type
ix) Ratio taps : Achievable by primary side

re connection
x) Rated continuous current : 1.2 continuous and 1.5 for 3 sec.
xi) Acceptable partial discharge

level at 1.1 times the rated
voltage : Less than 10 Pc
xii) Transformation Ratio :

(Indicative)
a) Core-I 1A-1A-1A-1A-1A 1A-1A-1A

b) Core-II 1A-1A
c) Core-III
d) Core- IV
e) Core- V
xiii) Rated insulation class : 145kV 36 kV
xiv) Basic insulation level
a) One minute power : 275 kV (rms) 70 kV (rms)

frequency withstand voltage
b)Lightning impulse : 650 kV(peak) 170 kV(peak)
withstand voltage
xv) Rated short time current for 3 sec. 31.5kA 25 kA
xvi) Class of accuracy & purpose: As per system description at 2.2.6.1
xvii) Saturation factor : 3.5: 15: 15
xviii) Rated burden on each winding: 30 VA 30 VA
xix) Rating of transformer : 40 (ONAN) / 50 (ONAF) MVA,

132 kV/33 kV
xx) Fittings and accessories : All necessary fittings and accessories

shall be provided
xxi) IS to be followed:
a) IS: 2705 : Specification for Current

Transformers (Part I-IV) (with latest
amendments)
b) IS: 2165 : Insulation Co ordination .
c) IS: 2099 Bushings for alternating voltage

above 1000 volts
d) IS: 3347 : Dimensions of Porcelain Transformer

Bushings for using highly polluted
atmosphere.
e) IS: 12063 : Classification of degrees of

protection provided by enclosures of
electrical equipment
f) IS: 2071 : Method of High Voltage Testing
g) IS: 335 : Insulation oil for Transformer

and switch gear
h) IEC: 185 : Current Transformers
i) IEC: 270 : Partial Discharge Measurement
j) IEC: 815 : Porcelain Housing for Instrument

Transformer
k) IEC: 171 : Insulation Co-ordination
l) IEC: 60 : High Voltage Test Techniques
m) IEC: 8263 : Method of RIV Test on High

Voltage Insulators
2.4.3.3 Recommended Spares
The Contractor shall furnish in his offer, a list of recommended spares

with unit rates for each rating of Instrument Transformer for a period of
two years. The Employer reserves the right for selection of items and
quantities of these spares if to be ordered. The costs of such spares
will not be considered for Tender evaluation.
2.4.3.4 Service requirements.
Equipment to be supplied against this specification shall be suitable for

satisfactory continuous operation over the years.
2.4.3.5 Standards
i) Unless otherwise specified elsewhere in this specification, the rating,

performance and testing of the instrument transformers and
accessories shall conform to the latest revisions of Indian Standards.
ii) Equipment meeting with the stipulations of equivalent IEC, ANSI,

CSA, DIN standards, which ensure equal or better quality than the
standards listed elsewhere shall also be acceptable. In such case the
Contractor should submit along with his offer, two copies of such
standards in authentic English translation, if the case of dispute, the
stipulations in the English translation, submitted by the Contractor,
shall prevail. Further, in the event of conflict between the stipulations of
the standard adopted by the Contractor and the corresponding Indian
Standard specification, the stipulation of Indian Standard specification
shall prevail.
2.4.3.6 Principal Parameters
The Current transformers covered in this specification shall meet the

technical requirements listed here after.
2.4.3.7 Surface Finish
The metal tanks shall be coated with at least two coats of Zinc rich
epoxy painting. All the ferrous hardware, exposed to atmosphere, shall
be hot dip galvanised .All other fixing nuts, bolts, washers shall be
made out of Stainless Steel
2.4.3.8 Insulating Oil
Insulating oil required for first filling of the instrument transformers shall
be covered in Contractors scope of supply. The oil shall meet the
requirements of latest edition of IS 335.
2.4.3.9 Prevention of Oil Leakage and Entry of Moisture.
i) As specified elsewhere in this specification, the Instrument

Transformers shall be guaranteed for a trouble free and maintenance
free performance for a period as specified elsewhere in this document.
Therefore, the Contractor shall ensure that the sealing of Instrument
Transformers is properly achieved. In this connection the arrangement
provided by the Contractor at various locations including the following
ones shall be described and supported by sectional drawings.
a) Locations of emergence of primary and secondary terminals.
b) Interface between porcelain housing and metal tanks
c) Cover of the secondary terminal box.
ii) Nuts and bolts or screws used for fixation of the interfacing porcelain
bushings for taking out terminals shall be provided on flanges
cemented to the bushings and not on the porcelain.
iii) For joints with gaskets wherever used Nitrite Butyl rubber gaskets
shall be used. The gasket shall be fitted in properly machined groove
with adequate space for accommodating the gasket under
compression.
2.4.3.10 Oil Level Indicators
i) Instrument transformer provided with nitrogen cushion for

compensation of oil volume variation shall be provided with prismatic
type oil sight window at suitable location so that the oil level is clearly
visible with naked eye to an observer standing at ground level. If metal
bellow is used for the above purpose, a ground glass window shall be
provided to monitor the position of metal bellow.
ii) For compensation of variation in volume of the oil due to temperature

variation, nitrogen cushion or Stainless Steel bellow shall be used.
Rubber diaphragms shall not be used for this purpose.
2.4.3.11 Earthing
i) Metal tank of the Instrument Transformer shall be provided with two

separate earthing terminals for bolted connection to 50 x 8 mm MS flat
for connection to station earth-mat.
ii) Instrument Transformers shall be provided with suitable lifting

arrangement to lift the entire unit. Lifting arrangement (lifting eye) shall
be positioned in such a way so as to avoid any damage to the
porcelain housing or the tanks during the process of lifting for
installation/transport. The general arrangement drawing shall show
clearly the lifting arrangements provided such a lifting eye, guide etc.
2.4.3.12 Name Plate
The name plate of Instrument Transformer shall be provided with photo

finish type plate legible with the information specified in relevant
standards, duly engraved/punched on it.
2.4.3.13 Terminal Connectors
i) The terminal connectors required for connection of the Instrument

Transformer shall be an integral part of the instrument transformers.
These terminal connectors shall be suitable for connection to ACSR
conductor.
ii) The current density adopted for the design of terminal connector
(TC) shall in no case exceed 1.6 A/ sq mm for copper and 1.0 A/ sq
mm for terminal contactor made of other material.
iii) For conductor insulation, the insulating materials shall meet the
requirements as per IS: 4800
2.4.3.14 Current Transformer (CT)
i) The CT shall be of dead tank design and shall be so constructed that

it can be easily transported to site within the allowable transport
limitations. The current transformers shall be preferably suitable for
horizontal transportation.
ii) The CT secondary terminals shall be brought out in a weather proof

terminal box. The terminal box shall be provided with removable gland
plate and glands. The cable glands shall be suitable for 1100 volts
grade, PVC insulated, PVC sheathed multi core stranded copper
conductor PVC cable of required size. The terminal box shall be dust
and vermin proof. Suitable arrangement shall be provided for drying of
air inside the secondary terminal box. The dimensions of the terminal
box and its opening shall be adequate to enable easy access and
working space with use of normal tools.
iii) Polarity shall be marked on each primary and secondary terminal.

Facility shall be provided for short circuiting and grounding of the CT
secondary terminals inside the terminal box.
iv) The CT shall be provided with a rating plate with dimensions and
markings as per IS 2705. The markings shall be punched and not
painted.
v) The Current Transformer shall be filled with oil after processing and
thereafter hermetically sealed to eliminate breathing and to prevent air
and moisture from entering into the tanks. Oil filling or oil sampling
cocks, if provided to facilitate factory processing, should be
permanently sealed before despatching the Current Transformer. The
method adopted for hermetic sealing shall be described in the offer.
vi)The castings of base, collar etc. shall be die-cast and tested before
assembly to detect cracks and voids if any.
vii) The instrument security factor of metering core shall be low enough
but not greater than 5. This shall be demonstrated on all the ratios of
the metering core, in accordance with procedure specified in IEC 185
or IS: 2705.
2.4.3.15 Primary Winding
i) Primary winding shall be hair pin type or wound type made out of
high conductivity copper. The Contractor may also offer CT with bar
type primary with inverted arrangement of construction, if considered
more appropriate. Specific reasons for selection of a particular
metal/alloy and its merits shall be clearly brought out in the offer.
Conductors used for the primary winding shall be rigid or housed in
rigid metallic shell. Unavoidable joints in the primary winding shall be
welded type. The details of such welded joints shall be indicated in the
drawings submitted. For primary winding current densities shall not
exceed the following limits for normal current:
If copper is used - 1.65 A/sq mm

For other material used - 1.0 A/sq mm
ii) The design density for short circuit current as well as conductivity of
the metal used for primary winding shall meet the requirement of IS
2705. The Contactor shall submit detailed calculations for selection of
winding cross sections at the time of approval of the drawings.
iii) The primary winding shall be designed for extended primary current
at 120% of rated primary current.
2.4.3.16 Secondary Windings
i) Suitably insulated Copper wire of electrolytic grade shall be used for

secondary windings. Type of insulation used shall be described in the
offer. Ratio selection shall be provided on the secondary side as
mentioned in the scope of work for 132 & 33 kV
ii) The exciting current of the CT shall be as low as possible. The

Contractor shall furnish along with his offer the magnetization curves
for all the core/s
2.4.3.17 Primary Terminals
i) The primary terminals shall be of standard size of 30 mm diameter,

80 mm length for all CTS. The primary terminals shall be of heavily
tinned electrolytic copper or aluminum of 99.9 % conductivity.
2.4.3.18 Secondary Terminals
i) Secondary terminal studs shall be provided with at least three nuts

and adequate plain and spring washers for fixing the leads. The studs,
nuts and washers shall be of brass, duly nickel plated. The minimum
out side diameter of the studs shall be 6 mm. The length of at least 15
mm shall be available on the studs for inserting the leads. The
horizontal spacing between centers of the adjacent studs shall be at
least 1.5 times the outside circum diameter of the nuts.
ii) The current transformer shall be provided with suitable test tap for
measurement of capacitance, tan delta as well as partial discharges, in
factory as well as at site. Provision shall be made of a screw on cap
for solid and secured earthing of the test tap connection when not in
use. A suitable caution plate shall be provided duly fixed on the cover
of the secondary terminal box indicating the purpose of the test tap and
necessity of its solid earthing as per prescribed method, before
energizing the C.T.
iii) Facilities shall be provided at the terminal blocks in the control

cabinets for series/parallel connection and star/delta formation of CT
secondary windings.
iv) Current Transformer characteristics shall be such as to provide

satisfactory performance for burdens ranging from 25% to 100% of
rated burden over a range of 10% to 100% of rated current in case of
metering Current Transformers and up to the accuracy limit factor/knee
point voltage in case of relaying Current Transformers.
v) All Current Transformers shall be provided with two terminal studs

per pole. Expansion chamber at the top of porcelain insulator should
be suitable for expansion of oil and have provision for primary
terminals.
vi) The following accessories/fittings shall be supplied along with the

Current Transformers.
a) Pressure release device.
b) Oil level indicator
c) Lifting lugs
2.4.3.19 Type Tests
All the equipments offered, shall be fully type tested as per relevant
standards. The Employer reserves the right to demand repetition of
some or all the type tests in the presence of Employers
representatives. For this purpose the cost of the test has to be born by
the Contractor.
2.4.3.20 Acceptance and Routine Tests
All acceptance and routine tests as stipulated in the relevant standards

shall be carried out by the Contractor in the presence of Employers
representative.
2.4.3.21 Additional Tests
Additional tests as listed below, if necessary, may be required to be

carried out in the presence of Employers representative, unless they
are waived off by the Employer. Irrespective of whether specified in
the relevant standards, one instrument transformer of each rating and
type shall be leak tested, preferably under fully assembled condition.
The pressure of testing shall be adequately above the normal operating
pressure. The facilities available for testing and method of leak testing
normally adopted by the Contractor shall be clearly described in the
offer.
2.4.3.22 List of Additional Tests
Sl.no. Name of the test Standards to which

conforms
1. High voltage power frequency wet withstand IS: 2705
voltage test on C.T. (Special test)
2. Commissioning test i) Ratio test
ii) Frequency test
iii) Insulation
Resistance
test
3. Partial Discharge Test (Special) IEC: 44 (4)-1980
(To be carried out as acceptance test. The
method is described below)
The test circuit for the measurement of partial

discharge (PD) shall be in accordance with sub
clause 4.2 of IEC:270-1968.The PD test shall be
carried out after all tests are completed. The
applied voltage shall be raised to rated voltage of
the CT and shall be maintained for a period greater
than or equal to 10 seconds. The voltage shall then
be reduced to measuring Voltage of 1.1 x rated
voltage of CT of rms phase / 3
to ground and maintained for a period greater than
or equal to 1 minute. The PD level shall not exceed
10 pico columbs
2.4.3.22 List of Drawings and Documents
The various drawings as specified elsewhere given in this document

shall be arranged.
2.4.4.0 SPECIFICATIONS OF POTENTIAL TRANSFORMERS
2.4.4.1 General
i) The specification covers design, manufacture assembly, testing at

manufacturers works, packing and delivery of outdoor Instrument
Transformers for protection and metering services in 132/33 kV
substation. All 132 kV instrument transformers shall be out door type,
single phase, oil immersed , self cooled and shall be supplied with first
filling of insulating oil and 33 kV instrument transformers shall be out
door type, single phase, Oil immersed type ,tank type .
ii)It is not the intent to specify completely herein all details of the design
and construction of equipments. However the equipment shall conform
in all respects to high standards of engineering, design and
workmanship and specifications mentioned and shall be capable of
performing in continuous commercial operation up to the Contractors
guarantee in a manner acceptable to the Employer, who will interpret
the meanings of drawings and specification and shall have the power
to reject any work or material which, in his judgment, is not in
accordance their with. The equipments offered shall be complete with
all components necessary for their effective and trouble free operation.
Such components shall be deemed to be within the scope of
Contractors supply, irrespective of whether those are specifically
brought out in this specification or not.
2.4.4.2 Technical Parameters of 132 kV and 33 kV Potential Transformer

(PT)
132 kV 33kV
i) Type - Single phase, Single phase,

outdoor type, outdoor type,
oil immersed, oil immersed , oil
self cooled type,tank
type, self cooled
ii) Type of mounting - Independent pedestal mounted
iii) Nominal system voltage 132 kV 33kV
iv) Highest system voltage 145 kV 36 kV
v) Insulation level
a) One minute power 275 kV (rms) 70 kV rms

frequency with stand voltage
b) Lightning impulse 650kV (peak) 170 kV (peak)

with stand voltage
vi) System neutral earthing -Effectively earthed neutral

vii) Frequency ---50 Hz-----
viii) No. of phases -----3-----
ix) Rated voltage factor - 1.2 continuous, 1.5 for 3 sec
x) Voltage transformation 132000V 110 V 33000V 110 V

------------ / ------ ,--------- / -------
3 3 3 3
xi) Rated burden on each 100 VA 100VA

on each winding
xii) Insulation level -- B --
xiii) Accuracy class ---- Measuring 0.5, Protection 3P ---
xiv) Accessories - As required to be indicated by the

Tenderer
xv) IS to be followed:
a) IS: 3156 Specification for voltage Transformers

(Part I-IV)
b) IS: 4201 Application guide for voltage

transformers
c) IS: 2099 Specification for High Voltage Porcelain

Bushings
d) IS: 3347 Dimensions of Porcelain Transformer

Bushings
e) IS: 335 Insulating oil for Transformer and

Switchgear
f) IS: 3202 Code of practice for Climate Proofing of

Electrical Equipment
g) IEC: 186 Voltage Transformers
h) Indian Electricity Rules, 1956 (with latest Amendments)

with unit rates for each rating of Instrument Transformer for a period of
two years. The Employer reserves the right for selection of items and
quantities of these spares if to be ordered. The costs of such spares
will not be considered for tender evaluation.
2.4.4.4 Service Requirements
Equipment to be supplied against this specification shall be suitable for

satisfactory continuous operation over the years.
2.4.4.5 Standards
i) Unless otherwise specified elsewhere in this specification, the rating,

performance and testing of the instrument transformers and
accessories shall conform to the latest revisions of Indian Standards.
ii) Equipments meeting with the stipulations of equivalent IEC, ANSI,

CSA, DIN standards, which ensure equal or better quality than the
standards listed elsewhere shall also be acceptable. In such case the
Contractor should submit along with his offer, two copies of such
standards in authentic English translation, if the case of dispute, the
stipulations in the English translation, submitted by the Contractor,
shall prevail. Further, in the event of conflict between the stipulations of
the standard adopted by the Contractor and the corresponding Indian
standard Specification, the stipulation of Indian Standard specification
shall prevail.
2.4.4.6 Principal Parameters
The Potential Transformers covered in this specification shall meet the

technical requirements listed here after.
The metal tanks shall be coated with at least two coats of Zinc rich
epoxy painting. All the ferrous hardware, exposed to atmosphere, shall
be hot dip galvanised. All other fixing nuts, bolts, washers shall be
made out of Stainless Steel
2.4.4.8 Insulating Oil
Insulating oil required for first filling of the instrument transformers shall
be covered in Contractors scope of supply. The oil shall meet the
requirements of latest edition of IS 335.
2.4.4.9 Prevention of Oil Leakages and Entry of Moisture
i) As specified elsewhere in this specification, the Instrument

Transformers shall be guaranteed for a trouble free and maintenance
free performance for a period as specified elsewhere in this document.
Therefore, the Contractor shall ensure that the sealing of Instrument
Transformers is properly achieved. In this connection the arrangement
provided by the Contractor at various locations including the following
ones shall be described and supported by sectional drawings.
a) Locations of emergence of primary and secondary terminals.
b) Interface between porcelain housing and metal tanks
c) Cover of the secondary terminal box.
ii) Nuts and bolts or screws used for fixation of the interfacing porcelain
bushings for taking out terminals shall be provided on flanges
cemented to the bushings and not on the porcelain.
iiii) For gasketed joints wherever used Nitrite Butyl rubber gaskets shall
be used. The gasket shall be fitted in properly machined groove with
adequate space for accommodating the gasket under compression.
2.4.4.10 Oil Level Indicators
i) Instrument transformer provided with nitrogen cushion for

compensation of oil volume variation shall be provided with prismatic
type oil sight window at suitable location so that the oil level is clearly
visible with naked eye to an observer standing at ground level. If metal
bellow is used for the above purpose, a ground glass window shall be
provided to monitor the position of metal bellow.
ii) For compensation of variation in volume of the oil due to temperature

variation, nitrogen cushion or Stainless Steel bellow shall be used.
Rubber diaphragms shall not be used for this purpose.
2.4.4.11 Earthing
i) Metal tank of the Instrument Transformer shall be provided with two

separate earthing terminals for bolted connection to 50 x 8 mm MS flat
for connection to station earth-mat.
ii) Instrument Transformers shall be provided with suitable lifting

arrangement to lift the entire unit. Lifting arrangement (lifting eye) shall
be positioned in such a way so as to avoid any damage to the
porcelain housing or the tanks during the process of lifting for
installation/transport. The general arrangement drawing shall show
clearly the lifting arrangements provided such a lifting eye, guide etc.
2.4.4.12 Name Plate
The name plate of Instrument Transformer shall be provided with

photo finish type plate legible with the information specified in
relevant standards, duly engraved/punched on it.
2.4.4.13 Terminal Connectors
i) The terminal connectors required for connection of the Instrument

Transformer shall be an integral part of the instrument transformers.
These terminal connectors shall be suitable for connection to ACSR
conductor.
ii) The current density adopted for the design of terminal connector
(TC) shall in no case exceed 1.6 A/sq mm for copper and 1.0 A/sq mm
for T.C. made of other material.
iii) For conductor insulation, the insulating materials shall meet the
requirements as per IS: 4800
2.4.4.14 Potential Transformer (PT)
i) The P.T. shall be filed with oil after processing and hermetically
sealed to eliminate breathing and to prevent air and moisture from
entering the tanks. Method adopted for hermetic sealing shall be
described in the offer. Oil filling and/or oil sampling cocks, if provided
to facilitate factory processing shall be permanently sealed before
dispatching the P.T.
ii) The P.T. shall be so constructed that it can be easily transported to

site within the allowable transport limitations, and in horizontal position
if the transport limitations so demand.
2.4.4.15 Primary Winding
Primary winding shall be of suitably insulated electrolytic, copper wire.

Type of insulation used, shall be described in the offer.
2.4.4.16 Secondary Winding
i) Suitably insulated Copper wire of electrolytic grade shall be used for

secondary windings. Type of insulation used shall be described in the
offer. The secondary windings of the Potential Transformer shall be
protected by two sets of HRC fuses in parallel for each core.
ii) The P.T. Secondary terminals shall be brought out in a weather

proof terminal box. The HRC fuses meant for protection of secondary
windings shall also be located in the terminal box. The terminal box
shall be provided with removable gland plate and glands suitable for
1100 volts grade, PVC insulated, PVC sheathed multi core stranded
copper cable of required size. The terminal box shall be dust and
vermin proof. Suitable arrangement shall be provided for drying of air
inside the terminal box. The dimensions of the opening of the terminal
box shall be adequate to enable easy access and working space with
the use of normal tools.
iii) Polarity shall be invariably marked on each Potential Transformer at

the secondary terminals in the terminal box.
iv)The P.T. shall be provided with a rating plate with dimensions and
markings as per IS 3156. The markings shall be punched and not
painted.
2.4.4.17 Primary Terminals
The primary terminal shall be of standard size of 30 mm diameter x 80

mm length for all PTs. The primary terminals shall be of heavily tinned
electrolytic Copper of Aluminum alloy of 99.9% conductivity.
2.4.4.18 Secondary Terminals
For external connection of secondary windings, terminal studs shall be

provided with at least three nuts, plain and spring washers. The studs,
nuts and washers shall be of brass properly nickel plated. The size of
the studs shall be 6 mm outside diameter. A length of at least 15 mm
shall be available on the studs for inserting the leads. Horizontal
spacing between centers of the adjacent studs shall be at least 1.5
times the circum diameter of the nuts.
2.4.4.19 Type Tests
All the equipments offered, shall be fully type tested as per relevant
standards. The Employer reserves the right to demand repetition of
some or all the type tests in the presence of Employers
representatives. The cost of the test shall be born by the Contractor.
2.4.4.20 Acceptance and Routine Tests
All acceptance and routine tests as stipulated in the relevant standards

representative.
2.4.4.21 Additional Tests
Additional tests as listed below, if necessary, may be required to be

carried out in the presence of Employers representative, unless they
are waived off by the Employer. Irrespective of whether specified in
the relevant standards, one instrument transformer of each rating and
type shall be leakage tested, preferably under fully assembled
condition. The pressure of testing shall be adequately above the
normal operating pressure. The facilities available for testing and

method of leak testing normally adopted by the Contractor shall be
clearly described in the offer.
2.4.4.22 List of Additional Tests
Sl.no. Name of the Test Standards to which conforms

(A) Potential Transformer
1. High voltage power frequency withstand IS: 3156

voltage test on outdoor type Potential
Transformer.
2. Commissioning test i) Ratio test

ii) Frequency test
iii) Insulation Resistance test
------------------------------------------------------------------------------------------------------
2.4.4.23 List of Drawings and Documents
The various drawings as specified elsewhere in this document.
2.4.5.0 SPECIFICATION OF 132 kV SF6 CIRCUIT BREAKER
2.4.5.1 Scope
i) This specification covers design, manufacture, assembly, testing

before supply, inspection, packing, delivery, at site of outdoor type SF6
circuit breakers of rated insulation class of 132 kV. The circuit breakers
shall be of the following types and shall be complete with all the
accessories and auxiliary equipment required for their satisfactory
operation in 132 kV /33 kV sub station.
ii) It is not the intent to specify, completely here in all the details of design
and construction of the circuit breaker. However, the breaker shall
conform, in all respects to high standards of engineering, design and
workmanship as listed here-after. It shall be capable of performing in
continuous commercial operation up to the Contractors guarantee in a
manner acceptable to the Employer who will interpret the meanings of
drawings and specifications and shall have power to reject any work or
material which, in his judgment, is not in accordance therewith. The
circuit breaker so offered shall be complete with all components
necessary for its effective and trouble-free operation. Such
components shall be deemed to be within the scope of Contractors
supply, irrespective of whether those are specifically brought out in this
2.4.5.2 Technical Parameters of Circuit Breaker
i) Highest System voltage of circuit breaker: 145kV
ii) Nominal system voltage(RMS): 132kV
iii) Rated frequency: --- 50 Hz ---
iv) Rated continuous current: 1250 Amps.
v) Type: SF6 gas filled
vi) Application ----- outdoor ------
vii) Short circuit fault interrupting 7201 MVA

capacity
viii) System neutral earthing -- Effectively earthed --
ix) No. of Poles & No. of 3&2

interruption unit/pole
x) Type of operation Individually three single

poles operated single gang
operated, pole/three
(mechanically poles
coupled)simultaneous
operation
xi) Automatic rapid re-closing -- Not required
xii) Operating duty cycle -- 0-3 min-CO3 minCO
xiii) Mounting -- On hot dip galvanized steel

support structures-
xiv) Basic insulation level (Lightning 650 kV

impulse withstand voltage (peak)
.2 /50 micro seconds.)
xv) One minute power frequency 275 kV

withstand voltage (rms)
xvi) Rated SF6 gas pressure To be supplied by the

Contractor
xvii) Auxiliary AC power -- 240 V AC +/- 5% --

voltage, single phase
xviii) Control circuit voltage -- 110V DC +/- 10% --
xix) Short time current rating for 3 sec. 31.5 kA
xx) (a) Operating mechanism Operating mechanism

shall be spring charge
stored energy type.
Operation control shall
be electrical from remote
as well as local. It shall
be trip free
xxi) Number of closing coils One (Operative from 80%-

110% of nominal voltage)
xxi) Number of shunt trip coil Two
xxii) Terminal connector with -- Two sets --

clamps for ACSR conductor
xxiii) Breaker control cubicle one set for assembly

comprising local/remote selector
switch , SF6 gas density
monitoring gauge with indicator
lamps and potential free out put

contacts for alarm/trip, compressed air
pressure gauge with potential free
output contacts, for alarm, contactor for
the drive motor of the compressor,
indicating lamps for breaker status, closing
and trip coils for breaker, space heater
with control switch and thermostat, socket
with switch for 240 V A.C, .hand lamp,
required number of auxiliary relay/ contactors
/ MCB fuse links etc.
xxiv) Type of breaker control cubicle Remote
xxv) Drive motor operating 80% to

voltage range 110% of
nominal
LT voltage
xvi) IS to be followed:
a) IS: 13118 High voltage Alternating Current circuit Breakers (with

latest amendments)
b) IS: 12063 Classification of degrees of protection provided

c) IS: 325 Specification for 3 Phase Induction Motor
d) IS: 2629 Recommended Practice for Hot Dip Galvanising of Iron

and Steel
e) IS: 4379 Identification of contains of industrial gas cylinder.
f) IS: 7311 Seamless high carbon steel cylinders for permanent and
high pressure liquefiable gases.
g) IEC: 2331 High Voltage Porcelain Bushings
h) IEC: 60 High voltage Test Techniques
i) IEC: 376 Specification and Acceptance of New

Supply of Sulphur Hexafluoride
j) IEC: 71 Insulation Coordination, Terms, Definitions, Principles

Part I & II and Rules
k) Indian Electricity Rules (with latest Amendments)

l) Fire Insurance Regulations
m) The Indian Electricity (Supply) Act
n) National Fire Code
o) DGMS Regulations

with unit rates for each circuit breaker that may be necessary for
satisfactory operation and maintenance of the circuit breaker for a
period of 2 years. The Employer reserves the right of selection of
items and quantities of these spares to be ordered. The cost of such
spares shall not be considered for tender evaluation.
2.4.5.4 Erection and Maintenance Tools
As specified elsewhere in the document.
2.4.5.5 Service Condition
i) Environmental Conditions:
The breakers and accessories to be supplied against this specification

shall be suitable for satisfactory continuous operation under the
following tropical conditions.
a) Maximum ambient temperature

(deg. C) : 50
b) Maximum ambient temperature in

shade (deg C) : 45
c) Minimum ambient temperature

(deg C) : 4
d) Relative Humidity (%) : 10 to 100
e) Maximum Annual rainfall (mm) : 1400
f) Maximum wind pressure (kg/sqm) : 150
g) Isoceraunic level (stormy days

per year ) : 50 (approx.)
h) Moderately hot and humid,

Tropical climate, conducive to rust and
fungus growth : Yes
2.4.5.6 Auxiliary Power Supply
The rating, quality and location of electrical supply system for operation
of the circuit breaker are described below. The auxiliary electrical
equipments provided by the Contractor for specific operation of the

circuit breaker, shall be suitable for operation on the same.
2.4.5.7 Ratings
i) For power devices (SF6 CB) 415 V +/- 5% three phase 4 wire
(drive motors) 50 Hz Neutral grounded AC supply
ii) For AC control & Protective devices, 240 V +/- 5% , single phase, 2
lighting fixtures, space heaters wire, 50 Hz AC supply with one
and fractional h.p. motors point grounded
iii) For DC alarm, control and 2 wire 110 V DC from batteries

protective device.
2.4.5.8 Standards
2.5.8.1 The circuit breaker shall conform to the latest revisions, available at the
time of placement of orders of relevant standards, rules and codes
listed at in this document. Equipments meeting with the stipulations of
equivalent IEC, ANCI, CSA, DIN standards, which ensure equal or
better quality than the standards listed in here after, shall also be
acceptable. In such case the Contractor should submit along with his
offer, two copiers of such standards in authentic English translation, if
the language of the standard is other than English. In case of dispute,
the stipulation in the English translation, submitted by the Contractor
shall prevail. Further, in the event of conflict between the stipulations
of standards adopted by the Contractor and the corresponding Indian
Standards Specification, the stipulation of Indian Standard
Specification shall prevail.
2.4.5.9 General Technical Requirements
i) Similar parts of the breaker, especially the removable ones, shall be

freely interchangeable without the necessity of any modification at site.
ii) The breakers will be required to break small inductive currents and line
charging current without causing excessive over voltage, and charging
current without re-strike. The breaker shall also be required to handle
evolving faults and meet the requirements regarding partial discharge,
radio interference etc, as specified in relevant standards.
2.4.5.10 Breaker Contacts
i) Main contacts shall have ample area and contact pressure for carrying
the rated continuous and short time current of the breaker without
excessive temperature rise which may cause pitting or welding.
Contacts shall be adjustable to allow for wear, shall be easily
replaceable and shall have minimum number of movable parts and
adjustments to accomplish test results, Main contacts shall be the first
to open and the last to close so that there will be little contact burning
and wear. Tips of main contacts shall be silver plated.
ii) Arcing contacts, if provided, shall be the first to close and the last to
open and shall be easily accessible for inspection and replacement.
The arcing contacts shall have tungsten alloy tipping
iii) In the case of multi break interrupters, they shall be so designed and
augmented that a fairly uniform voltage distribution is developed across
them.
iv) The inside operating rod or insulated fiber glass connecting rods
wherever used, shall be sturdy and shall not break during the entire life
period of the breaker. The insulated rods shall have anti-tracking
quality towards electrical stresses.
2.4.5.11 Take off Terminals Pads
i) Terminal pads shall be provided with silver plating of required thickness

if these are made of metal other than aluminum. A certificate to this
effect is to be furnished. No such plating shall be required if the
terminal pad is made out of aluminum. The pads shall be suitably
designed to take the terminal loads. The terminal connectors required
for connecting the Circuit Breaker to Bus Bars shall be suitable for
mounting on aforesaid terminal pad.
ii) The breaker shall be designed to withstand the rated terminal load,
wind load/Earth quake load and short circuit forces. The short circuit
forces to be considered or the design shall be based on length of bus
bar consisting of conductors and phase to phase spacing.
iii) The current density adopted for the design of the terminal pad shall in
no case exceed 1.6A/sq .mm for copper pad and 1.0 A/sq .mm for pad
made of other material.
iv) The vertical clearance of lowest terminal pad from ground level
(including concrete foundation plinth) shall be approximately 4.6 m
2.4.5.12 Porcelain Housing
The porcelain housing for the interrupter shall be of a single piece

construction without any joint. It shall be made of homogeneous,
vitreous porcelain of high mechanical and dielectric strength. Glazing
of porcelain shall be of uniform brown or dark brown colour with a
smooth surface arranged to shed away rain water or condensed water
particles (fog).
2.4.5.13 Support Insulator
Breaking units shall be mounted on insulator column of multiple

insulators of suitable rating and size in each column
All metal surfaces exposed to atmosphere shall be given two primer

coats of zinc phosphate and two coats of epoxy paints with epoxy base
thinner. All metal parts not accessible for painting shall be made of
corrosion resisting material. All machine finished or bright surfaces
shall be coated with a suitable preventive compound and suitable
wrapped or otherwise protected. All paints shall be carefully selected
to withstand tropical heat and extremes of weather within the limits
specified. The paints shall be battleship gray shade no. 632 of IS 5.
The paint shall not scale off or wrinkle or be removed by abrasion due
to normal handling. All components shall be given adequate treatment
of climate proofing as per IS:3202, so as to withstand corrosion.
2.4.5.15 Galvanising
All ferrous parts including nuts, bolts, plain and spring washers of M10
and above, support channels, structures, etc. shall be hot dip
galvanised to conform to latest version of IS 2629 or any other
equivalent authoritative standard. All other fixing nuts, bolts washers of
size below M 10 shall be made out of stainless steel
2.4.5.16 Earthing
The operating mechanism housing, support structures etc. shall be

provided with two separate earthing terminals for bolted connection to
50 x 8 mm MS flat for connection to station earth mat. The connecting
point shall be marked with earth symbol.
2.4.5.17 Name and Rating Plate
i) Circuit breaker and its operating device shall be provided with rating
plate made out of photo finish type plates, marked with the following
data. The data shall be either punched or engraved on the plate and
name plate surface should be coated with colour less epoxy powder.
a) Manufacturers name or trade mark by which he may be readily

identified.
b) Serial number and type designation
c) Year of manufacture
d) Rated voltage
e) Rated lightning impulse withstand voltage
f) Rated switching impulse withstand voltage
g) Rated normal current
h) Rated short circuit breaking current
i) Rated duration of short circuit
j) Rated auxiliary D.C. supply voltage of closing and opening devices.
k) Rated pressure of compressed air/gas
l) Rated out of phase breaking current
m) Rated supply voltage of auxiliary circuit
n) Rated insulation level
o) Rated frequency
p) 1st pole -to -clear factor
q) Rated line-charging breaking current
r) Contractor/purchase order reference
s) Rated operating duty
ii) The rating plates shall be installed in such positions that the same
are clearly visible to man standing on ground.
iii) The coils of operating devices shall be marked clearly with the
catalogue number/reference number as indicated in control wiring
diagram.
2.4.5.18 Control Circuits
The control circuit shall include the following features :
i) Two electrically independent trip circuits including two trip coils per
pole.
ii) One local / remote selector switch
iii) Conveniently located manual emergency trip
iv) Anti-pumping feature
v) Auxiliary switches as specified else where
vi) Independence of trip circuit from of local/remote selection
vii) Alarms, indications, monitoring equipments interlocks as specified

elsewhere
viii) Trip circuit supervision for pre trip as well as post trip. 2 nos. per
breaker.
ix) The trip circuit supervision relays shall be capable of monitoring the
trip circuits irrespective of whether the breaker is open or closed.
x) Separate cabinets shall be provided for housing operating

mechanism and control circuit. These cabinets shall meet the standard
requirements.
2.4.5.19 Auxiliary Switches
Each operating mechanism of the circuit breaker shall be provided with

Cam/snap type auxiliary switches with minimum Ten (10) normally
open and Ten (10) normally closed contacts exclusively for other use
with continuous current rating of 10 Amp. D.C. Breaking capacity of
the contacts shall be minimum 2 A with circuit time constant less than
20 mille seconds at the rated D.C. voltage. Normal position of auxiliary
switches refers to contact position when circuit breaker is open.
2.4.5.20 Alarms and Indications
Potential free contacts shall be provided, duly wired up to the operating

mechanism housing/control cabinet for the following alarms and
indications on control panel.
i) Alarms
a) General lockout for SF6 gas
b) Low pressure of SF6 gas
c) Auxiliary A.C. supply failure
d) Low operating air pressure
ii) Indications
Breaker on-off
iii) Mechanical indications
The operating mechanism housing shall be provided with the following

mechanical indication/counters:
a) Breaker on-off
b) Operation to register the number of breaker operations.
2.4.5.21 Interlocks
It is proposed to electrically and mechanically interlock the circuit

breaker with air break isolating switches in the switch yard in
accordance with switch yard safety interlocking scheme. The details of
the scheme shall be furnished by the successful Contractor. The
requirement of auxiliary contacts to be provided in breaker operating
mechanism for successful operation of the scheme has to be
specified by the Contractor.
2.4.5.22 Mounting
i) The design and construction of support structure, required for

mounting the Circuit Breaker in switch yard, will be lattice type or
tubular type and shall be made out of hot dip galvanised steel. Wheel
mounted type support shall not be accepted. The support structure will
be installed on a concrete plinth of at least 300 mm height to be
constructed by the Contractor. The height of the support structure will
meet following requirements.
a) Vertical clearance of lowest terminal pad as specified else where

above.
b) Minimum height above the top of concrete plinth shall be maintained

as per the statutory requirement.
ii) The Circuit Breaker shall be connected to adjacent equipment in the

switch yard through ASCR conductor. The maximum unsupported
length of conductor on both sides of the Circuit Breaker shall be as per
accepted standard practices.
iii) The loading data to be considered by the Contractor for design of

support structure shall include the following.
a) Dead weight of the Circuit Breaker, Structure, Bus bars
b) Operational steady state and impact loading.
c) Wind load on a Circuit Breaker, Structure, Bus bars
d) Short circuit forces.
iv) The support structure shall be designed on the basis of applicable

Indian/International Standards and codes of practice.
v) The Contractor shall furnish following details along with first lot of
Drawings to be submitted by him along with the schedule.
a) Mechanical loading data considered for design of support structure.

This data should be supported by calculations.
b) Detailed structural Design calculations
2.4.5.23 Operating Mechanism and Associated Equipments
i) The circuit breaker shall be designed for electrical local and remote
control. In addition there shall be provision for local mechanical
control.
ii) The operating mechanism shall be of motorized spring charged

stored energy type.
2.4.6.24 Operating Mechanism Housing
i) Operating mechanism of unit compressor and all accessories shall

be enclosed in a weather-proof cabinet of hot dip galvanised sheet
steel construction, the thickness of which shall not be less than 3 mm.
Hinged doors giving access to the mechanism at the front and sides
shall be provided.
ii) Suitable space heaters shall be mounted in the housing to prevent

condensation. Heaters shall be controlled by differential thermostat so
that the cubicle temperature is always, maintained approximately 5
deg. C above the outside air temperature. ON/Off switch and fuse
shall be provided for the heaters. Heaters shall be suitable for 240 V
AC single phase supply. The heater leads shall be covered with
porcelain material upto sufficient length to avoid melting of insulation of
the leads.
2.4.6.25 Specification for Operating Mechanism Housing and Control

Cabinets.
i) The control cabinets shall be of free standing floor mounting type.
ii) Control cabinets shall be sheet steel enclosed and shall be dust,
water and vermin proof. Sheet steel shall be at least 2.6 mm thick
when control cabinets are specified for indoor use and at least 3.0 mm
thick when control cabinets are intended for outdoor operation. There
shall be sufficient reinforcement to provide level surfaces, resistance to
vibrations and rigidity during transportation and installation. Control
cabinets shall be provided with double hinged door and padlocking
arrangements. The door hinges shall be of union joint type to facilitate
easy removal and the distance between hinges shall not exceed 350
mm. Door shall be properly braced to prevent wobbling.
iii) Equipment and devices shall be suitable for operation on specified

auxiliary AC supply system
iv) Motors rated 1 kW and above being controlled from the control
cabinet would be suitable for operation on a 415V, +/- 6% , 3 phase 50
Hz system. Fractional kW motors would be suitable for operation on a
240 V , +/- 6% , 1 phase, 50 Hz AC supply system.
v) Push button shall be rated for not less than 6 Amps, 415 Volts AC or
2 Amps, 110 V DC and shall be flush mounted on the cabinet door and
provided with appropriate name plates. Red, green and amber
indicating lamps shall be flush mounted and provided with series
resistors.
vi) For motors upto 5 kW, contactors shall be direct on line, air break,
single throw type and shall be suitable for making and breaking the
stalled current of the associated motor which shall be assumed equal
to 6.5 times the full load current of the motor at 0.2 p.f. For motors
above 5 kW, automatic star delta type starters shall be provided. 3
pole contactors shall be furnished for 3 phase motors and 2 pole
contactors for single phase motors. Reversing contactors shall be
provided with electrical interlocks between forward and reverse
contactors. If possible, mechanical interlocks shall also be provided.
Contactors shall be suitable for uninterrupted duty and shall be of duty
category class AC4 as defined in IS 13947. The main contacts of the
contactors shall be silver plated and the insulation class for the coil
shall be class E or better. The dropout voltage of the contactors shall
not exceed 70% of the rated voltage.
vii) Contactor shall be provided with a three element, positive acting

ambient temperature compensated, time lagged, hand reset type
thermal over load relay with adjustable setting. Hand reset button shall
be flushed with the front door of the cabinet and suitable for resetting
with starter compartment door closed. Relays shall be either direct
connected or CT operated depending on the rated motor current.
viii) Single phasing and thermal over load protection shall be provided
for all three phase motors.
ix) Power cables will be of 1100 Volt grade stranded copper conductor,
PVC sheathed single steel wire armoured FRLS type and PVC
jacketed. All necessary wiring will be complete with cable terminating
accessories such as glands, crimp type tinned copper lugs etc. for
power as well as control cables. Suitable brass cable glands shall be
provided for cable entry.
x) Wiring for all control circuits shall be carried out with 1100 Volts
grade PVC insulated tinned copper stranded conductors of sizes not
smaller than 2.5 sq. mm. Atleast 20% spare terminal blocks for control
wire terminations shall be provided on each panel. The terminal blocks

shall be similar ELMEX type CAT-44 or better type. All terminals shall
be provided with ferrules indelibly marked or numbered and these
identifications shall correspond to the designations on the relevant
wiring diagrams. The terminals shall be rated for adequate capacity;
which shall not be less than 10 Amps.
xi) Control cabinet shall be provided with 240 V, 1 phase 50 Hz., 11 W

compact fluorescent lighting fixture with on/off switch and a suitable
rated 240 , 1 phase, 5 Amp, 3 pin socket for hand lamp.
xii) Suitable heaters shall be provided inside each cabinet. Heaters

shall be controlled by suitable toggle switch of industrial quality.
xiii) All AC control equipment shall be suitable for operation on 240V,

+/-6% , 1 phase two wire 50 Hz system, with neutral grounded.
xiv) Items inside the cabinet made of organic material shall be coated
with a fungus resistant varnish.
2.4.5.26 Special Requirements of SF6 Gas Breaker
i) SF6 breaker shall be so designed that upon loss of pressure the gap
between open contacts shall be adequate to withstand at least the
rated voltage at atmospheric pressure of gas.
ii) The Contractor shall clearly bring out in his offer the precautions to
be taken in the use of SF6 breaker
iii) Following features shall be provided for monitoring of SF6 gas in the
breaker:
a) SF6 gas density meter with two potential free contacts of suitable
rating. One of these contacts shall be used for annunciation of low
density. The other contact shall be used to ensure breaker lockout in
the event of low SF6 gas density. The Contractor shall furnish a chart
showing relation between pressure and density of SF6 gas, as well as
settings for alarm and lockout.
b) Suitable pressure gauges shall be provided for SF6 gas, pneumatic

air, as applicable. Gauge dials shall be clearly visible with naked eye
to an observer standing on ground
c) Adequate number of pressure switches shall be provided for

monitoring pressure of SF6 gas. The pressure switches shall be
provided with sufficient number of potential free NO/NC contacts for
use in control, protection and alarm circuits.
iv) Closing coil shall operate correctly at all values of voltage between
85% and 110% at the rated control voltage and trip coil shall operate
correctly at all values of voltage between 70% and 110% of the rated
control voltage as specified elsewhere
v) The Contractor shall furnish along with the offer, detailed Schematic
drawings showing all types of control, protection, monitoring schemes
to be employed by him. The Contractor shall be required to modify the
schemes, if necessary, after discussions with the Employer.
2.4.5.27 Tests
i) Type Tests
a) The equipment / material offered in the tender should be

successfully type tested in line with standard technical specification
within the last 5 (five) years from the date of opening of the tender.
The Contractor shall be required to submit four copies of the type test
reports along with the offer.
b) If there is any change in the components or design in the equipment

since after earlier passing of the type test, the Contractor shall bring
out in his offer all such changes made in components, materials,
designs, etc. In such cases the bidder shall carry out the type test at
his cost and in presence of the representative of Employer.
c) Even if the equipment/material has been type tested earlier, the

Employer reserves the right to demand repetition on one or more test
included in the list of type test in the presence of representative.
d) The Employer reserves the right to conduct tests included in the list
of type tests on requisite number of samples/items at Contractors cost
in the presence of Employers representative. If the
equipment/material does not withstand the type test, then the
equipment/material supplied will be liable for rejection. The Contractor,
in such an eventuality, shall be allowed to modify the equipment and
type test the same again at his cost in the presence of the Employers
representative. These type tests shall however the conducted by the
Contractor within a reasonable time. After successful passing of the
type tests, all the equipments/material supplied shall be modified in line
with the equipment/materials which have successfully passed the type
test. In case Contractor fails to carry out the type test within
reasonable time or does not agree to carry out the type test at his cost,
his equipment/material supplied earlier shall be rejected and payments
made earlier for these equipment shall be recovered by the Employer.
ii) Acceptance and Routine Tests
a) All acceptance and routine tests as stipulated in IS: 13118 1991

representative without any extra cost to the Employer.
b) After the finalisation of the programme of type/acceptance/ routine

tests the Contractor shall give three weeks advance intimation to the
Employer to enable him to depute his representatives for witnessing
the tests.
c) The inspection may be carried out by the Employer at any stage of

manufacture. The Contractor shall grant free access to the Employers
representative/s at a reasonable notice when the work is in progress.
Inspection and acceptance of any equipment under this specification
shall not relieve the Contractor of his obligation of furnishing equipment
in accordance with the specification and shall not prevent subsequent
rejection of the equipment found to be defective.
d) The supplier shall keep the Employer informed in advance, about

the manufacturing program so that arrangement can be made for stage
inspection.
e) The Employer reserves the right to insist for witnessing the

acceptance/routing testing of the items. The Contractor shall keep the
Employer informed, in advance, about such testing program.
2.4.5.28 Drawings
The following drawings shall be supplied after placement of order ;
i) General out line drawing of the Breaker indicating foundation details,

overall dimensions, net and gross weight etc.
ii) Detailed drawings for the operating mechanism.
iii) Out line drawings of the bushings
iv) Sectional views showing the general constructional features of the

breaker and operating mechanism.
2.4.5.29 Limits of Temperature and Temperature Rise For Various Parts

Materials and Dielectrics
----------------------------------------------------------------------------------------------------------------
Sl. Various part of material and of the Maximum permissible values of temperature &
No. Dielectric Temperature rise in (deg.C)
for air temperature not exceeding 50 dg. C
1 2 3 4
----------------------------------------------------------------------------------------------------------------
1. Contacts (see note 3)
Bare copper and bare
Copper alloy
- in air 75 25
- in SF6 90 40
( Sulpuer Hexafluoride)
- in oil 80 30
Silver coated or nickel

Coated (see note 4)
- in air 105 55
- in SF6 105 55
- in oil 90 40
Tin coated (see note 4 and 5)

- in air 90 40
- in SF6 90 40
- in oil 90 40
2. Connection, bolted or the

Equivalent (see note 6)
Bare copper, bare copper
Alloy or aluminum alloy
- in air 90 40
- in SF6 105 55
- in oil 100 50
Silver coated or nickel coated

- in air 115 65
- in SF6 115 65
- in oil 100 50
Tin coated
- in air 105 55
- in SF6 105 55
- in oil 100 50
3. All other contacts or connection made

of bare metals or coated
with other materials See note 7 See note 7
4. Terminals for the connection to

external conductors by screws or bolts
(see note 8)
- bare 90 40
- Silver, nickel or tin coated 105 55
- Other coatings See note 7 See note 7
5. Oil for oil switching devices 90 40

(See notes 9 and 10)
6. Metal parts acting as springs See note 11 See Note 11
7. Material used as insulation and metal

parts in contact with insulation of the
following classes (see note 12)
- Y(for non-impregnated materials) 90 40
- A (for materials immersed in oil or

Impregnated 100 50
- E 120 70
- B 130n 80
- F 155 105
- Enamel : oil base 100 50
- Synthetic 120 70
- H 180 130
- C See note 13 See note 13
8. Any part of metal or insulating material

in contact with oil, except contacts 100 50
Notes:
1) According to its function, the same part may belong to several categories
as listed in table. In this case the permissible maximum value of
temperature and temperature rise to be considered are the lowest amount
of the relevant categories.
2) Care shall be taken to ensure that no damage is caused to the

surrounding insulating material.
3) When contact parts have different coating, the permissible temperature

and temperature rises shall be those of the part having the lower value
permitted in table.
4) The quality of the coated contacts shall be such that a layer of coating
material remains at the contact area:
a) After making and breaking tests (if any):
b) After short time withstand current test:
c) After the mechanical endurance test:

according to the relevant specification for each equipment. Otherwise,
the contacts shall be regarded as bare.
5) For fuse contacts, the temperature rise shall be in accordance with IEC
publications on High Voltage Fuses.
6) When connection parts have different coatings, the permissible

temperature rises shall be those of the parts having the higher value
permitted in table.
7) When materials other than those given in table are used, their
properties shall be considered, notably in order to determine the
maximum permissible temperature rises.
8) The values of temperature and temperature rise are valid even if the
conductor connected to the terminals is bare.
9) At the upper part of the oil.
10) Special consideration should be given when low flash point oil is used
in regard to vaporization and oxidation.
11) The temperature shall not reach a value where the elasticity of the
material is impaired.
12) The following classification of insulating materials is in accordance

with IEC-85.
Class Y: Insulation consists of materials or combinations of materials

such as cotton, silk and paper when suitably impregnated. Other
materials may be included in this class if by experience or accepted tests
they can be shown to be capable of operation at Class Y temperatures.
Class A: Insulation consists of materials or combinations of materials

such as cotton silk and paper when suitably impregnated or coated or
when immersed in a dielectric liquid such as oil. Other materials or
combination of materials may be included in this class if by experience or
accepted tests they can be shown to be capable of operation at Class A
temperatures.
Class E: Insulation consists of materials which by experience or

accepted tests can be shown to be capable of operation at Class E
temperatures.
Class B: Insulation consisting of materials or combinations of materials

such as mica, glass fiber, asbestos, etc. with suitable bonding
substances. Other materials or combination of materials, not necessarily
inorganic, may be included in this class if by experience or accepted tests
they can be shown to be capable of operation at Class B temperatures.
Class F: Insulation consisting of materials or combinations of materials

they can be shown to be capable of operation at Class F temperatures
Class H: Insulation consisting of materials or combinations of materials

such as siliconed elastoner and combination of material such as mica,
glass fiber, asbestos, etc. with suitable bonding substances such as
appropriate silicone resine. Other materials or combination of materials
may be included in this class if by experience or accepted tests they can
be shown to be capable of operation at Class H temperatures
Class C: Insulation consists of materials or combination of materials

such as mica, porcelain, glass and quartz with or without an inorganic
binder. Other materials or combinations of materials may be included in
this class if by experience or accepted tests they can be shown to be
capable of operation at temperatures above the Class H limit. Specific
materials or combinations of materials in this class will have temperature
limit which is dependent upon their physical, chemical and electrical
properties.
13) Limited only be requirement to any damage to surrounding parts.
2.4.5.30 Specifications of New Sulphur Hexafluoride Gas
i). Physical properties : Colour less, odour less, non

toxic and non-flammable
ii). Density at 20 deg. C and 1 bar : 6.16 grams/litre
iii) Electric strength: Two and one half times that of Nitrogen
iv) Compatibility: Upto temperature of about 1800 deg. C

its compatibility with material used in
electrical construction shall be similar
to that of Nitrogen.
v) Toxic impurities: SF6 gas shall comply with the

requirements of the test as per relevant
clause of IEC: 376-1971.
Impurity or group Maximum

of impurities permitted concentration by mass.
----------------------- ------------------------
CF4 0.05%
Oxygen + Nitrogen 0.05%
(Air)
Water 15 ppm.
Acidity expressed 0.3 ppm

as HF
Hydrolysable 1.0 ppm

Fluorides expressed As HF
Oil content Substantially

free from oil
vi) Standard sizes of 3,5,10,20,40,60,150 and 500 litres

cylinders
vii) Preferred size of cylinders 10 and 40 litres
viii) Test pressure of cylinder According to gas cylinder rules 1981

and to comply with IS 7285-1974
ix) Maximum filling ratio According to gas cylinder rules

for tropical country. 1981 and to comply with IS 7285-
1974
x). Tests:
a) Toxicity test Clause no. 22 of IEC 376-1974
b) Water content and

condensation temperature Clause nos. 23,24,25 and 26 of
IEC 376 B- 1974
c) Carbon tetra fluoride Clause nos. 27,28,29,30 and 31

` oxygen and nitrogen contents of IEC 376-1975
d) Hydrolysable Clause nos. 32, 33, 34, 35, 36& 37 of

fluoride content IEC 376-1976
e) Acidity Clause nos. 38,39,40,41 and 42 of

IEC 376-1976
f) Oil content Section 13 of IEC 376 A -1973
2.4.6.0 SPECIFICATION OF 33 kV VACUUM CIRCUIT BREAKER
2.4.6.1 Scope
i) This specification covers design, manufacture, assembly, testing

before supply, inspection, packing, delivery, at site of outdoor type
Vacuum circuit breakers of rated insulation class of 33 kV . The circuit
breakers shall be of the following types and shall be complete with all
the accessories and auxiliary equipment required for their satisfactory
operation in 132 kV /33 kV sub station.
ii) It is not the intent to specify, completely here in all the details of design
and construction of the circuit breaker. However, the breaker shall
conform, in all respects to high standards of engineering, design and
workmanship as listed here-after. It shall be capable of performing in
continuous commercial operation up to the Contractors guarantee in a
manner acceptable to the Employer who will interpret the meanings of
drawings and specifications and shall have power to reject any work or
material which, in his judgment, is not in accordance therewith. The
circuit breaker so offered shall be complete with all components
necessary for its effective and trouble-free operation. Such
components shall be deemed to be within the scope of Contractors
supply, irrespective of whether those are specifically brought out in this
2.4.6.2 Technical Parameters
i) Highest System voltage of circuit breaker: 36 kV RMS
ii) Nominal system voltage(RMS) : 33kV
iii) Rated frequency: --- 50 Hz ---
iv) Rated continuous current: 1250 and 800 Amps.

As per scope of supply
v) Type Vacuum
vi) Application ----- outdoor ------
vii) Short circuit fault interrupting 1430 MVA

capacity
viii) System neutral earthing -- Effectively earthed --

-
ix) No. of Poles & No. of 3&2

interruption unit/pole
x) Type of operation Individually three single

poles operated single gang
operated pole/three
(mechanically poles
coupled)simultaneous
operation
xi) Automatic rapid re-closing -- Not required
xii) Operating duty cycle -- 0-3 min-CO3 minCO
xiii) Mounting -- On hot dip galvanized steel

support structures-
xiv) Basic insulation level (Lightning 170 kV

impulse withstand voltage (peak)
.2 /50 micro seconds.)
xv) One minute power frequency 70 kV

withstand voltage (rms)
xvii) Auxiliary AC voltage -- 240 V AC +/- 5% --

voltage, single phase
xviii) Control circuit voltage -- 110V DC +/- 10% --
xix) Short time current rating for 3 sec. 25 kA
xx) (b) Operating mechanism Operating mechanism

shall be spring
charged motor operated
type. Operation control
shall be electrical from
remote as well as local.
It shall be trip free
xxi) Number of closing coils One (Operative from 80%-

110% of nominal voltage)
xxi) Number of shunt trip coil Two
xxii) Terminal connector with -- Two sets --

clamps for ACSR conductor
xxiii) Breaker control cubicle one set for breaker

comprising local/remote selector assembly unit
switch with indicator
lamps and potential free out put
contacts for alarm/trip, contactor for
spring charge motor,
indicating lamps for breaker status, closing
and trip coils for breaker, space heater
with control switch and thermostat, socket
with switch for 240 V A.C, .hand lamp,
required number of auxiliary relay/ contactors
/ MCB fuse links etc.
xxiv) Type of breaker control cubicle Remote
xxv) Drive motor operating 80% to

voltage range 110% of
nominal
LT voltage
xvi) IS to be followed:
a) IS: 13118 High voltage Alternating Current circuit Breakers (with

latest amendments)
b) IS: 12063 Classification of degrees of protection provided

c) IS: 325 Specification for 3 Phase Induction Motor
d) IS: 2629 Recommended Practice for Hot Dip Galvanising of Iron

and Steel
e) IS: 4379 Identification of contains of industrial gas cylinder.
f) IEC: 2331 High Voltage Porcelain Bushings
g) IEC: 60 High voltage Test Techniques
h) IEC: 71 Insulation co ordination, Terms, Definitions,

Part I & II Principles and Rules
i) Indian Electricity Rules (with latest Amendments)
j) Fire Insurance Regulations
k) The Indian Electricity (Supply) Act
l) National Fire Code
m) DGMS Regulations

with unit rates for each circuit breaker that may be necessary for
satisfactory operation and maintenance of the circuit breaker for a
period of 2 years. The Employer reserves the right of selection of
items and quantities of these spares to be ordered. The cost of such
spares shall not be considered for tender evaluation.
2.4.6.4 Erection and Maintenance Tools
As specified elsewhere in the document.
2.4.6.5 Service Condition
i) Environmental Conditions:
The breakers and accessories to be supplied against this specification

shall be suitable for satisfactory continuous operation under the
following tropical conditions.
a) Maximum ambient temperature

(deg. C) : 50
b) Maximum ambient temperature in

shade (deg C) : 45
c) Minimum ambient temperature

(deg C) : 4
d) Relative Humidity (%) : 10 to 100
e) Maximum Annual rainfall (mm) : 1400
f) Maximum wind pressure (kg/sqm) : 150
g) Isoceraunic level (stormy days

per year ) : 50 (approx.)
h) Moderately hot and humid,

Tropical climate, conducive to rust and
fungus growth : Yes
2.4.6.5 Auxiliary Power Supply
The rating, quality and location of electrical supply system for operation
of the circuit breaker are described below. The auxiliary electrical
equipments provided by the Contractor for specific operation of the
circuit breaker, shall be suitable for operation on the same.
2.4.6.6 Ratings
i) For power devices 240 V +/- 5% , single phase, 2 wire

(drive motors) 50 Hz Neutral grounded AC supply
ii) For AC control & Protective devices, 240 V +/- 5% , single phase, 2
lighting fixtures, space heaters wire, 50 Hz AC supply with
one point grounded
iii) For DC alarm, control and 2 wire 110 V DC from batteries

protective device.
2.4.6.7 Standards
The circuit breaker shall conform to the latest revisions, available at the
time of placement of orders of relevant standards, rules and codes
listed at in this document. Equipments meeting with the stipulations of
equivalent IEC, ANCI, CSA, DIN standards, which ensure equal or
better quality than the standards listed in here after, shall also be
acceptable. In such case the Contractor should submit along with his
offer, two copiers of such standards in authentic English translation, if
the language of the standard is other than English. In case of dispute,
the stipulation in the English translation, submitted by the Contractor
shall prevail. Further, in the event of conflict between the stipulations
of standards adopted by the Contractor and the corresponding Indian
Standards Specification, the stipulation of Indian Standard
Specification shall prevail.
2.4.6.8 General Technical Requirements
i) Similar parts of the breaker, especially the removable ones, shall be

freely interchangeable without the necessity of any modification at site.
ii) The breakers will be required to break small inductive currents and line
charging current without causing excessive over voltage, and charging
current without re-strike. The breaker shall also be required to handle
evolving faults and meet the requirements regarding partial discharge,
radio interference etc, as specified in relevant standards.
2.4.6.9 Breaker Contacts
i) Main contacts shall have ample area and contact pressure for carrying
the rated continuous and short time current of the breaker without
excessive temperature rise which may cause pitting or welding.
Contacts shall be adjustable to allow for wear, shall be easily
replaceable and shall have minimum number of movable parts and
adjustments to accomplish test results, Main contacts shall be the first
to open and the last to close so that there will be little contact burning
and wear. Tips of main contacts shall be silver plated.
ii) Arcing contacts, if provided, shall be the first to close and the last to
open and shall be easily accessible for inspection and replacement.
The arcing contacts shall have tungsten alloy tipping
iii) In the case of multi break interrupters, they shall be so designed and
augmented that a fairly uniform voltage distribution is developed across
them.
iv) The inside operating rod or insulated fiber glass connecting rods
wherever used, shall be sturdy and shall not break during the entire life
period of the breaker. The insulated rods shall have anti-tracking
quality towards electrical stresses.
2.4.6.10 Take off Terminals Pads
i) Terminal pads shall be provided with silver plating of required thickness

if these are made of metal other than aluminum. A certificate to this
effect is to be furnished. No such plating shall be required if the
terminal pad is made out of aluminum. The pads shall be suitably
designed to take the terminal loads. The terminal connectors required
for connecting the Circuit Breaker to Bus Bars shall be suitable for
mounting on aforesaid terminal pad.
ii) The breaker shall be designed to withstand the rated terminal load,
wind load/Earth quake load and short circuit forces. The short circuit
forces to be considered or the design shall be based on length of bus
bar consisting of conductors and phase to phase spacing.
iii) The current density adopted for the design of the terminal pad shall in
no case exceed 1.6A/sq .mm for copper pad and 1.0 A/sq .mm for pad
made of other material.
iv) The vertical clearance of lowest terminal pad from ground level
(including concrete foundation plinth) shall be approximately 3.7 m.
2.4.6.11 Porcelain Housing
The porcelain housing for the interrupter shall be of a single piece

construction without any joint. It shall be made of homogeneous,
vitreous porcelain of high mechanical and dielectric strength. Glazing

of porcelain shall be of uniform brown or dark brown colour with a
smooth surface arranged to shed away rain water or condensed water
particles (fog).
2.4.6.12 Support Insulator
Breaking units shall be mounted on insulator column of multiple

insulators of suitable rating and size in each column
All metal surfaces exposed to atmosphere shall be given two primer

coats of zinc phosphate and two coats of epoxy paints with epoxy base
thinner. All metal parts not accessible for painting shall be made of
corrosion resisting material. All machine finished or bright surfaces
shall be coated with a suitable preventive compound and suitable
wrapped or otherwise protected. All paints shall be carefully selected
to withstand tropical heat and extremes of weather within the limits
specified. The paints shall be battleship gray shade no. 632 of IS 5.
The paint shall not scale off or wrinkle or be removed by abrasion due
to normal handling. All components shall be given adequate treatment
of climate proofing as per IS:3202, so as to withstand corrosion.
2.4.6.14 Galvanising
All ferrous parts including nuts, bolts, plain and spring washers of M10
and above, support channels, structures, etc. shall be hot dip
galvanised to conform to latest version of IS 2629 or any other
equivalent authoritative standard. All other fixing nuts, bolts washers of
size below M 10 shall be made out of stainless steel
2.4.6.15 Earthing
The operating mechanism housing, support structures etc. shall be

provided with two separate earthing terminals for bolted connection to
50 x 8 mm MS flat for connection to station earth mat. The connecting
point shall be marked with earth symbol.
2.4.6.16 Name and Rating Plate
i) Circuit breaker and its operating device shall be provided with rating
plate made out of photo finish type plates, marked with the following
data. The data shall be either punched or engraved on the plate and
name plate surface should be coated with colour less epoxy powder.
a) Manufacturers name or trade mark by which he may be readily

identified.
b) Serial number and type designation
c) Year of manufacture
d) Rated voltage
e) Rated lightning impulse withstand voltage
f) Rated switching impulse withstand voltage
g) Rated normal current
h) Rated short circuit breaking current
i) Rated duration of short circuit
j) Rated auxiliary D.C. supply voltage of closing and opening devices.
k) Rated pressure of compressed air/gas
l) Rated out of phase breaking current
m) Rated supply voltage of auxiliary circuit
n) Rated insulation level
o) Rated frequency
p) 1st pole -to -clear factor
q) Rated line-charging breaking current
r) Contractor/purchase order reference
s) Rated operating duty
ii) The rating plates shall be installed in such positions that the same
are clearly visible to man standing on ground.
iii) The coils of operating devices shall be marked clearly with the
catalogue number/reference number as indicated in control wiring
diagram.
2.4.6.17 Control Circuits
The control circuit shall include the following features :
i) Two electrically independent trip circuits including two trip coils per
pole for 33 kV circuit breakers.
ii) One local / remote selector switch
iii) Conveniently located manual emergency trip
iv) Anti-pumping feature
v) Auxiliary switches as specified else where
vi) Independence of trip circuit from of local/remote selection
vii) Alarms, indications, monitoring equipments interlocks as specified

elsewhere
viii) Trip circuit supervision for pre trip as well as post trip. 2 nos. per
breaker for 33 kV.
ix) The trip circuit supervision relays shall be capable of monitoring the
trip circuits irrespective of whether the breaker is open or closed.
x) Separate cabinets shall be provided for housing operating

mechanism and control circuit. These cabinets shall meet the standard
requirements.
2.4.6.18 Auxiliary Switches
Each operating mechanism of the circuit breaker shall be provided with

Cam/snap type auxiliary switches with minimum Ten (10) normally
open and Ten (10) normally closed contacts exclusively for other use
with continuous current rating of 10 Amp. D.C. Breaking capacity of
the contacts shall be minimum 2 A with circuit time constant less than
20 mille seconds at the rated D.C. voltage. Normal position of auxiliary
switches refers to contact position when circuit breaker is open.
2.4.6.19 Alarms and Indications
Potential free contacts shall be provided, duly wired up to the operating

mechanism housing/control cabinet for the following alarms and
indications on control panel.
i) Alarms
b) Low operating air pressure
c) Auxiliary A.C. supply failure
d) Low operating air pressure
ii) Indications
Breaker on-off
iii) Mechanical indications
The operating mechanism housing shall be provided with the following

mechanical indication/counters:
a) Breaker on-off
b) Operation to register the number of breaker operations.
2.4.6.20 Interlocks
It is proposed to electrically and mechanically interlock the circuit

breaker with air break isolating switches in the switch yard in
accordance with switch yard safety interlocking scheme. The details of
the scheme shall be furnished by the successful Contractor. The
requirement of auxiliary contacts to be provided in breaker operating
mechanism for successful operation of the scheme has to be
specified by the Contractor.
2.4.6.21 Mounting
i) The design and construction of support structure, required for

mounting the Circuit Breaker in switch yard, will be lattice type or
tubular type and shall be made out of hot dip galvanised steel. Wheel
mounted type support shall not be accepted. The support structure will
be installed on a concrete plinth of at least 300 mm height to be
constructed by the Contractor. The height of the support structure will
meet following requirements.
a) Vertical clearance of lowest terminal pad as specified else where

above.
b) Minimum height above the top of concrete plinth shall be maintained

as per the statutory requirement.
ii) The Circuit Breaker shall be connected to adjacent equipment in the

switch yard through ASCR conductor. The maximum unsupported
length of conductor on both sides of the Circuit Breaker shall be as per
accepted standard practices.
iii) The loading data to be considered by the Contractor for design of

support structure shall include the following.
a) Dead weight of the Circuit Breaker, Structure, Bus bars
b) Operational steady state and impact loading.
c) Wind load on a Circuit Breaker, Structure, Bus bars
d) Short circuit forces.
iv)The support structure shall be designed on the basis of applicable

Indian/International Standards and codes of practice.
v) The Contractor shall furnish following details along with first lot of
Drawings to be submitted by him along with the schedule.
a) Mechanical loading data considered for design of support structure.

This data should be supported by calculations.
b) Detailed structural Design calculations
2.4.6.22 Operating Mechanism and Associated Equipments
i) The circuit breaker shall be designed for electrical local and remote
control. In addition there shall be provision for local mechanical
control.
ii) The operating mechanism shall be of Spring charge motor operated

by electrical control under normal operation. The mechanism shall be
adequately designed for the specified tripping and closing duty. The
entire operating mechanism control circuitry, individual breaker
compressor unit etc. as required, shall be housed in an outdoor type,
hot dip galvanised steel enclosure. This enclosure shall conform to the
degree of protection IP-55 of IS-12063. The enclosure shall be
invariably be mounted on a separate concrete plinth of at least 300 mm
height.
(iii) The mechanism shall be provided with motor starter fitted with
overload release, auxiliary switches and socket for inspection lamp.
The charging for springs shall be done by a 240 V AC single phase
motor. The remote control switch will be provided on the control panel.
Closing and tripping devices shall operate at 110 V DC. It is envisaged
that C.T. operated direct acting trip coil will also be fitted for reliable
operation. Some of the important precautions required are mentioned
below :
- the spring, if charged, can not be released when the circuit breaker is
closed.
- Interlock shall be provided to prevent slow closing or opening of the
circuit breaker in its service position.
- If the spring fails, it should be possible to close the circuit breaker
manually.
- It should be possible to recharge the spring automatically while the
circuit breaker is closed, thus preparing in advance for the next closing
operation.
- Necessary limit switches shall be incorporated in the automatic spring
charging circuit. The release of the spring shall be electrically operated
coil for remote control. An emergency hand release should be provided
to work in case of power supply failure.
The vacuum interrupter should enable the metal vapour for arch
discharge through the plasma and is extinguished near current zero.
The conductive metal vapour should condense within a few micro
second leading to the rapid build up of dielectric strength across the
open contact gap.
iv) All metal parts in the mechanism shall be of corrosion resistant

material. All bearings which require greasing shall be equipped with
pressure grease fittings.
v) The design of the operating mechanism shall be such that it shall be

practically maintenance free. The guaranteed number of years of
maintenance free operation, the number of possible full load and full
rated short circuit current breaking operations without requiring any
maintenance or overhauling shall be clearly stated in offer. As far as
possible, the need for lubricating the operating mechanism shall be
kept to the minimum and eliminated altogether, if possible.
vi) The operating mechanism shall be anti pumping and trip- free.
There shall be no rebounds in the mechanism and it shall not require
any critical adjustments at site. Operation of the power operated
closing device, when the circuit breaker is already closed, shall not
cause damage to the circuit breaker or endanger the operator.
vii) Provision shall be made for attaching an operation analyser to

facilitate testing of breaker at site.
2.4.6.23 Operating Mechanism Housing
i) Operating mechanism of unit compressor and all accessories shall

be enclosed in a weather-proof cabinet of hot dip galvanised sheet
steel construction, the thickness of which shall not be less than 3 mm.
Hinged doors giving access to the mechanism at the front and sides
shall be provided.
ii) Suitable space heaters shall be mounted in the housing to prevent

condensation. Heaters shall be controlled by differential thermostat so
that the cubicle temperature is always, maintained approximately 5
deg. C above the outside air temperature. ON/Off switch and fuse
shall be provided for the heaters. Heaters shall be suitable for 240 V
AC single phase supply. The heater leads shall be covered with
porcelain material upto sufficient length to avoid melting of insulation of
the leads.
2.4.6.24 Specification for Operating Mechanism Housing and Control

Cabinets.
i) The control cabinets shall be of free standing floor mounting type.
ii) Control cabinets shall be sheet steel enclosed and shall be dust,
water and vermin proof. Sheet steel shall be at least 2.6 mm thick
when control cabinets are specified for indoor use and at least 3.0 mm
thick when control cabinets are intended for outdoor operation. There
shall be sufficient reinforcement to provide level surfaces, resistance to
vibrations and rigidity during transportation and installation. Control
cabinets shall be provided with double hinged door and padlocking
arrangements. The door hinges shall be of union joint type to facilitate
easy removal and the distance between hinges shall not exceed 350
mm. Door shall be properly braced to prevent wobbling.
iii) Equipment and devices shall be suitable for operation on specified

auxiliary AC supply system
iv) Motors rated 1 kW and above being controlled from the control
cabinet would be suitable for operation on a 415V, +/- 6% , 3 phase 50
Hz system. Fractional kW motors would be suitable for operation on a
240 V , +/- 6% , 1 phase, 50 Hz AC supply system.
v) Push button shall be rated for not less than 6 Amps, 415 Volts AC or
2 Amps, 110 V DC and shall be flush mounted on the cabinet door and
provided with appropriate name plates. Red, green and amber
indicating lamps shall be flush mounted and provided with series
resistors.
vi) For motors upto 5 kW, contactors shall be direct on line, air break,
single throw type and shall be suitable for making and breaking the
stalled current of the associated motor which shall be assumed equal
to 6.5 times the full load current of the motor at 0.2 p.f. For motors
above 5 kW, automatic star delta type starters shall be provided. 3
pole contactors shall be furnished for 3 phase motors and 2 pole
contactors for single phase motors. Reversing contactors shall be
provided with electrical interlocks between forward and reverse
contactors. If possible, mechanical interlocks shall also be provided.
Contactors shall be suitable for uninterrupted duty and shall be of duty
category class AC4 as defined in IS 13947. The main contacts of the
contactors shall be silver plated and the insulation class for the coil
shall be class E or better. The dropout voltage of the contactors shall
not exceed 70% of the rated voltage.
vii) Contactor shall be provided with a three element, positive acting

ambient temperature compensated, time lagged, hand reset type
thermal over load relay with adjustable setting. Hand reset button shall
be flushed with the front door of the cabinet and suitable for resetting
with starter compartment door closed. Relays shall be either direct
connected or CT operated depending on the rated motor current.
viii) Single phasing and thermal over load protection shall be provided
for all three phase motors.
ix) Power cables will be of 1100 Volt grade stranded copper conductor,
PVC sheathed single steel wire armoured FRLS type and PVC
jacketed. All necessary wiring will be complete with cable terminating
accessories such as glands, crimp type tinned copper lugs etc. for
power as well as control cables. Suitable brass cable glands shall be
provided for cable entry.
x) Wiring for all control circuits shall be carried out with 1100 Volts
grade PVC insulated tinned copper stranded conductors of sizes not
smaller than 2.5 sq. mm. Atleast 20% spare terminal blocks for control
wire terminations shall be provided on each panel. The terminal blocks
shall be similar ELMEX type CAT-44 or better type. All terminals shall
be provided with ferrules indelibly marked or numbered and these
identifications shall correspond to the designations on the relevant
wiring diagrams. The terminals shall be rated for adequate capacity;
which shall not be less than 10 Amps.
xi) Control cabinet shall be provided with 240 V, 1 phase 50 Hz., 11 W

compact fluorescent lighting fixture with on/off switch and a suitable
rated 240 , 1 phase, 5 Amp, 3 pin socket for hand lamp.
xii) Suitable heaters shall be provided inside each cabinet. Heaters

shall be controlled by suitable toggle switch of industrial quality.
xiii) All AC control equipment shall be suitable for operation on 240V,

+/-6% , 1 phase two wire 50 Hz system, with neutral grounded.
xiv) Items inside the cabinet made of organic material shall be coated
with a fungus resistant varnish.
2.4.6.25 Tests
i) Type Tests
a) The equipment / material offered in the tender should be

successfully type tested in line with standard technical specification
within the last 5 (five) years from the date of opening of the tender.
The Contractor shall be required to submit four copies of the type test
reports along with the offer.
b) If there is any change in the components or design in the equipment

since after earlier passing of the type test, the Contractor shall bring
out in his offer all such changes made in components, materials,
designs, etc. In such cases the bidder shall carry out the type test at
his cost and in presence of the representative of Employer.
c) Even if the equipment/material has been type tested earlier, the

Employer reserves the right to demand repetition on one or more test
included in the list of type test in the presence of representative.
d) The Employer reserves the right to conduct tests included in the list
of type tests on requisite number of samples/items at Contractors cost
in the presence of Employers representative. If the
equipment/material does not withstand the type test, then the
equipment/material supplied will be liable for rejection. The Contractor,
in such an eventuality, shall be allowed to modify the equipment and
type test the same again at his cost in the presence of the Employers
representative. These type tests shall however the conducted by the
Contractor within a reasonable time. After successful passing of the
type tests, all the equipments/material supplied shall be modified in line
with the equipment/materials which have successfully passed the type
test. In case Contractor fails to carry out the type test within
reasonable time or does not agree to carry out the type test at his cost,
his equipment/material supplied earlier shall be rejected and payments
made earlier for these equipment shall be recovered by the Employer.
ii) Acceptance and Routine Tests
a) All acceptance and routine tests as stipulated in IS: 13118 1991

representative without any extra cost to the Employer.
b) After the finalisation of the programme of type/acceptance/ routine

tests the Contractor shall give three weeks advance intimation to the
Employer to enable him to depute his representatives for witnessing
the tests.
c) The inspection may be carried out by the Employer at any stage of

manufacture. The Contractor shall grant free access to the Employers
representative/s at a reasonable notice when the work is in progress.
Inspection and acceptance of any equipment under this specification
shall not relieve the Contractor of his obligation of furnishing equipment
in accordance with the specification and shall not prevent subsequent
rejection of the equipment found to be defective.
d) The supplier shall keep the Employer informed in advance, about

the manufacturing program so that arrangement can be made for stage
inspection.
e) The Employer reserves the right to insist for witnessing the

acceptance/routing testing of the items. The Contractor shall keep the
Employer informed, in advance, about such testing program.
2.4.6.26 Drawings
The following drawings shall be supplied after placement of order ;
i) General out line drawing of the Breaker indicating foundation details,

overall dimensions, net and gross weight etc.
ii) Detailed drawings for the operating mechanism.
iii) Out line drawings of the bushings
iv) Sectional views showing the general constructional features of the

breaker and operating mechanism.
4) The quality of the coated contacts shall be such that a layer of coating
material remains at the contact area:
a) After making and breaking tests (if any):
b) After short time withstand current test:
c) After the mechanical endurance test:

according to the relevant specification for each equipment. Otherwise,
the contacts shall be regarded as bare.
5) For fuse contacts, the temperature rise shall be in accordance with IEC
publications on High Voltage Fuses.
6) When connection parts have different coatings, the permissible

temperature rises shall be those of the parts having the higher value
permitted in table.
7) When materials other than those given in table are used, their
properties shall be considered, notably in order to determine the
maximum permissible temperature rises.
8) The values of temperature and temperature rise are valid even if the
conductor connected to the terminals is bare.
9) At the upper part of the oil.
10) Special consideration should be given when low flash point oil is used
in regard to vaporization and oxidation.
11) The temperature shall not reach a value where the elasticity of the
material is impaired.
12) The following classification of insulating materials is in accordance

with IEC-85.
Class Y: Insulation consists of materials or combinations of materials

such as cotton, silk and paper when suitably impregnated. Other
materials may be included in this class if by experience or accepted tests
they can be shown to be capable of operation at Class Y temperatures.
Class A: Insulation consists of materials or combinations of materials

such as cotton silk and paper when suitably impregnated or coated or
when immersed in a dielectric liquid such as oil. Other materials or
combination of materials may be included in this class if by experience or
accepted tests they can be shown to be capable of operation at Class A
temperatures.
Class E: Insulation consists of materials which by experience or

accepted tests can be shown to be capable of operation at Class E
temperatures.
Class B: Insulation consisting of materials or combinations of materials

they can be shown to be capable of operation at Class B temperatures.
Class F: Insulation consisting of materials or combinations of materials

they can be shown to be capable of operation at Class F temperatures
Class H: Insulation consisting of materials or combinations of materials

such as siliconed elastoner and combination of material such as mica,
glass fiber, asbestos, etc. with suitable bonding substances such as
appropriate silicone resine. Other materials or combination of materials
may be included in this class if by experience or accepted tests they can
be shown to be capable of operation at Class H temperatures
Class C: Insulation consists of materials or combination of materials

such as mica, porcelain, glass and quartz with or without an inorganic
binder. Other materials or combinations of materials may be included in
this class if by experience or accepted tests they can be shown to be
capable of operation at temperatures above the Class H limit. Specific
materials or combinations of materials in this class will have temperature
limit which is dependent upon their physical, chemical and electrical
properties.
13) Limited only be requirement to any damage to surrounding parts.
2.4.7.0. SPECIFICATION OF 40/50 MVA, 132kV/33kV OUTDOOR

TRANSFORMER
2.4.7.1 Two numbers of 40 (ONAN)/ 50 (ONAF) MVA, 132kV/33kV

transformers will be installed in the substation. It is proposed that both
the transformers will be identical in all respects. The transformer shall
be core type, two winding, oil immersed with external heat exchanger.
The type of cooling shall be ONAN/ONAF.
2.4.7.2 Technical Parameters:
i)(a) Nominal system voltage, Number of : 1) Primary - 132 kV

phases and frequency. ` 3 phases, 50 Hz
2) Secondary - 33kV
3 phases, 50 Hz.
i)(b) Highest system voltage, : 1) Primary - 145kV

2) Secondary - 36kV
ii) Capacity : 40 MVA (ONAN)/

50 MVA (ONAF)
iii) Type of cooling : ONAN/ONAF
iv) Continuous ONAN rating : 40 MVA
v) Continuous ONAF rating : 50 MVA
vi) Transformation Ratio at no : 132000V/33000 Volt

load condition
vii) HV connections : STAR with neutral

brought out for effective
earthing
viii) LV connections : STAR with neutral

brought out for effective
earthing
ix) Vector group reference : Star/Star (YN-yn-o)
x) Winding : Two winding
xi) Tapping range : +/- 10%
xii) Type of tap changer : ON LOAD
xiii) No. of steps : 16 (excluding normal)
xiv) Rate of steps : 1.25%
xv) Winding on which tapping will : On HV side

be provided
xvi) Control/operation of tap changer : a) LOCAL manual

b) LOCAL electrical
c) REMOTE electrical
xvii) Impedance at rated current and : shall be as per IS

frequency and at 75 deg. C(%)
xviii) Reactance at rated current and : shall be as per IS

frequency (%)
xix) Zero phase sequence impedance : shall be as per IS
xx) Terminal Bushing Arrangement
a) HV Phase : 3nos. 145kV outdoor

condenser bushings
with terminal clamps
b) LV Phase : 3nos. 36 kV outdoor

condenser bushings
with terminal
clamps
c) HV Neutral }
Brought out on
separate bushing
d) LV Neutral }
(Neutral of HV & LV shall be solidly earthed)
e) Insulation Level of neutral : HV neutral insulated

for 38 kV terminals
(power freq.),
9 5kV (impulse)
and LV neutral
uniformly insulated as
per respective line
voltage .
xxi) Basic Insulation Level
a) Rated short duration power : 275kV (r.m.s.) for 132

frequency withstand voltage for kV and 70 kV for 33 kV
1 minute system
b) Rated impulse with stand voltage : 650 kV (peak) for 132

kV system
170kV (peak) for 33kV
system
xxii) Temperature rise over specified

Ambient temperature of 50 deg. C (max.)
a) In oil : 50 deg. C
b) In winding : 55 deg. C
xxiii) The following GA drawings shall be submitted by the Tenderer

after placement of order.
1. GA drawings with various overall dimensions of

transformer
2. GA drawings of 145 kV and 36 kV bushings.
3. GA drawings of under- carriage arrangement
4. GA drawing of on-load tap changer
5. GA drawing of marshalling box
6. GA drawing of OTI, WTI, pressure relief valve, Explosion
vent etc.
7. GA drawing of core assembly
8. GA drawing of oil reservoir and cooling assembly
9. GA drawing of transformer tank
10. Sectional view and dimensions of core, and winding
11. Sectional view and dimensions of marshalling box, OLTC,
cooling arrangement
12. Sectional details of 145 kV and 36 kV bushings.
13. Details of name plate.
xxiv) All type test and routine test certificates as recommended in IS

shall be submitted.
2.4.7.3 Tests
i) In accordance with requirement of IS:2026 and any latest

revision thereof the routine test, type test supplementary test
shall be carried out in order to ensure their being electrically and
mechanically sound in every respect and also to meet the
guaranteed performance. All tests, as stipulated in IS: 2026
shall be carried out by the Contractor in the presence of
Employers representative without any extra cost to the
Employer.
ii) Routine Tests
The transformer shall be subjected to routine tests at the

manufacturers works. The routine tests shall comprise
a) Measurement of winding resistance

b) Measurement of voltage ratio and check of voltage vector
relationship
c) Measurement of impedance voltage/short circuit impedance
(principal tapping) and load loss.
d) Measurement of no-load loss and current.
e) Measurement of insulation resistance.
f) Dielectric tests
g) Tests on on-load tap-changers
h) Induced over-voltage withstand
iii) Type Tests
In case the transformer is representative of one being

purchased and the test certificates furnished are of the
representative one, the Purchaser may accept these as
evidence of type test instead of actual tests. The type tests are
as below:
a) Impulse voltage withstand test

b) Temperature rise test
c)Measurement of voltage ratio and check of voltage vector
relationship
d) Short circuit test
e) Measurement of insulation resistance
f) Dielectric tests
g) Temperature rise test
iv) Carrying out type test of the transformer and submission of

type test certificate will be the sole responsibility of the
Contractor.
v) Special Tests
The following test shall be carried out at the manufacturers

works as per relevant standards:
a) Measurement of zero-sequence impedance

b) Short circuit test.
c) Measurement of acoustic noise level
d) Measurement of harmonics of no-load current.
e) Measure of power consumption by fans.
f ) Tan delta test
g) Oil leakage test on transformer oil tank
vi) Tests on on-load Tap-changer
The on-load tap-changer shall be subjected to tests as specified

in IS: 2026 (Part-I) and IS: 8468 (with amendment no. 1)
2.4.7.4 Type of Load and Duty Requirements
i) The transformer shall supply power to mining machinery loads

of opencast HEMM , large pumps, CHP & Washery loads etc.
These loads are fed at 6600V, 3300V and 415V through
transformation from 33 kV to above utilisation voltages.
ii) The system load of mines reduces to 25% to 30% during

change over of shifts and the above equipment are switched on
during shifts.
iii) The transformer design shall take care of the starting load of
the above large equipment
iv) The anticipated load factor is around 50-60%
2.4.7.5 Fittings and Accessories
The following fittings and accessories shall be fitted with each

transformer:
i) Oil conservator with oil level gauge, drain valve and filling
holes with air tight cap.
ii) On-load tap changer.
iii) Silica gel breather (Dehydrating breather)
iv) Explosion/Relief vent with double diaphragm equaliser

connection.
v) Double float Bucholoz relay with valves for two sides and with
potential free alarm and trip contacts wired upto the marshalling
box. The approach facility and inspection facility should be
provided for bucholoz relay with live transformer.
vi) Oil sampling device for the tank top and bottom oil sampling
with valves.
vii) Magnetic oil level gauge/indicator with low oil level alarm
contacts.
viii) One number dial type of suitable size thermometer with

maximum reading pointer and adjustable potential free contacts
for alarm and trip for top oil temperature.
ix) One set of winding temperature measuring device with RTDs

embedded in winding (2 nos. per phase).
x) Additional pockets for mercury-in-glass thermometer for

measuring oil and winding temperature.
xi) Rating and diagram plates and terminal marking plate.
xii) Identification marking plate.
xiii) Marshalling box mounted on the transformer, weather

proof and suitable for outdoor mounting, housing control and
signaling equipment for AF cooling fans, oil motors and terminal
connection for various alarm and trip circuits etc. provided in the
transformer. A heater shall be provided inside the marshalling
box to avoid any condensation.
xiv) Under carriage suitable for moving on a suitable rail track,

The under carriage shall be mounted on required number of
single flanged CI/CS wheels with axils.
xv) Under carriage suitable with jacking pads and with hauling
holes/hook.
xvi) Lifting lugs for the cover.
xvii) Lifting/jacking lugs for core and winding.
xviii) Lifting lugs and transport lugs for the complete transformer.
xix) Air release device and plugs at the top of the transformer
and busing turrets.
xx) Supervisory alarm and trip contacts for oil temperature

indicator.
xxi) Supervisory alarm and trip contacts for winding temperature

indicator.
xxii) Supervisory alarm and trip contacts for gas operated double
float relay.
xxiii) Supervisory alarm contacts for oil level indicator.
xxiv) Drain valve with plug for the transformer tank.
xxv) Inspection cover.
xxvi) 132 kV and 33 kV bushings
xxvii) 132 kV and 33 kV neutral bushings.
xxviii) Oil filling hole and cap.
xxix) Filter valves.
xxx) First filling of transformer oil as per IS 335.
xxxi) Independent Nitogen injection system for fire fighting of

40/50 MVA transformers have been envisaged for each
transformer. The design and construction of the
transformers shall be such that the fire fighting system can
be fitted with the transformers individually.
2.4.7.6 IS to be followed (with latest amendment):
a) IS: 2026 Specification for power transformers
b) IS: 335 Insulation oil for Transformer and

switchgear
c) IS: 3347 Dimensions of Porcelain Transformer

Bushings
d) IS: 2099 Specification for High Voltage Porcelain

Bushings
e) IS: 3639 Fittings and Accessories for Power

Transformers
f) IS: 8468 On load tap changers
g) IS: 4257 Dimensions for clamping arrangements for

Bushings
h) IS: 2165 Insulation co-ordination guide
i) Indian Electricity Rules, 1956 (with latest amendments)
j) IS 3401 Silica gel
k) The transformer shall be manufactured and conform to

IS:2026 or latest revision thereof.
2.4.7.7 Test Certificate
i) Manufacturers test certificate of all tests on transformer shall be

provided by the Contractor.
ii) All the details as per Schedule of this volume should be duly filled in
and submitted along with the offer.
2.4.7.8 Insulation
The condition of earthing is that neutral end of winding is solidly

connected to earth through a connection where no impedance has
been added intentionally. The offer should clearly specify whether
uniformly insulated winding or graded insulation winding is offered
2.4.7.9 Type of Coil Winding
i) The type of coil winding on 132 kV and 33 kV side shall be indicated

in the offer. Continuous disc section for 33 kV and shielded layer
winding for 132 kV shall be preferred.
ii) The coils and shield provided shall be so dimensioned that they form
number of substantially equal capacitance in series, thus ensuring
relatively uniform distribution through the winding of surge voltages as
well as power frequency voltages.
2.4.7.10 Construction in Brief
i) Core: It shall be built up from cold rolled grain oriented Silicon alloy
steel of the best magnetic properties. Debarring process shall be duly
carried out, so that it will build into a core with a high space factor, low
loss and maximum reliability. Lamination shall be annealed to relieve
cutting and piercing strain wherever required. To further lower iron
losses, laminations are mitered and core bolts for clamping are kept to
minimum. Further, manufacturing details on core shall be submitted by
Tenderer. All structural steel work associated with the core is shot
blasted to remove scales, and coated with oil proof varnish.
ii) Coil Winding:-It shall be cylindrical & arranged concentrically,

Continuous disc sections and shielded layer windings as necessary
may be considered at the time of design. Further details shall be
furnished by manufacturer.
iii) Core and Coil Assembly:- Details are to be furnished by

manufacturer. However, as per normal practice, immediately after core
and coil assembly, preliminary ratio and copper loss test are to be
carried out.
iv) Experimental investigations shall also be carried out to determine

the magnitude or nature of the impulse stress. The voltage that would
be appearing between the various points of a winding under surge
condition shall also be found out at this stage by recurrent surge
oscilloscope.
v) Tank :Tank shall be designed to withstand appropriate vacuum and

pressure test and also tested for these. The mechanical stresses are
analysed and welding are checked for any defect by suitable method
like finite element method, ultrasonic / dye penetration method. Gasket
sealing for prevention of leakages and suitable anchoring arrangement

shall be provided to prevent movement of core & winding in transit.
2.4.7.11 Tap Changer:
i) The transformer shall be provided with an on-load tap changer

having a range of + 10% to 10% with 16 steps of 1.25% each. The
tap changer shall be effectively designed for remote electrical, local
electrical and local manual operation.
ii) The tap changer shall include the following:-
a) Oil immersed tap selector and arcing switch provided with resistor.
b) Motor operated mechanism.
c) Control and protection device.
d) Local normal operating device.
e) Local tap changer position indicator.
iii) The tap changer shall be designed such that the contacts do not
interrupt arcs within the main tank of the transformer. The oil filled
compartment of tap selector switch shall be provided with means of
releasing the gas produced due to arcing. It shall be designed so as to
prevent the oil of tap selector compartment from mixing with the oil of
the transformer compartment from mixing with the oil of the transformer
tank. Operating mechanism of OLTC shall be designed such that only
one step is actuated by each command and subsequent step is
actuated by new or repeat command.
iv)The transformer shall give full load output at all taps. The tap
changer shall be provided with out of step protection.
v) The following accessories shall be provided with tap changer:
1. Raise and lower push button (remote).
2. Tap position indicator (remote)
3. Indication lamp showing tap changing is in progress.
4. Motor starter contactor with O/L and single phasing protection.
5. Contactor for forward and reverse.
6. Raise/lower operation on local electrical control.
7. Raise//lower limit switches.
8. Anti condensation heater with switch.
9. Provision and accessories for local manual operation.
10. Interlock between manual and electrical operation.
11. Tap position indicator, mechanical.
12. Operation counter.
2.4.8.0 SPECIFICATIONS OF CONTROL AND RELAY PANEL
2.4.8.1 General Requirements
i) The control/relay panels (CR panel) shall be simplex type suitable for
indoor installation. The cubicles shall be free-standing, floor mounting
type, and shall be made of rigid structural frames enclosed completely
with specifically selected, smooth finished rolled sheet steel of
thickness not less than 3 mm (min.) for front of control panels and 2.5
mm (min) for sides, top and bottom portions as well as doors. There
shall be sufficient reinforcement to ensure level surfaces, resistance to
vibration and rigidity during transportation, installation and operation.
The cubicles shall be vermin, dust and moisture proof and shall provide
degree of protection not less than IP: 31 as per IS: 12036.
ii) All sheet steel works shall be properly phosphated and treated as per
the relevant standards. The cubicles shall be finally painted by powder
coating process or by oven baking process. The colour shade for final
paint shall be Light Grey to shade no. 631 as per IS-5 for both interior
and exterior surfaces.
iii) The General Arrangement and constructional details, as also the

mounting arrangement of different equipment on the control and relay
panels shall be as per standard practices in similar EHV substations.
The schematic/ wiring diagrams shall be in line with standard wiring
diagrams. These drawings shall be furnished by the successful
Tenderers along with the offer.
iv) All wiring shall be carried out with 660 V grade single core multi-strand
flexible copper conductor wires with PVC insulation. Colour coded
wires shall be used for CT/PT circuits. Wiring troughs shall be used for
routing the cables. Ferrule numbers shall be provided at both ends of
cable and the ferrule numbering shall correspond to the numbering in
the approved schematic drawings.
v) Terminal blocks shall be 660V grade, 10 Amps rated, one-piece

mounted type, complete with insulated barriers, stud type brass
terminals, washers, brass nuts and identification strips. Markings on
the terminal strip shall conform to the terminal numberings on the
approved wiring diagram. Terminals meant for CT and PT supplies
shall be provided with disconnecting type terminals, and having
shorting facility for CT circuits. The terminals meant for bus-wiring
shall be provided at the top.
vi) The overall dimensions of the control and relay panel shall be suitably
and appropriately designed by the Tenderer. The relay panels shall be
modular rack-mounting type in accordance with relevant standards.
The protective relays shall be drawout / plug in type as far as possible.
Non-draw out type relays and ancillary components like switches,
lamps etc. wherever required in protection circuits shall be installed on

plates suitable for mounting in racks.
vii) All front mounted as well as internally mounted equipment shall be

provided with individual labels having equipment designation engraved
on. Metal photo-printed anodized aluminum plates or PVC strips duly
engraved (white lettering in black background) shall be used for labels.
viii) All control switches and instrument switches shall be rotary type, with
escutcheon plates clearly marked to show the operating positions.
ix) Semaphore indicators with mimic diagram shall be provided for actual
status indication (ON/OFF) of isolators and circuit breakers.
x) Mimic diagrams depicting the bus-bar arrangement shall be provided

on the control panel. These shall be painted (overlaid) type or screw-
on type aluminum strips. The mimic shade shall be as follows:
a) 132 kV - Dark brown to shade no. 412 as per IS:5
b) 33 kV - Brilliant green to shade no. 221 as per IS:5
c) Earth - Black
xi) Static annunciators suitable for visual and audible alarm annunciation
shall be provided on the control panel. Annunciator fascia units shall
have translucent plastic windows for each alarm point. Annunciator
shall be provided with Accept/Reset/Lamp test push buttons. One bell
for trip alarm and one buzzer for non-trip alarm shall be provided for
each annunciation scheme. Visual alarm shall continue to glow till the
abnormality is cleared. Provision for testing of healthiness of visual &
audio alarm shall be provided.
xii) It shall be ensured that spurious/nuisance alarm does not occur due to
influence of external magnetic field or switching disturbances from
neighboring circuits within the panel.
xiii) Auxiliary supply available for the C&R panels will be as follows:
a) Main DC -110 V with variation (-15%) to (+10%) :

for control, indication, relays, trip etc.
b) AC supply -240V, single phase & 415V, 3 phase 50 Hz, with

voltage variation (-5%) to (+5%) and frequency variation (+/- )3% :
for cubicle lighting, space heaters, power plug etc.
xiv) All the indicating instruments shall be of suitable. size. All 132
kV and 33 kV meters shall be digital microprocessor based power
meters for various data display with memory for storing data. Meters
shall be provided with TTB (Testing Terminal Board). The meters shall
have long life and reliability. For this supporting literatures and test
certificates shall be provided with the offer.
2.4.8.2 Special Requirements
i) Contact multiplication relays if required for multiplication of auxiliary

contacts of breaker and isolator, a single latch relay (electrically
operated type) having N/O and N/C contacts as per the scheme
requirement may be provided for breaker/isolator. These relays shall
be mounted on a frame inside the respective control panel, and shall
be accessible after opening the rear doors.
ii) In transformer relay panels, auxiliary relays (self reset type with hand
reset flags) shall be provided for supervisory functions of transformer
buchholz, WTI, OTI, etc.
iii) In the control and relay panels, separate fuses are to be provided for
various sub-circuits, as per standard practices. Each of these fuses
shall be supervised using suitable auxiliary relays and an alarm shall
be sounded when failure of any fuse takes place. The DC supervision
scheme is to be suitably designed so that failure of 110V DC supply will
be announced through a hooter and indicating lamp.
iv) 132kV/33 kV transformers shall be provided with biased differential

protection and earth fault protection. The relay shall have adjustable
bias setting, and shall be immune to magnetizing in rush currents, but
shall operate correctly for internal faults. The relays shall be suitable
for 2-winding transformers.
v) Each control panel shall have individual fire extinguisher inside the
panel with auto sensor.
vi) The control panel shall be electronic circuit based.
2.4.9.0 SPECIFICATIONS OF STATION TRANSFORMER
2.4.9.1 The station transformer shall be outdoor type, mineral oil immersed,
core type, Copper wound, three phase step down transformer, suitable
for solidly grounded system. The winding shall be uniformly insulated.
The transformer shall conform to IS: 2026 and IS: 6600 (latest). The
temperature rise shall be as specified in IS specifications. Provision of
+7.5% to -7.5% in 7 steps of 2.5% tappings shall be made on the HV
winding. These tappings shall be controlled by an externally operated
OFF CURCUIT tap changing gear capable of being locked in position.
Two separate earth terminals shall be provided on the body of the
transformer for transformer earthing. The transformer shall be supplied
with first filling of transformer oil as per IS: 335 of 1972.
2.4.9.2 Technical Specifications
1) Rated capacity : 200 kVA
2) Rated voltage
HV nominal : 33 kV RMS
HV highest system : 36 kV RMS
LV nominal : 415 volts- 230 V(L-L) RMS
3) No. of phases : 3
4) Frequency : 50 Hz
5) Application : Outdoor
6) Type of cooling : ONAN
7) Method of system earthing
LV side : Neutral solidly earthed
8) Vector group : DY 11
9) Insulation of winding
HV side : Uniformly insulated
LV side : Uniformly insulated
10) Tap changer to be provided

in HV winding
a) Type : OFF LOAD
b) No. of tappings : +7.5% to - 7.5%

(7 steps each of 2.5%)
11) Terminal arrangement : Bushing type on HV & LV side
12) Neutral : Brought out on separate bushings
13) Type of cooling medium : Mineral oil
14) Temperature rise
a) In oil : 50 deg. C
b) In winding : 55 deg. C
2.4.9.3 List of Fittings and Accessories
The transformer shall be fitted with the following accessories:
i) Rating and diagram plate
ii) Two earthing terminals
iii) Lifting lugs for core of the transformer
iv) Dehydrating breather with silicagel
v) Oil level indicator with minimum and filling level markings
vi) Thermometer pocket
vii) Oil filling hole with cover
viii) Oil conservator and drain valve with cover plate
ix) Air relief device
x) Explosion vent
xi) 50 mm bottom filter valve with plug
xii) 50 mm flange type drain valve with plug
xiii) 50 mm top filter valves at top and bottom of transformer tank
xiv) Two nos. of sampling valves at top and bottom of transformer

tank
xv) LT cable end box
xvi) Dial type maximum temperature indicator with maximum reading

pointer.
2.4.9.4 Tests
i) The offer shall include all test certificates as required by IS and Indian
Electricity Rules
ii) The Contractor shall furnish the technical particulars, as indicated

elsewhere in this document.
2.4.10.0 SPECIFICATIONS OF AC POWER DISTRIBUTION BOARDS
2.4.10.1 Intent of specifications
The following requirements shall be applicable for controlling power

distribution to various equipment, operating at 415 V, 3phases or 230V,
phase, 50 Hz supply. Any item not specified but are required for
successful and trouble free operation of the system shall be furnished
under these specifications. These specifications shall be read in
conjunction with the plant description and scope of supply / scope of
work as described else where in this document.
2.4.10.2 General requirements
The general requirements of the distribution board shall be as given

below.
i) This shall be of indoor type and suitable for 415 V, 3 phases, 50 Hz,
solidly earthed neutral system with a fault level of 35 MVA.
ii) The incoming feeders and sectionaliser control will be by Moulded case
circuit breaker with back up HRC fuse.
iii) All the incoming panels shall have digital type ammeter, voltmeter,
power factor meter and frequency meter. Other panels shall have
ammeter only.
iv) The out going feeder at power distribution board feeding power to the
lighting distribution board and load 5kW & above shall be controlled by
3 pole Moulded Case circuit breaker with backup HRC fuses.
v) All other feeders shall be provided with 4 pole/ 2 pole MCBs of suitable
rating with backup HRC fuses.
vi) All motor control feeders shall be provided with independent single
phasing protection.
vii) 10 % of spare out lets for each type (minimum one) shall be provided.
2.4.10.3 Constructional features
i) The power distribution board shall be designed and manufactured as

per relevant Indian standards, practices and requirements.
ii) The distribution board shall be free standing, floor mounting, multi tire
(4 compartments), cubicle type, single front, non draw out type. The
enclosure shall be dust, vermin and weather proof type. The enclosure
shall have a degree of protection not less than IP 52. The board shall
have provision of cable entry from the bottom.
iii) The distribution board shall be fabricated from not less than 2 mm thick
steel sheet and properly stiffened. All panel edges and cover / door
edges shall be properly stiffened against distortion by rolling, bending.
The supporting structure shall be free from flaws, twists and bends.
Rear side of the distribution boards will be covered by removable
bolted covers. The hinged doors provided in the front shall be provided
with proper locking facility and rubber gaskets all around. Proper inter
locking arrangement shall be provided so that incoming MCCBs is
brought to OFF position before the door is opened. The minimum
clearance between the floor and bottom of the panel shall be 500mm
and is covered from the front and end sides by detachable MS sheet.
The structural steel shall be properly surface treated. Two coats of lead
primer shall be applied first over which two coats of synthetic enamel
paint shall be applied for a smooth and elegant surface. The operating
handles, meters, required labels, danger plates shall be provided on
front door of the board.
iv) The board shall consist of number of panels for feeding power to
various loads. Each panel shall be of maximum 4 tire formation. The
bottom compartment shall house terminal blocks for terminating cables.
An earth bus shall be provided in this compartment and extended
throughout the length of the board. The earth bus shall have sufficient
cross section to carry the momentary short circuit and short time fault
currents occurred in the system to the earth. The panel shall have two
earth terminals. The earth bus shall be made of galvanised steel.
Vertical earth bus shall be provided in each panel.
v) In the top compartment 4 numbers of bus bars (3 phases and 1

neutral) and required Isolator will be provided. The bus bars shall run
throughout the length of the board. The bus bars shall be accessible
and properly spaced. These bus bars shall be properly supported on
non-combustible, track resistant and high strength type polyester fibre
glass moulded insulators. Separate supports shall be provided for each
bus bar. If a common support is provided, anti tracking barrier shall be
provided between the supports. The bus bars shall be made of hard
drawn copper and provided with proper colour sleeves of PVC (Red,
Yellow, Blue, Black) to identify the phases and neutral. The bus bars
will be sufficient cross section and uniform throughout the length. The
cross section of bus bar shall be able to withstand stresses due to
specified short circuit currents, however the bus bar rating shall not be
less than the rating of incoming Moulded case circuit breaker rating.
The bus bar temperature shall not be more than 70 degrees Celsius at
full load considering the ambient temperature as 50 degree Celsius. All
bus bar joints shall be provided with high tensile steel bolts, Belleville
/spring washers and nuts to ensure good contacts at joints. Non-silver
plated bus bar joints will be thoroughly cleaned at the locations and
suitable contact grease shall be applied just before making a joint.
Dropper bus bars shall run entire height of the panel behind for feeding
power to each cubicle.
vi) The incoming feeder and sectionliser shall be controlled by a Moulded

case circuit breaker of 3 poles, with backup HRC fuses, non draw out
type with fault level of 35 MVA. The circuit breaker shall have over
load, short circuit, earth fault protections. Digital ammeter, voltmeter,
power factor and frequency meter shall be provided on the front panel
of incoming feeder. Indications such as ON, OFF, shall be provided.
vii) The outgoing feeder for lighting distribution board, load 5kW and above
shall be controlled by MCCB with backup HRC fuse. All other outgoing
feeders shall be controlled by 4/2 pole MCB with back up HRC fuse. All
out going feeders shall be provided with earth leakage protection.
Motor protection relay shall be provided for comprehensive protection
to the motors.
viii) One set of indicating lamps of LED type shall be provided in the front
panel of cubicle for indicting the status.
ix) All the internal wiring shall be carried out in the factory with 660 V
grade, single core, 2.5 sq. mm or larger cross section as per
requirement. The cables shall be PVC insulation type with copper
conductors. Extra flexible wires shall be used for wiring various devices
mounted on hinged doors. All wiring shall be properly supported, neatly
arranged, readily accessible and securely connected to the equipment
terminals and terminal blocks. Internal terminations of standard
conductors shall be made with solder less crimping type tinned copper
lugs which shall finally grip the conductors. Insulating sleeves shall be
provided on exposed lugs or joints. Proper ferrules shall be provided
for identification of wiring
x) Necessary indicating name boards shall be provided on the front door

of the panel.
2.4.10.4. Main components of switch board
i) Moulded case circuit breaker
The Moulded case circuit breakers shall conform to the following

technical parameters:
Quantity : As per requirement

Service : Incoming, sectionliser and outgoing
Normal supply voltage : 415 Volts
Rated current : 200 amps.( minimum )
No. of phases : Three
Frequency : 50 Hz
Application : Indoor
Type : Air break
Breaking capacity : 35 MVA
Construction : Indoor type, single front.
Contacts Copper contacts heavily, silver plated

AC3 duty
Cable entry : From the bottom of the panel
Operation : Manually operated with trip free
mechanism
Indication : Positive ON-OFF
Protection : Overload, short circuit, earth fault
ii) Modules with MCBs
The outgoing modules shall have MCBs with backup HRC fuses:
Quantity : As per requirement

Service : Outgoing
Normal supply voltage : 230/415 volts
Frequency : 50 Hz
Application : Indoor
No. of phases : Single/Three
MCBs rating : 2/4 pole of suitable rating.
Protection : i) overload
ii) Short circuit
iii) Earth leakage
Cable entry : From bottom of the panel
2.4.11.0 SPECIFICATION FOR LIGHTING DISTRIBUTION BOARD

2.4.11.1 General
The lighting distribution board shall be of indoor type and suitable for
operation at 230 V (L-L), 50 Hz supply system. These specifications
shall be read in conjunction with scope of work/supply.
2.4.11.2 Constructional Features
The lighting distribution board shall be designed and manufactured as

per relevant Indian Standards, practices and requirements.
The distribution board shall be fabricated from sheet steel not less than
2mm thick and properly stiffened. The enclosure of distribution boards
shall be weather, dust and vermin proof. The door of the board shall
be provided with pad locking arrangement. The board shall be
adequately surface treated and painted with double coat synthetic
enamel paint after application with two coats of red oxide primer. The
distribution boards will be suitable for mounting on wall as well as on
pedestals. The distribution boards will be of front opening type.
The size of the enclosure shall be suitable to accommodate the

required number of MCCB/ MCB s , HRC fuses, busbars etc. as the
case may be with proper clearance for safety and easy maintenance.
The arrangement of bus-bar, MCCB/MCB, HRC fuses shall be so
designed that they can be easily replaced.
The busbars of adequate size made of copper shall be provided. The

busbars shall be properly spaced to facilitate making vertical
connections to individual circuits through MCCB/MCBs having back up
HRC fuses. The busbar sizes shall be so selected that the
temperature shall not be more that 70oC at full load taking ambient
temperature as 50o C. However the busbar rating shall not be less
than the rating of incoming MCCB rating. The busbar shall be provided
with proper colour sleeves for phases and neutral for proper
identification as per standard practice.
The distribution boards assembly shall be fully factory wired as per

requirement. The busbar, bare conductors, terminals of cables shall be
shrouded with proper insulated tape. Suitable cable termination
arrangement shall be provided to accommodate the incoming and
outgoing PVCSWA copper conductor cables from bottom of each panel
of the distribution boards. Proper cable glands shall be provided.
All distribution boards shall have minimum two earthing terminals.
2.4.11.3 The MCCB s / MCB s shall have built in overload and short circuit
protections. The MCCB will have short circuit breaking capacity of
35kA and MCB will have short circuit breaking capacity of 9kA. The
MCCB will be of 3 pole type, whereas MCB will be of two poles. The
MCB shall be 16A rating. Suitable HRC cartridge fuses shall be

provided for back up protection for each panel.
2.4.11.4 The MCCB/MCB s shall be of quick make, quick break, current limiting
type having trip free mechanism. These shall be provided with
magnetic release which will protect the circuit against short circuit. The
operating lever shall give a clear trip indication and shall be suitable for
interlocking with cubical door. The MCCBs shall ensure operating of all
the three phases in case of a fault in one phase.
.
2.4.11.5 All the components and the boards shall conform to relevant
Indian Standards.
2.4.12.0 SPECIFICATIONS OF 110 V DC SUPPLY ARRANGEMENTS
2.4.12.1 General Particulars
i) The Direct Current supply system shall comprise one set of 110 V ,
200 AH (minimum) sealed maintenance free battery along with
associated float and boost charger (two numbers, one working and one
standby) and distribution boards for supplying 110 V DC for control,
protection, breaker tripping, indications etc.
ii) The charger unit shall be suitable for initial charging, float charging and
boost charging of the battery set concerned. The unit shall be in fully
assembled and completely wired up condition with all the equipments
and accessories fitted in place.
iii) The battery shall be suitable for indoor operation (station type), with
ready grouped plates. The battery shall comprise the required number
of series connected standard 2 volts HDP lead-acid cells.
iv) The inter-connectors (inter-cell and internal cell as also inter row/inter
tier) shall be of lead plated copper.
v) Each battery set shall be complete with the required accessories,

including, but not limited to the following:
Sl .No. Qty. Description
1 1 set Battery rack/stand made of teak

wood painted with 3 coats of acid
resistant paint.
2 1set Porcelain insulators, pad, etc. for

supporting the cells.
3 1 set Inter cell/inter row/inter tier

connectors for the battery.
4 LOT Electrolyte for first filling + 10%

extra in non-returnable containers
5 2 nos. Rubber syringes for electrolyte

handling.
6 1 set Cell number plates and fixing pins.
7 1 set Logbooks for maintaining record.
8 1 set Cell bridge connectors.
9 2 nos. DC Voltmeter scaled (-3) to (+3)

volts with suitable leads for
measuring cell voltage.
10 2 nos. Syringe type hydrometer for

measuring specific gravity of
electrolyte, graded in steps of
0.002.
11 2 nos. Pocket thermometers with specific

gravity correction scale.
12 2 nos. Acid resistant jugs of adequate

capacity
13 2 nos. Acid resistant funnels
14 2 nos. Rubber aprons
15 2 pairs Rubber (hand) gloves
2.4.12.2 Float cum boost Charger and DC Distribution Board (DCDB) for
110 V Battery
i) This unit shall comprise two float charger cum boost charger (one
working and one standby) and two nos. distribution board along with
necessary controls, indication, annunciation and accessories. The unit
shall be made of sheet steel of 14 gauge thickness, and shall have
appropriate and required dimensions.
ii) The sheet steel used for charger cubicle shall be properly surface-
treated before painting. The final shade of paint shall be Light
Admiralty Grey, shade no. 697 as per IS:5., Powder coating process
or, alternatively oven baking process may be adopted for painting. The
enclosure shall provide degree of protection not less than IP:42 in
accordance with IS:12063.
iii) Float cum boost charger shall incorporate silicon controlled rectifiers
along with semiconductor fuses. It shall be possible to use the boost
charger in constant voltage mode also so as to use it as a float charger
in case the main float charger fails. In constant current mode, it shall
have a current stability of +/- 2% of the set value. The constant
current setting shall have step less range variable between 20% and
100% of the rated current. Both the float and boost units shall have
provision for manual setting of the required settings in addition to the
automatic regulator.
iv) The float charger and boost charger shall have current rating of 10 A,
and 20 A respectively. During normal condition the battery will be
floated across the float charger at 2.16 V per cell (+/- 1%), and the
station DC requirement shall be met by the charger.
v) The float and boost charger circuits shall be provided with filtering
devices to limit the ripple content to 5%. Suitable interlock using a DC
contactor and reverse blocking diodes shall be provided so as to
ensure that during boost charging of battery, the float charging circuit is
not connected to the battery, but operates independently feeding to the
station DC loads.
vi) The annunciation scheme shall be fascia window type, and shall have
required number of points for various alarms. Annunciation scheme
shall incorporate static components and circuitry and shall have reset
alarm feature.
vii) Insulation failure (earth leakage) detection circuits shall be provided to

give alarm if any earth leakage occurs.
viii) The DC distribution boards shall have aluminum bus-bars and

adequately rated sub-circuits provided with switch/fuses/indicating
lamps, etc. The no. of circuits required to be decided by the Tenderer.
However, one feeder of 10A rating for emergency lighting shall be
included.
ix) The 110 V rating charger cum DCDB unit (2 nos.) shall be complete
with all the components and accessories including, but not limited to,
the following:
1 1no. 96 sq mm DC Voltmeter to read float/boost/

(0 to 250 V) load voltage
2 4 nos. 96 sq mm DC Ammeter
a) 0 to 30 A Float out-put current
b) 0 to 40 A Boost out-put current
c) 40-0-100A Charge/discharge
current of battery.
d) (-10) (0) (+10) MA Earth leakage current.
3 1 set required no. of window For various alarms

facia annunciator
along with Accept/Test
PBs and alarm buzzer/Hooter
4 As required Selector Switches
a) Auto/Manual selection Float circuit /boost

switch (2 nos.) circuit
b) CC/CV selector Boost circuit.

Switch (1 no.)
c) Voltmeter selector Voltmeter

switch (1 no.)
d) Ammeter selector switch (1no.) Earth leakage circuit
e) Lamp ON/OFF switch (1 no.) Cubicle lamp
f) Feeder ON/OFF switch for outgoing feeders

(As required)
5. Required nos. of LED for Incomer/feeder circuit ON indication
6. Indicating lamps
a) Float charger/boost charger AC ON Float/boost circuit

. as required
b) Float /boost output ON indication as required -do-
c) Battery connect/disconnect (DC contactor

ON/OFF) indication as required Change-over/interlock
kit.
7. 5 nos. MCB/MCCB
a) AC MCB (40A/32A) (2 nos.) Float /Boost circuit
b) DC MCB (40 A/32A) (2nos.) -do-
c) DCDB incomer MCCB (200 A) (1 no.) DC incomer
8. 1 set AC contactor AC incomer circuit
9. 1 no. DC contactor 100A Float/Boost interlock circuit

110 V for interlock/ changeover
10. 1 set Circuitry for supervision/ Different circuits

monitoring fuses, earth leakage,
DC overload etc.
11. 1 set Cubicle illumination lamp Lighting
12. 1 set Power plug and switch AC circuit
2.4.12.3 Transformer used in Chargers
Main transformer shall be dry type double wound, natural air cooled
having continuous rating of at least 125% of the rating of the charger.
Class of insulation shall be class B but, the temperature rise shall be
limited to as that of class A insulation in accordance with IS:4540.
Reactance of the transformer shall be suitable to take care of
regulation and surge.
2.4.12.4 Battery
i) The battery offered shall be stationary, sealed maintenance free, lead

acid type with High Discharge Performance (HDP) conforming to
IS:1651-1991 (Table-5)
ii) The battery shall be suitable for indoor operation and shall be open
type (without cover) with ready grouped plates.
iii) Battery of 110V, 200 AH rating shall consist of minimum 55 nos. of

HDP lead acid cells having 200 ampere-hour capacity at 10 hrs.
discharge rate connected in series.
iv) Cell containers shall be of unbreakable poly carbonate type and shall
be sufficiently robust and free from flaws/manufacturing defects.
v) Cell lids shall be of drop on type together with suitable rubber or plastic
gasket as per relevant clause of IS: 1951-1891.
vi) The inter-cell and internal cell connectors shall be lead plated copper
having minimum thickness of 4 mm and sufficient cross section to carry
the high currents.
vii) The positive (+ve) and negative (-ve) terminal posts shall be clearly
and neatly marked for easy identification. Nuts and bolts for
connecting the cell shall be of brass having effective coating of lead.
viii) The battery shall operate satisfactorily at optimum output.
ix) Battery racks and stand shall be constructed out of seasoned and
matured teak wood of sufficient cross-section. These shall be painted
with at least 3 coats of acid resistant paint. The racks shall be rigid,
free standing type and free from warp and twist. The assembled racks
shall be suitable for being bolted end to end to form a continuous row if
required,.
x) All cells shall be suitable numbered with number plates and fixing pins.
xi) One DC voltmeter having scale of -3v to +3v with suitable leads for
measuring cell voltages shall be provided.
xii) One syringe type hydrometer for measuring specific gravity of

electrolyte in steps of 0.002 shall be provided.
xiii) Additional 5 nos. 2 V cells shall be provided as spares.
2.4.13.0 SPECIFICATION OF 250W (HPSV)/400W ( METAL HALIDE) FLOOD

LIGHT FITTING
The luminaries consist of housing with reflector, glass cover, control

gear box, capacitor, terminal blocks etc.
All components of light fittings including bulbs shall confirm to relevant
Indian Standard or any other international standard.
The luminaries shall be suitable for mounting on structures, poles and
towers. The luminaries mounted on towers shall be of flood light
fittings and others are of street light fittings/flood light fittings.
The flood light luminaries shall be heavy duty industrial type, dust, rain,
weather, vermin and insect proof type suitable to accommodate 250
W(HPSV)/400W metal halide lamp for operation of 200-240V, single
phase, 50 Hz., supply system.
The luminaries shall have a housing made of cast aluminum alloy with
low copper content for excellent corrosion resistance.
It should be provided with heat resistant glass cover to ensure insect
free performance without ingress of water. The glass cover shall be of
plain glass with good transparent properties. A felt gasket impregnated
with insecticide and water repellant chemical shall be provided
between the housing and glass cover. The housing should be closed
from the front. It shall have reflector of high purity aluminum, electro-
chemically brightened and anodised to optimized light distribution.
The control gear box shall be made of suitable aluminum alloy. An
aluminum lid shall be used to close the control gear compartment. The
control gear housing shall be pre-wired with high quality low loss heavy
duty copper wound blast, capacitor to maintain minimum power factor
of 0.9 (lagging). Suitable electronic igniter, connector blocks shall be
provided.
Provision for varying the angle of mounting of luminaries shall be
provided.
The housing shall be provided with cable entry box along with glands
suitable for PVC copper cables of suitable size.
The fitting shall be provided with brackets which can be used for top
mounting or side mounting.
2.4.14.0 SPECIFICATION FOR FLOURESCENT TUBE LIGHT FITTINGS
The light fittings consist of a housing, reflector, electronic ballast,

fluorescent tube rod, terminal blocks, condenser, rotor holder, rear
wiring etc.
All components of light fittings shall confirm to relevant Indian Standard
or any other international standard.
The light fitting shall operate in the voltage range of 200-240V, single
phase, 50Hz, supply system.
The tube light fitting shall be box type and suitable to accommodate
one/two nos. 1.2 m (4feet) long 11 W fluorescent lamps.
The housing shall be made from stove enameled and phosphated
CRCA sheet steel not less than 20 SWG.
Provision shall be made on the base of the box so that the whole set
can be fitted on wall or suspended from roof by conduit pipes.
The box shall be housed with electronic ballast, in-built capacitor if
required, starter along with its base and end holders for holding the
tube rods. The box shall house the required wires for connecting the
various components of the set.
Suitable in-built condenser may be provided to achieve minimum p.f. of
0.9 (lagging). Electronic ballast shall operator without humming and
with low losses.
Suitable sleeves shall be provided at the terminals of wires. Wire
termination arrangement shall be on terminal blocks.
2.4.15.0 POWER, LIGHTING, CONTROL AND SPECIAL CABLES
2.4.15.1 General Requirements
The following are broad requirements and shall be applicable to the

power, lighting, control and special cables furnished under these
specifications. The Bidder shall however submit detailed specification
for all type of cables.
Cables shall be designed and manufactured so that damage will not
result from transportation, installation and operation under all the
climatic and operating conditions to which they may be subjected.
2.4.15.2 Construction
415 volt power cable shall be of 1100 volt grade, copper stranded
conductor, PVC insulated and PVC sheathed single layer armoured
suitable for solidly earthed neutral system.
Lighting cable shall be of 1100 volt grade, stranded copper conductor,
PVC insulated and PVC sheathed single layer armoured.
Control cable shall be of 1100/660 volt grade, multi core copper
conductor, PVC insulated and PVC sheathed, single layer armoured
having a minimum size of 2.5 square mm.
The individual cores of cable shall be identified by different coloured
insulation. For control cables having more than 4 cores, it is preferable
to provide the core number embossed on each individual core.
2.4.15.3 Sizes and Lengths
The cable size and type for 415 volts system shall be selected in
accordance with the system requirements and customer approval.
Bidder shall indicate the size and length of cables necessary to tie up
all the equipment under their scope of supply. However, during
erection if it is found that the quoted lengths are not adequate, the
Bidder shall have to supply the additional quantities to complete their
erection at no extra cost.
Size of the power and lighting cables shall be based on the following
consideration -
a) Short circuit withstand for 1 second.
b) Voltage drop - the maximum allowable voltage drop in the cable
shall not exceed 5% under full load normal working condition and 15%
under starting conditions for the highest and/or most distant located
load.
Length of cables shall be ascertained from the layout drawing so that
straight through cable joints are avoided.
De-rating factors for various conditions of installation including the
following
for all type of cables shall be considered while choosing the conductor
sizes:
a) Variation in ambient air temperature
b) Variation in ground temperature
c) Depth of laying
d) Soil resistively
e) Grouping of cables.
De-rating factors selected shall be based on factors recommended by
reputed cable manufacturers/ IS. The factors considered shall be
clearly brought out in the offer. If it is found that the de-rating factors
considered are not adequate, the Bidder shall have to revise his cable
sizes at no extra cost to the customer satisfaction. The overall de-
rating factor shall not exceed 0.6 in any case.
2.4.15.4 Special Cables
Special cables including but not limited to the following:
a) temperature detectors to the selector switches,
b) temperature indicators, from coal bunker level,
c) indicator temperature detectors to associated electronic
enclosure, etc.
These cables shall be heavy duty fire retarding self extinguishing,
colour coded, shielded, armoured copper conductor 650/1100 volts
grade coaxial screwed compensating mineral insulated etc.
2.4.16.0 SPECIFICATION FOR LIGHTING MAST

2.4.16.1 Scope
The scope of this specification covers the manufacture, installation,
testing and commissioning of complete lighting system, using raising
and lowering type of carriage mounting the luminaries, including the
civil foundation and all items required for safe and efficient operation
and maintenance of lighting system including high mast light fittings
and cables and any other items stated in following pages or not shall
be included in the scope.
2.4.16.2 High Mast
The high mast shall be continuously tapered, polygonal cross section
pleasing appearance and shall be based on proven in-tension design
to give an assured performance and reliable service. The structure
shall be suitable for wind loading as per IS: 875 part 3 and shall be
measured at a height 15m above ground level. The design life of the
mast shall be at least 25 yrs.
The mast shall be fabricated from special steel plate cut and folded to
form a polygonal section and shall be telescopically jointed and welded
and tested as per relevant standards. Mast shall be delivered in
multiple sections of effective length of 15 m (max.). At site the section
shall be connected together by slip and stressed fit method. No site
welding and bolted joint shall be done on the mast. The minimum
overlap distance shall be 1.5 times the diameter at penetration. The
dimensions of the mast shall be decided based on design calculations
shall be submitted for verification.
The mast shall be provided with fully penetrated flange, which shall be
free from any lamination or incursion. The welded connection of the
base flange shall be fully developed to the stress of the entire section.
The base flange shall be provided with supplementary gussets
between the boreholes to ensure elimination of helical stress
concentration. For the environmental protection of mast, the entire
fabricated mast shall be hot dip galvanised, internally and externally
having a uniform thickness of coat.
An adequate door opening shall be provided at the base of the mast
and the opening shall be such that it permits clear access of equipment
like winches, cables, plug and sockets etc. and also facilitate easy
removal of winch. The door opening shall be complete with close
fitting, vandal resistant, weather proof door, provided with internal lock
with paddle key.
The size of the door opening shall be such that it can avoid bulking of
mast section under heavy wind condition.
A fabricated lantern carriage shall be provided for fixing and holding six
numbers 400W metal halide flood light fittings and control gear boxes.
It shall have a perfect self balance. The carriage shall be able to
accommodate wires also. The carriage shall be so designed and have
protective arrangement so that no damage is caused to the surface of
mast during the raising and lowering operation of the carriage. The
entire lantern carriage shall be hot dip galvanised after fabrication.
A weather proof junction box made of cast aluminum or any other
suitable material shall be provided on the carriage assembly as
required from which the interconnections to the flood light luminaries
and control gears fixed on the carriage will be made. The connections
shall be by means of PVC flexible cables of 3 cores, 1.5 sq mm.
For the installation and maintenance of the luminaries and lamps it will
be necessary to lower and rise the lantern carriage assembly. To
enable this suitable wire rope winch along with head frame assembly
shall be provided.
A suitable terminal box shall be provided at base compartment of the
high mast for terminating the incoming cable. The electrical connection
from the bottom to the top shall be made by special trailing cable
having flexibility and endurance. This shall have inbuilt facilities for
testing the luminaries while in lowered position.
Suitable earthing terminals shall be provided at convenient location on
the base of the mast for lighting and electrical earthing of the mast.
2.4.17.0 SPECIFICATIONS OF POST/DISC INSULATORS
2.4.17.1 The insulators shall comply with following requirements:
i) Support the required mechanical loads like tension, torsion and

compression with adequate safety margin.
ii) Shall have sufficient dielectric strength to prevent puncture.
iii) Provide sufficient air gap to give the required electrical characteristics
and withstand values.
iv) Shall provide enough total creepage and protected creepage distance
(not limited to the creepage distance as indicated elsewhere) to
operate in polluted (coal dust laden) atmosphere.
v) Glazing shall be glossy dark brown to prevent accumulation of dust and

dirt.
2.4.17.2 Post insulator
i)The post insulators (for support of 132 kV and 33 kV jumpers, bus

bars etc.) shall be suitable for use in outdoor. The insulators shall be
made of homogeneous and vitreous porcelain of high mechanical and
dielectric strength. Glazing of the porcelain shall be of uniform brown
or dark brown color, with a smooth surface arranged to shed away rain
water.
ii)The post insulators will be provided with a completely galvanized

steel base designed for mounting on the support structure. The base
and mounting will be such that the insulator will be rigid and self
supporting and no guying or cross bracing between phases shall be
necessary.
iii) The post insulator shall be provided with cap of high grade
malleable steel casting. It shall be machine-faced and hot dip
galvanized. The castings shall be free from blow-holes, cracks and
such other defects. All necessary nuts, bolts, washers etc. required for
the assembly of the insulator stack shall be hot-dip galvanized and also
shall form a part of each insulator unit.
iv)The insulator surfaces that come in contact with cement shall be

made rough by sand glazing. All other exposed surfaces shall be
brown glazed. The thickness of the glazing shall be uniform
throughout. The glazing shall remain under compression on the
porcelain body throughout the working temperature range.
v) The ball pins shall be made of drop forged steel. All the ferrous
parts (caps, pins etc.) shall be duly hot-dip galvanised. The security
clips shall be made of phosphor bronze or stainless steel.
vi) Cement used as filler material shall be quick setting, fast curing
portland cement. It shall not cause fracture by expansion or loosening
by contraction. Cement shall not react chemically with metal parts in
contact with it and its thickness shall be as small and as uniform as
possible.
vii) Each insulator shall be legibly and indelibly marked to show the
following
a) Name and trade mark of the manufacturer
b) Month and year of manufacture
c) Electro-mechanical strength in kN
d) Country of manufacture
e) ISI certification mark
2.4.17.3 Disc Insulator
i) Tension type (Dead end) disc insulators shall be ball and socket type
each with a R type security clip. The color of the unit shall be brown
or dark brown. It shall be made of homogenous and vitreous porcelain
of high mechanical and dielectric strength. The ball and socket will
generally conform to IS: 2486- Part II.
ii) Each insulator shall be legibly and indelibly marked to shown the
following
a) Name and trade mark of the manufacturer
b) Month and year of manufacture
c) Electro-mechanical strength in kN
d) Country of manufacture
e) ISI certification mark
iii) The quality of porcelain and hardware duly galvanised as per

relevant IS and workmanship should be of the highest grade suitable
and customary for extra high tension voltages. The porcelain shall be
round, free from defect homogenous, vitrified and smoothly glazed.
Unless otherwise specified the glazing shall cover all exposed
porcelain parts of the insulator. Glazing shall be uniform and free from
defects.
iv) The stresses due to expansion and contraction in any part of the
insulator shall not cause deterioration. Cement used in manufacture of
insulator shall not fracture due to expansion or loosening due to

contraction.
2.4.17.4 Tests
i) For both post type and tension type insulators as described above
suitable number of individual units and complete strings/slacks shall be
subjected to tests in accordance with IS:731-1971 with any
amendments made from time to time and upto date. Type test reports
recently carried out i.e. max. 3 yrs. Prior to the date of opening of the
tender, shall be submitted for individual and string/slack insulators.
However, the Employer reserves the right to carry out the type test for
the samples at the cost of the Contractor if decided by the Employer
and in the presence of the Employers authorised representative.
2.4.17.5 Technical Parameters of Post and Disc (Tension) Insulators 33kV

and 132 kV
Post insulator Disc/String

Insulator
33 kV 132 kV 33kV 132 kV
1. Mechanical
Guaranteed mechanical 10kN 10kN 45kN 45kN

Failing load (not less than)
2. Electrical
a)impulse withstand voltage 170 kV 650kV 170 kV 650kV

(Peak) (Peak) (Peak) (Peak)
b. Power frequency withstand 75 kV 275 kV 75kV 275kV

voltage dry test
c. Power frequency withstand 75 kV 275 kV 75kV 275kV

voltage wet test
d. Puncture withstand voltage 180 kV 1.3 times the

actual dry flash
over voltage of the
unit.
III.. IS to be followed
a) IS: 731 Porcelain insulators for overhead power

lines with a nominal voltage greater than
1000 volts
b) IS: 3188 Characteristics of string insulators.
c) IS: 8765 Specification for ceramic insulating materials

for electrical purposes.
d) IS: 8704 Methods for artificial pollution tests on high voltage

insulators for use on A.C. systems.
e) IS: 8269 Methods for switching impulse tests on high

voltage insulators.
f) Any other relevant IEC recommendations and standard approved

practices
2.4.18.0 SPECIFICATION OF FIRE FIGHTING EQUIPMENT:
2.4.18.1 SPECIFICATION OF AUTOMATIC FIRE DETECTION AND ALARM SYSTEM:
a)Application:-
The system shall be capable of detecting various types of fires that are
likely to occur due to electrical short circuits, burning of false ceilings,
wooden panels, paper, oil, grease, coal etc. in the substation. The
system shall be capable of providing signals to initiate alarms (both
audio and visual) and initiate operation of fire pump and audible
signals. The system shall consist of fire detection units, alarm system,
control and indicating system (PLC based), associated cabling etc.
b) Duty condition: -
The system shall be in operation round the clock. It shall be capable of

operation in an ambient temperature from 4 to50 degrees centigrade in
summer and relative humidity of upto 100% in rainy season.
c) Scope:-
The system shall comply with all the latest applicable statutory rules,
regulations, acts and safety codes which may be in force during the
period of execution and which are related with design and construction
of equipment in the locality where it is to be installed. The statutory
regulations are
i) Fire insurance regulations

ii) Tariff advisory committee regulation
iii) Type approval for smoke detector by CBRI, Roorkee
iv) Indian Electricity Act
v) Indian Electricity Rules
vi) Radiation, safety approval by Atomic Energy Regulatory
Board (AERB), BARC.
The scope of supply in general shall be as enumerated below:
i) Smoke detectors
ii) Heat detectors
iii) Central control and indicating equipment (PLC based)
iv) Alarm system
v) Annunciating panel
vi) Backup power supply
vii) Required power cable, power distribution, control cables
etc.
viii) Any other items which are required for the efficient
operation of the system and not listed above.
d) System Requirements:-
i) Fire detection and alarm system shall be designed, planned and

installed as per the 'Rules for fire alarm system' of Tariff
Advisory Committee.
ii) The equipment involved shall conform to relevant Indian

Standards and in their absence, international standards shall be
used. Copy of the international standards shall be attached
along with the offer.
iii) The system shall be designed and laid in such a way that it will
help to reduce the resultant loss by reducing the delay between
ignition and the start of effective fire fighting.
iv) The system chosen shall be able to differentiate between a fire

and normal environment existing and best suited to the
conditions and that provide reliable warnings.
v) In order to initiate and co-ordinate different activities such as

provision of assistance, commencement of fire fighting
operations, emergency evacuation, summoning of fire brigade
etc. the total area shall be divided into different sectors/zones.
vi) The automatic fire detection system shall consist of a

combination of heat detectors and smoke detectors, while
selecting the combination of heat sensors susceptibility of the
contents to heat, smoke and water damage shall be considered.
vii) The heat detectors shall be of linear type non- integrating and
responds to the temperature of gases in the vicinity. The
detectors may be combination of fixed temperature element type
or rate of rise temperature elements. The heat detectors shall
comply with IS: 2175. The operating temperature shall be at
least 30 degree above the maximum anticipated ambient
temperature of 50C.
viii) Combination of smoke detectors operating on different principles

shall be used for efficient detection and elimination of false
alarms. The smoke detectors shall conform to IS:
11360.Tenderer shall clearly specify the type of detectors used.
ix) The sensors and call points shall be properly designed for easy
identification, so that there may not be any difficulty in identifying
the zones from which signals have been received.
x) Automatic detectors provided in each zone shall be connected

to a separate panel which in turn will be connected to the central
control panel.
xi) The electrical installation of the entire fire alarm shall be

independent of other system.
xii) The central control panel shall be of PLC type. This shall consist
of equipment for the reception of signals from the automatic
detectors and any other signals in the system as needed are
received and commands are given for audio-visual alarm, the
LED shall light up on the panel indicating system 'ON' leaving all
LED's of control panel 'OFF'. The control panel/mimic panel
shall show all the fire protection devices.
xiii) The indications from the mimic panel/control panel shall be

clearly visible, if necessary additional lighting can be provided by
taking supply from alarm circuits.
xiv) The zonal /sector /control and indicating equipment shall be

governed by the relevant provisions under IS 2189. The
provision shall include audio-visual alarm signals, fault signals,
meters, alarm sounders, MCP's etc. In case of fire in a particular
zone/sector, the signal shall be received in the control panel
through the detectors/manual points and these shall be
translated into audio and visual alarm.
xv) The indications on the control panel shall be through LED's and
such that they can be easily, quickly and unambiguously relate
to the position of fire in the plant i.e. sector/zone from where
alarm has originated.
xvi) The indications in the panel may be through display of numbers

or permanent mimic diagram or video display units as the case
may be.
xvii) The control and indicating equipment shall be protected from

adverse surroundings.
xviii) The audible indications/alarms from the panel shall be distinctly

heard and shall be either 65 DB (A) or 5 DB (A) above any other
noise likely to persist shall be required for the sounders.
xix) The panel audible alarm can be silenced by accept push button.
However, the visual indication shall remain on. After taking the
corrective action of fire and when the situation becomes normal,
the system can be reset to its normal position by RESET push
button. However, the alarm shall be re-activated in presence of
smoke/heat in the affected area and can be reset only after the
cause of alarm completely removed. In case the fire spreads to
another area, the panel audible alarm shall reactivate and the
LED's of the affected area light up with the help of respective
alarm facility provided in the panel.
xx) The control room shall have emergency lighting system.
xxi) An UPS system with maintenance free batteries and boost

charger of sufficient capacity shall be provided for operating the
system for 48 hours in case of power failure. Simultaneously it
should guarantee operation of detectors in at least 25 percent of
zones and the operation of fault detector. The operation of
trigger devices in further zones must not result in cancellation of
fire alarms existing at that time.
xxii) The control and indicating equipment shall be connected to

mains through an exclusive circuit with all protections and shall
not be interrupted as a result of switching off mains power to
premises.
xxiii) The cables used for wiring the various components in the fire
alarm system shall be PVC insulated copper conductor cables
having minimum 1 sq. mm cross sectional area conforming to IS
694.
xxiv) Cables shall be completely encased in PVC conduits of required

diameter with min. 2 mm wall thickness. The cables shall be
used exclusively for the detection system and not clubbed with
other cables and wiring. These shall be laid well away from
them.
xxv) Cables connected to detectors, sounders, panels shall be given

'S' loop on both sides and properly clamped. Proper cable
glands shall be provided for the armoured cable near terminals
of junction box.
xxvi) Proper identification marks shall be provided for identification of

wires at junction and terminal blocks. Colour bands shall be
provided along the cable length for identification.
xxvii) Overhead lines shall not be used for interconnecting fire alarm
system. These shall be through u/g cables according to IS 1255.
xxviii) The minimum capacity of the normal main supply shall be

calculated, so as to meet the total power consumption of the
entire system in quiescent condition plus that of all the sounders
with at least 25 percent zones in alarm condition.
xxix) Automatic load switch over to standby supply in case of main

supply failure shall be provided. Similarly automatic charging of
batteries when main resumes shall also be provided.
e) Design Features of Central Control Panel:-
i) The control panel shall be wall/Desk mounting or floor standing type

and shall be made of mild sheet steel of thickness not less than 1.6
mm.
ii) The control panel shall be micro-processor based and fully field
programmable. It shall have sufficient memory to support its operating
system and data bases including fire management, alarm
management, historical and trend data, maintenance support
applications, operator's unit etc. It shall consist of the following:
- Central processing unit
- Built in printer
- Power supply arrangement (Built in battery charger)
- Fire alarm initiating and indicating devices
- Visual display unit
- Cables and accessories to make the operating system complete
iii) Fire alarm control shall function both as independent as well as

interface between control processing unit and the fire detectors, their
accessories and audio visual indicating devices.
iv) It shall have facility to process the input signal and also to control all
the input data received from detectors, manual call points and other
field devices and switches.
v) The control panel shall have following features:
- Logging an alarm, time and action text on printers.

- Status check of disabled alarm addresses before restoration
- Scoring of alarm
- Connection to detectors, manual call points, alarm initiating
device through interface unit.
- Facility of supporting a repeater panel having duplicate indicator/
alarm and switches for activation/ acknowledgement.
- The manual controls for switching OFF/ON of main/standby
power.
vi) The audible and visual alarm state shall be maintained by the
repeater and main control panel without a continued signal from the fire
detectors. The sound characteristics of the alarm shall be similar
throughout the protected premises.
vii) The operation of fire detector/manual call points shall initiate

transmission of signal resulting.
- An audible signal on the main control panel

- A visual signal on main control panel
- At least one external alarm sounder
- A visual indicator for each loop in which detector/ manual call
point operates.
- An audible signal on repeater panel of that loop, if any.
viii) In case, the alarm in the first instance is not acknowledged on main
control panel within 60 seconds, a general evacuate alarm shall sound
on all protected areas.
ix) The audible alarms shall continue to operate until silenced

manually. The operation of silencing switch shall automatically result in
an audible/visual signal being given on main control panel until the fire
alarm is reset.
x) An immediate fault warning shall be given by an audible alarm and

visible indicator on the main control panel. The fault warning alarm
shall be distinct from the fire alarm.
xi) At the main control panel fault warning shall be given for the
following occurrence:
- Failure or disconnection of normal power supply.

- Failure or disconnection of standby power supply.
- Failure or disconnection of battery charging equipment
- Short circuit or disconnection of the leads to trigger device.
- Removal of any triggered device of the plug in type or
Disconnection from its transmitter or power supply.
- Short circuit or disconnection of any of the leads to alarm
Sounder external to the control panel.
- Failure of a scanning device to interrogate detection of area or
failure of any monitoring or integrating system within the control
equipment.
xii) It shall have distinct earth fault indication on the loop wiring.
xiii) It shall have provision for isolation of different loops inside the
panel not accessible to the outside people and whenever isolation is
used, visible indication shall be given on the panel.
xiv) The circuit and mechanical design of the panel shall be such that
operation of one indicator does not prevent the operation of other
indicators and the alarm is not inhibited by any defect/failure in the
indicator.
xv) Each fire/fault indicator shall be clearly labelled with loop address
from which the call originates.
xvi) Test facility shall be provided to test alarm circuit, sounder indicator
etc.
xvii) The following shall be provided :
- Acknowledge button
- Alarm cancel indicator wherever required.
- Isolation/reset facility
- Related fuses/protective devices.
xviii) The control panel shall have electronic/electrical relays for the
following facilities:
- It shall have a pair of red LED to indicate origin of fire and an

amber LED to indicate the origin of fault.
- A sounder with distinct audible sound for fire and fault alarm
- Audible signal acknowledge/silence button and LED to indicate
Its operation.
- Voltmeter and ammeter on main D.C. power circuits.
- System 'ON' standby 'ON' indicators, test key/button, operation
indicator and facility to isolate repeater panel/main control panel
from rest of the system.
- Where repeater panel is isolated, its signal shall come on the
main control panel.
- Failure of any indicator circuit shall not prevent the fire alarm
from sounding or acknowledgements/ silencing of alarm from
one loop to another alarm coming from other loop on the panel.
- Switches to actuate alarm from main control panel to repeater
panels.
- Test facility to check fire alarm/fault circuit, indicators etc.
xix) Indicators for the following shall be provided:
- System healthy
- Alarm
- Pre-alarm
- Fault
- Test
- Alarm silence
- Fault silence
- Processor run
- Processor halt
- Isolate
It shall also have the LED indicator for:
- Mains 'ON'
- Battery output 'ON'
- Charger 'ON'
- Battery under voltage
- Battery disconnected
- Battery reverse
In case, any of the above failure the panel audible shall be activated
emitting continuous sound. The alarm shall be silenced by accept push
button.
xx) The control panel shall have facility for the following features :
- Control panel self test

- LED/LCD test
- Fault test (Detector fault and battery fault)
- Sounder test (external and internal)
xxi) It shall have facility of brief user guide menu to enable the operator
for use of various menu functions.
xxii) The VDU shall display the following:
- Event (Alarm, pre-alarm, fault isolate)

- Commands, reports and graph of each loop to pin point the area
under fire along with composite display of each loop covering the
area.
xxiii) The control panel shall be protected from short circuit on the
detector lines and display appropriate message.
xxiv) Control panel shall also monitor open circuits on the detector lines
and display appropriate message.
xxv) Provision of on line change of modules.
xxvi) The control panel shall have full fledged built in diagnostics.
xxvii) The control panel having built in battery charger which shall have
facility for float cum trickle charging with boost facility.
xxviii) The main panel shall have the following interfaces:
- One port for remote annunciation

- One port for city tie connection
- One port for service and field programming
- One port for printer
xxix) Test Certificates:
The offer shall include all test certificates as required by relevant BIS
and international standards.
2.4.18.2 SPECIFICATIONS OF STAND POST TYPE FIRE HYDRANT AND HYDRANT

VALVES
i) Application:
Stand post type fire hydrants at DG shed, transformer oil filtration cum
purifier shed, oil storage shed ,pump house and substation building
along with adaptors, hydrant valves will be installed as required for

supplying water at required pressure and quantity to suppress the fire.
This will be connected to the main pipeline through reducer pipe and
adopters. The valves shall be able to work in dusty atmosphere. Fire in
the outdoor yard equipment (except power transformer) shall be
quenched by CO2/ Dry type chemical powder fire extinguishers. The
40/50 MVA transformers shall be fitted with Nitrogen injection system
for fire fighting purpose.
ii) Scope of Supply:
The scope of supply shall consist of the following items in required

quantities as per the specifications mentioned in the subsequent
clauses
- Stand post type fire hydrant.
- Underground hydrant valve.
- Hydrant key and required accessories.
- Any other items for efficient use.
iii) Constructional Details:-
-The stand post type fire hydrant shall be manufactured as per IS:
908(Current).
-The hydrant post shall be of suitable internal diameter at the inlet it

shall have a male outlet which can be screwed into the female end of
underground hydrant valve. The outlet shall have female end so that
fire hydrant hose can be fitted to it.
-The hydrant post may be made of cast iron or MS steel. The minimum
height of post shall be 900 mm.
-The hydrant post shall be able to deliver required quantity of water at

required pressure
-The hydrant valve shall be of gun metal and manufactured as per

relevant Indian Standards.
-The hydrant valve shall have flanged inlet suitable for inlet pipe as per
design and the outlet shall be female type of suitable diameter with
standard threads on it.
-The hydrant valve shall be suitable to be installed underground and

shall have provision to be operated by a hydrant key made up of MS
bar of suitable size and length.
-The hydrant valve shall be of single outlet type.
-The flange of the valve need not be provided with holes. Holes will be
made at site to suit the flange of the 'T' joint of the main pipe.
-Suitable stuffing boxes shall be provided in the hydrant valve.
-All the fittings shall be of good quality and workmanship, finish and
free from turns and sharp edges.
-The forgings and castings shall be sound and free from blow hole,
scales and other imperfections. On inspection if any of the defects are
noticed in any one piece, the entire lot may be rejected.
-The design shall be such that it will operate at maximum efficiency

with minimum maintenance.
-The valve and hydrant post shall be tested to a suitable hydraulic

pressure and there shall not be any leakage.
-All M.S. and C.I. parts exposed to water shall be painted with anti-
corrosion paint and outside shall be painted with post office red enamel
paint.
2.4.18.3 SPECIFICATIONS OF FIRE HOSE BOXES/CABINETS
i) Application:
The fire hose boxes/cabinets will be used to store the fire hoses
together with nozzles and will be installed near the hydrant points on
posts. The cabinets are mainly meant for increasing the life of the
hoses by preventing them from exposing to heat, rains and other
atmospheric conditions. These cabinets shall also help in preventing
thefts of hoses and shall be always ready for use in emergency
conditions.
-Fibre glass fire hose cabinet suitable to store two rolls of 15 m long
and hose pipe together with requisite nozzles and hose pipe couplers if
required.
-Brackets and posts to erect the cabinet near the hydrant point.
-The supply shall be as per the specifications mentioned in the

subsequent clauses.
iii) Description of the cabinet:
-The cabinet shall be moulded out of red pigment of fibre reinforced

plastic.
-The cabinet shall be fitted with fibre glass doors.
-The size of the cabinet shall be suitable to accommodate two rolls of

15 m. length fire hoses in rolled condition along with couplers and
nozzle.
-The cabinet shall be capable to resist the weight of the above-

mentioned hoses.
-The back wall of the cabinet shall be provided with metal inserts to
provide extra strength for mounting it on the suitable posts/on wall.
-The surface of the cabinet shall be finished to have a glassy surface.
-The cabinet shall be fitted with double doors. The doors shall be fitted
with brass hinges, ball type, self-locking arrangement, extra lock facility
and handles. The centre of the door panels shall be fitted with
transparent acrylic sheets.
-The cabinets shall be of light weight and shall be dust and water proof.
Rain guards and dust seals shall be provided at the doors.
-The material of the cabinet shall be non-corrosive, non-conductive,

non-bendable, un breakable and shall be more durable.
-The colour of the cabinet shall be red. `Fire hose cabinet' shall be
written with paint on the glass panel.
-Suitable brackets shall be provided to fix the cabinet on the post.
iv) Standards:
The cabinets shall be as per latest relevant Indian Standards or

equivalent International Standards.
2.4.18.4 SPECIFICATIONS OF FIRE HOSES:
i) Application:
The fire hoses will be used for supplying large quantities of water at
high pressure in an uninterrupted way from a suitable drain point up to
the place where fire occurs. The hoses will be stored in roll form in
fibre glass hose cabinets. These cabinets will be kept in open
atmosphere wherein temperatures as high as 50 degrees Celsius are
expected to reach in summer and relative humidity of 100% is

expected in rainy season.
Scope of Supply:
The supply shall be as per the specifications mentioned in subsequent

clauses and shall consist of the following:
Fire hoses of suitable diameter and 15 m long.
Constructional details:
i) The hose shall be made up of false canvas.
ii) The canvas shall be treated with suitable substance to improve

its mildew resistance characteristics so that flexing
characteristics does not deteriorate even though it is wet.
iii) The hose shall be light in weight.
iv) The hose shall have least resistance to flow of water so that
frictional losses are less.
v) It shall have long life and suitable for fighting industrial fires. It
shall not get damaged even after coming in contact with hot
objects or due to the heat radiated from fires that are being
extinguished.
vi) The hose shall be resistant to rotting.
vii) Provision for fitting the gun metal female couplers shall be made
to connect another hose very easily, if required.
viii) Maximum length of the roll shall be 15 m.
ix) The hose shall withstand bursting pressures of at least 32

kg/cm2 or as per relevant IS.
x) The hose shall not loose its characteristics even though they are
kept in atmosphere where temperature as high as 50 degrees
Celsius are reached and also relative humidity of 100% are
reached.
Standards:
The hose shall be manufactured as per IS: 8423 current or any other
equivalent International Standards.
2.4.18.5 SPECIFICATIONS OF BRANCH PIPES, NOZZLES, NOZZLE SPANNERS AND

HOSE COUPLINGS
i) Application:
The hose couplings consists of male and female half couplings to

which branch pipe will be attached along with the nozzle for
discharging water from the fire hose on to the fire. These items will be
stored in the fire hose cabinets situated near the vertical hydrant posts.
The scope of supply in each set shall include the following items
conforming to the specifications given in the subsequent clauses. The
complete set shall be kept inside the fire hose cabinets for ready use in
case of emergency.
(a) One set of male and female couplings.
(b) One nozzle.
(c) One set of branch pipe
(d) Tools required for the assembly and dismantling of the above
items.
iii) Constructional details:
- All fittings shall be of good workmanship, finish and free from burns
And sharp edges.
- The forgings and castings shall be sound and free from blow-holes,
scales, cracks and other imperfections.
- The water way of the fittings shall have smooth finish.
- All the fittings shall conform to IS: 903 Current.
- All the accessories shall be able to withstand a hydraulic pressure of

2.1 MN/ sq mm (21 kgf / sq cm) for a period of 2 minutes. The hose
shall not show any sign of leakage or sweating.
- All the castings and forgings shall be made of copper alloy (gun metal).
The specifications of the material shall conform to the relevant Indian
Standards as specified in IS: 903 Current.
IV) DELIVERY HOSE COUPLING
- It shall consist of male half coupling, female half coupling and suitable
washers, nuts, bolts, etc.
- Provision shall be made so that both couplings can be tied together.
- The coupling shall be suitable for fire hose with 63 mm internal

diameter and other dimensions shall conform to IS: 903.
- Provision shall be kept to fix another half of a different branch pipe to

the female half coupling.
- Phosphor bronze wire conforming to IS: 7608 shall be used in the

coupling.
- The washer used in the coupling shall conform to Type 'A' of IS:1937
(Current).
- The coupling surface shall be such that the hose can be fitted easily
and will not come out during operation.
v) NOZZLE:
- The nozzle shall be able to deliver the required quantity of water

smoothly.
- The constructional details and dimensions shall be as per IS: 903

Current.
- One end of the nozzle shall be provided with threads conforming to

IS:2643 (Part-I) so that it can be fitted to the branch pipe.
- The inside diameter at discharge end of the nozzle shall be 30mm.
vi) NOZZLE SPANNER:
- The nozzle spanner shall be made out of steel of Grade C-35 or C-40
as per IS: 1570(Part 5).
- The shape and size of the spanner shall be as per IS: 903.
- The nozzle spanner shall be given anti-corrosive treatment by a

suitable coat of chromium or zinc.
- The spanner shall be tested as specified in IS: 903 for testing the
permanent deflection of the spanner job.
v) BRANCH PIPE:
- It shall be of required diameter and length
- The wall thickness shall be sufficient to withstand the water pressure.
- The branch pipe shall have provision at one end for connecting the
female half coupler of the hose and the other end with threads for fitting
the nozzle.
- The branch pipe shall conform to IS 903 (current).
vi) Standards:
All the accessories such as fire hose couplings, branch pipes, nozzles,
nozzle spanners shall be manufactured as per IS: 903(Current).
2.4.18.6 SPECIFICATIONS OF PORTABLE CO2 FIRE EXTINGUISHERS
i) Application:
The portable CO2 type fire extinguisher will be used where fires due to
wood, paper, inflammable liquids, rubbish and fires due to electrical
short circuits are expected.
ii) Duty Conditions:
These fire extinguishers shall normally be stored at suitable locations in

the substations and shall be able to be used effectively whenever
required in shortest possible time. The places where these will be
stored are usually dusty at relative humidity in monsoon at 100% and
temperature at 50 degrees Celsius in summer.
iii) Scope of Supply:
The fire extinguisher shall conform to the specifications given in the

subsequent clauses and the scope of supply shall consist of the
following:-
-Fire extinguisher consists of container along with cap, valve, rubber

hoses, brackets to support the extinguisher on the wall or on structural
members.
-Initial charge and required accessories.
-Operating manual giving details of recharging method also.
-Any other items required.
iv) Constructional details:
-The extinguisher shall be of 4.5/5 kg capacity
-The extinguisher shall be compact in size, light in weight so that it can

be carried very easily from one place to other to combat fires.
-The extinguisher shall use CO2 as ingredient.
-The body of the extinguisher shall be made of stainless steel sheets of

adequate thickness to withstand the pressure.
-The mouth of the container shall be fitted with stainless steel pipe,
nozzle, valve, PVC hose etc. The valve provided at the mouth shall be
able to control the discharge of fluid as required.
- CO2 shall be charged in gas cartridges which are applied with suitable
material to avoid corrosion.
-The container shall be rechargeable type after its use.
-The life of the liquid shall be sufficiently long and properties shall not
be changed even though they are kept in temperatures of 50 degrees
centigrade continuously for long periods.
-The container shall be coated with two coats of signal red colour and
enamel paint.
-Every extinguisher shall have instruction plate fitted to it for easy use
at times of emergency.
-The extinguisher type shall be engraved on the container.
-The nozzle provided at the mouth shall be able to discharge CO2 at

high velocity so that it can cover larger areas and also penetrate deep
into the fire very fast.
2.4.18.7 DRY POWDER TYPE FIRE EXTINGUISHERS
i) Application:
The dry powder type fire extinguisher will be used where fires due to
wood, paper, inflammable liquids, rubbish and fires due to electrical
short circuits are expected.
ii) Duty Conditions:
These fire extinguishers shall normally be stored at suitable locations in

the substation and shall be able to be used effectively whenever
required in shortest possible time. The places where these will be
stored are usually dusty at relative humidity in monsoon at 100% and
temperature at 50 degrees centigrade in summer.
iii) Scope of Supply:
The fire extinguisher shall conform to the specifications given in the

subsequent clauses and the scope of supply shall consist of the
following:-
- Fire extinguisher consists of container along with cap, valve, rubber

hose, brackets to support the extinguisher on the wall or on structural
members.
- Initial charge and required accessories.
- Operation manual giving details of recharging method also.
- Any other items required.
iv) Constructional details:
- The extinguisher shall be 22.5 kg capacity, trolley mounted.
- The extinguisher shall use dry powder as ingredient.
- The body of the extinguisher shall be made of stainless steel sheets

of adequate thickness to withstand the pressure.
- The mouth of the container shall be fitted with stainless steel pipe,
nozzle, valve and PVC hose. The valve provided at the mouth shall be
able to control the discharge of fluid as required.
- Dry powder shall be charged in gas cartridges which are applied with
suitable material to avoid corrosion.
- The container shall be rechargeable type after its use.
- The life of the material used shall be sufficiently long and properties
shall not be changed even though they are kept in temperatures of 50
degrees centigrade continuously for long periods.
- The container shall be coated with two coats of signal red colour and
enamel paint.
- Every extinguisher shall have instruction plate fitted to it for easy use
at times of emergency.
- The extinguisher type shall be engraved on the container.
- The nozzle provided at the mouth shall be able to discharge dry

powder at high velocity so that it can cover larger areas and also
penetrate deep into the fire very fast.
2.4.18.8 SPECIFICATIONS OF PIPES AND PIPE FITTINGS
i) Application:
The pipes will be used for supplying water to the post type fire
hydrants, wall mounted hydrants points etc. from the sump to
extinguish the fire through a high pressure pump. The pipes may be
buried underground or supported on saddles on the ground as per
requirements.
The scope of supply shall be as per the specifications given in the

subsequent clauses and the quantity shall be as follows:-
-GI pipes of suitable diameter along with couplers - LOT.
-GI pipe 'U' bends 'L' bends - LOT.
-GI 'T' joints - LOT.
-Sluice valves along with gaskets -LOT.
-Pipes of different diameters as per requirement along with required

number of sluice valves, non return valves etc. - As Required
iii) Constructional details:
The details of pipes and pipe fittings are as follows:-
-The pipes shall have internal diameter as per requirements.
-The pipes shall be centrifugally cast (spun) iron, pressure pipes of

class 'A'.
-The pipes shall be of standard lengths.
-The inside walls of the pipes shall be well finished to reduce the
frictional losses. The pipes shall be free from blow holes.
-The pipes shall be able to withstand the water pressure as per

standards.
-The pipes shall be manufactured as per relevant Indian standards.
-The pipe fittings such as bends and 'T' joints shall be made of G.I.
-Radius of the bends and the hole in 'T joints shall be such that there
will not be any obstruction to the flow of water in required quantities.
-The sluice valves shall be suitable to G.I. pipes manufactured as per

latest Indian Standards and shall be operated by a hand wheel.
-The sluice valves shall be manufactured to withstand 16 kg/cm2 water

pressure.
2.4.18.9 SPECIFICATIONS OF SAND BUCKETS
i) Application:
These buckets will be used to store sand and will be kept in switching
room, substations, pump house, drive houses, compressor house,
hydraulic power pack room, various floors in silo and sampler house
etc.
ii) Constructional details:
a) The sand bucket shall be of 9 litre capacity.
b) These shall be made/manufactured from M.S. sheet steel of 24

gauge conforming to relevant I.S.
c) The bucket shall be of round bottom.
d) The bucket shall have a handle so that it can be hung from

hooks placed in the brackets or fire bucket stand.
e) Riveting/welding shall be used for joining the ends of vertical

wall.
f) The whole bucket shall be galvanised after manufacture.
g) The bucket shall be painted with two coats of corrosion resistant

red paint. The bottom shall be painted with black colour. On the
outer surface of the bucket letters 'fire' shall be written in black
colour. The inside of the bucket shall be painted with an
anticorrosive paint of dark shade.
2.4.18.10 SPECIFICATIONS OF LANDING VALVES FOR INTERNAL FIRE HYDRANTS:
i) Application:
Landing valves for internal fire hydrants will be installed at different

locations in side the substation building for supplying water to suppress
the internal fires. These valves will be connected to the main water
supply line through reducer, flanges etc.
ii) Scope of supply:
The scope of supply shall consist of the following items in required

quantities as per the specifications mentioned in the subsequent
clauses:
a) Double head type valve along with independent controlling

valves
b) Brackets to support the valves
c) Installation drawing
d) Any other items for efficient use of the landing valve
iii) Constructional features:
a) The landing valve shall conform to IS: 5290 (current) and shall have
the approval of Tariff Advisory Committee for use in high rise industrial
structures.
b) The landing valve shall be of double ended type with outlets at right
angles to the axis of main pipe.
c) Independent control valves shall be provided for the outlets.
d) Suitable arrangement shall be made for supporting the valve on wall.
e) The hydrant valve shall be made of Gun Metal. The wheel shall be
of cast iron.
f) Suitable stuffing boxes shall be provided in the valves to avoid any

leakage.
g) All the fittings shall be of good quality and workmanship, finish and
free from turns and sharp edges.
h) Forgings and castings shall be wound and free from blow holes,
cracks, scales and other imperfections on inspection, if any defect is
noticed in any one piece, the entire lot may be rejected.
i) Design shall be such that it will operate at maximum efficiency with

minimum maintenance.
j) All M.S. and C.I. parts exposed to water shall be painted with anti-
corrosion paint and out side shall be painted with post office red
enamel paint. Alloy parts shall also be painted with suitable paint.
2.4.18.11 SPECIFICATIONS OF ELECTRICALLY OPERATED CENTRIFUGAL PUMP-

MOTOR SET
i) Application:
The pump motor set shall be used on surface for pumping water for fire
fighting purposes. The pump shall draw water from an underground
sump (1,35,000 litre capacity, minimum) and supply to the nozzles for
spraying the water at fire.
ii) Duty:
The pump motor set shall be able to operate continuously at full load in
ambient temperature upto 50 degrees Celsius, relative humidity up to
100%. The motor and pump shall be suitable for frequent starts and
stops.
iii) Scope:
The scope of supply shall consist of the following:

(a) Pump along with coupling, motor and starter (push button type)
(b) Standard Accessories: These shall include bed frame, priming

funnel, pressure gauge, strainer, non return valve etc.
(c) First fill of grease etc.
(d) Foundation bolts.
(e) Special tools for maintenance of the pump
(f) Any other items which are necessary for efficient operation of
the pump but not covered in this list.
The other specifications of the Pump motor set shall be as given in

subsequent clauses.
iv) Description of the Equipment:
Mechanical:
a) The pump shall be of centrifugal type.
b) The impeller shall be made from close grained C.I. of Grade 20

conforming to IS: 210(Current). This shall be free from blow
holes. Impeller shall be properly balanced to avoid undue
vibration. Provision of holes in the impeller for balancing is not
acceptable.
c) The pump casing shall be of horizontal split type depending on

design considerations. This shall be made from close grained
cast iron of Grade 20 conforming to IS: 210(Current) for the
main pump. The casing shall be free from blow holes. The
casing shall be of volute construction for smooth and efficient
flow of liquid.
d) The pump shall have priming funnel for priming purpose. The
pump shall not get damaged when it is started in partially primed
condition.
e) Proper flanges shall be provided on the pump body for

connecting the suction and delivery pipes.
f) Proper sealing arrangement consisting of stuffing boxes fitted

with suitable packing material shall be provided to prevent
leakage within the casing. The sealing arrangement shall be
such that replacement of packing material does not require
dismantling of any other parts except the glands.
g) Suitable deep groove ball bearings or any other type antifriction

bearings with proper lubrication shall be provided. The bearings
shall have a life of min.50000 hours at full load.
h) The bearing housing shall be provided with effective sealing

arrangement against the entrance of water or dust. Grease
cups shall be provided for lubrication purpose. A drain plug
shall be provided below each housing of the pump. The
housings shall be provided with grease nipples also.
i) 'V' belt drive is not acceptable. Motor shall be connected to the

Pump through a pin bush type flexible coupling.
j) The flexible coupling with output transmitting capacity 1.25 times

the motor rating shall be provided. The coupling shall be
provided with a coupling guard. The coupling shall be able to
absorb combination of parallel, angular and axial misalignments.
k) The base frame shall be fabricated from M.S. structural steel to

meet the duty condition. The pump and motor shall be properly
aligned in the works of manufacturer before supply. Lifting lugs
shall be provided for easy lifting.
l) The pump shall be suitable for frequent starts and stops.
m) The pump offered shall be suitable for operating at a head

variation of +20% to -20% of the duty point head.
n) Suitable arrangement shall be provided for balancing the

hydraulic thrust.
o) Direction of rotation of pump shall be indicated clearly on the

pump body.
Electric Motor:
a) The motor shall be horizontal, foot mounted, squirrel cage

induction type, TEFC, Non-flameproof. The enclosure
protection of motor shall be IP-54 and S1 - continuous duty with
Class 'B' insulation suitable for DOL starting. It shall be suitably
rated to meet the duty conditions and also requirement at any
point of the pump operating range.
The synchronous speed of the motor shall be 1500 r.p.m. The

motor shall be suitable for 415 V, 3 phases, 50 Hz A.C. supply.
The cable end boxes shall be suitable for copper conductor
PVCSWA cables of suitable size. The operating characteristics
at rated output, frame size, insulation class shall be given in the
offer.
b) Motor shall be capable to deliver rated output with -
-the terminal voltage differing from its rated value by not more
than+/-10% or
-the frequency differing from its rated value by not more than +/-
6% or any combination of above limiting to 10 %
c) Motor shall be operated from a remote place.
d) Motor Earthing: Provision for earthing of Motor in accordance

with relevant provision of IS: 3043-1966 or latest revision thereof
and relevant IE rules shall be given. There shall be min.2
points.
e) Limits of Vibration shall be as per IS: 4729-1968. Double

amplitude of vibration for the motors shall be within the limit
specified in IS: 4729.
f) The motor shall conform to the following IS or their latest

revisions thereof:
- IS: 325-1978 - Specifications of 3 phase

induction motor
- IS: 4691 - Degrees of Protection provided by
Enclosures for rotating Electrical
machinery
- IS: 6362 - Cooling
- IS: 4722 - Duty type
- IS: 4728 - Terminal Marking
- IS: 8789 - Value of performance characteristics
- IS: 7538 - Motor with centrifugal pump
- IS: 1231 - Dimensions of three phase foot

Mounted induction motor
- IS: 2253 - Type of construction and mounting of

motors
Starter:
A push button type start / stop switch will be provided in the pump
house for starting and stopping in case emergency. The pump will
receive power from a MCC and controlled from a central control room.
A diesel operated pump shall also be supplied and installed in the
pump room for fire fighting purpose.
2.4.18.12 SPECIFICATIONS OF NITROGEN INJECTION SYSTEM FOR POWER

TRANSFORMERS
The offered product should be an integrated safety system designed

for oil filled transformers in order to prevent tank explosion and the fire
during internal faults and also extinguish the external oil fires on
transformer top cover due to tank explosion and /or external failures
like bushing fires, OLTC fires.
The system shall drain a pre- determined quantity of oil from the tank
top through outlet valve to reduce the tank pressure and inject nitrogen
gas at high pressure from the lower side of the tank through inlet
valves to create stirring action and reduce the temperature of top oil
surface below flash point to extinguish the fire. Conservator tank oil
shall also be isolated during bushing bursting, tank explosion and oil
fire to prevent aggravation of fire.
The system shall be designed to operate automatically with manual

override. It should be designed with dedicated backup power supply so
as to respond in case of power supply failure.
The system shall consist of following:
(i) Microprocessor based PLC Control panel placed in the control

room with audio-visual alarm indication, common for control of
two transformers.
(ii) Human machine interface to be provided with control panel

depicting system layout, real time monitoring of system
operation , control and remote operation, common or control of
two transformers.
(iii) Rate of pressure rise relay (RPRR) for detection of fault

condition.
(iv) Flame sensors - UV/IR spectrum based , for external and early
pre-arc fume fire detection.
(v) Fusible alloy type sensor for backup protection.
(vi) Necessary valves with real-time response for conservator, oil

drain and OLTC. Electromechanical control equipment should
be provided for the same.
(vii) Fire extinguishing cubicle placed on a suitable plinth with IP 65

protection.
(viii) A dedicated backup power supply should be provided with the

system
(ix) A signal box for interconnecting and securing cables should be

provided.
(x) Fire survival cables to be provided for connection between all

sensors, actuators and control panel.
(xi) Sensor should be magnetic mount/thread or flange type to avoid

structural changes in original design of transformer.
(xii) Nitrogen cylinder should be fitted with pressure regulator and

falling pressure electrical contact manometer.
(xiii) Oil drain pit of suitable volume should be constructed.
(xiv) All necessary pipe lines, fittings , cabling and required

accessories along with mandatory spares should be provided.
(xv) The system should comply with latest international/national

standards and should be tested and certified by
international/national testing body (NABL accredited body).Bidder
is required to submit documents related to the same.
Civil specifications NIT for 132kV Substation at Kusmunda OCP
2.5.0. CIVIL SPECIFICATIONS

2.5.1.0 TECHNICAL SPECIFICATION FOR SOIL INVESTIGATION
WORK:
2.5.1.1 Scope:
This specification is intended to cover the complete soil exploration
of the Plant area, as elaborated hereunder and as may be required
in the interest of the work.
Making test bores in the area for soils including taking out requisite
number of undisturbed samples at different depths for Laboratory
tests, making standard penetration tests at different depths,
recording ground water levels, maintaining driving record,
preparation of bore-hole log for each bore-hole etc.
Conducting plate bearing load test including cyclic loading and
unloading operations wherever required.
Laboratory tests on requisite numbers of collected samples for
determining natural moisture content, particle size analysis, index
properties, wet and dry density, unconfined compression test,
shear test by tri-axial compression, consolidation tests, permeability
tests etc and chemical analysis for soil and water samples collected
from bore holes for SO4 & CL.
If rock is encountered, drilling through rock up to 3 m including core
recovery, 90% core recovery is to be obtained and determination of
crushing strength of rock samples.
Direct undisturbed soil sample testing by open trial pit.
Preparation and submission of a comprehensive soil report with
recommendations for type of foundation, bearing capacities for
shallow foundation, method of deep excavation, probable
settlement for foundations etc.
Locations of performing direct load test and open trial pit are to be
selected by the contractor, but before carrying out the tests prior
approval should be taken from the Purchaser regarding the location
of such test.
2.5.1.2 Records:
All field records shall be submitted to the Engineer-in-charge in
duplicate as and when they are recorded during the process of soil
investigation.
2.5.1.3 Test Boring:
Test boring through different layers of soil shall be carried out by
the Contractor at the locations as marked on approved system
drawings and at such other places within the plant areas as
directed by the Engineer-in-charge in a manner described below.
Depth of boring shall be 20 m or refusal strata, whichever is lesser,
below the natural ground level. If the present formation level is
NIT 688 dtd 17.09.14 Job No.502255 (VOL II) Page no-163
above the natural ground with filled up soil, the depth of boring
mentioned shall exclude such filled up soil. Various methods of
boring are described in IS code of practice IS 1892 latest revision,
which may be adopted. Shell and auger type boring with boring
diameter not less than 150 mm should preferably be carried out in
such type of soil as found in the site. However, the Contractor shall
describe in detail, the equipment and method of boring he proposes
to use.
Samples of undisturbed soil shall be obtained preferably at every
1.5 m or where a change in strata is indicated but in no case, more
than 3 m and a sample shall be obtained on the average for every
2.0 m depth of boring, since it is intended to ascertain the
characteristics of the soil at various depths. If, however, there are
uniformity in the characteristics of the soil for certain depths, the
Engineer-in-charge may limit the number of samples stipulated
above.
The size of soil test samples specially undisturbed samples shall
preferably conform to the type of sampler used. The contractor
may use either open tube samplers or piston samplers. While
collecting undisturbed samples the boring rods along with the
sampler should be pushed into the soil and in no case the
contractor should resort to hammering. If there is any surface
water on the top of sample, this shall be wiped off with soaking
paper and immediately sealed with wax and marked with respective
test bore numbers, depth at which the sample was taken and other
relevant information.
Ground water level for each bore hole shall be checked during
boring operation and shall be recorded in bore log. The contractor
shall maintain a bore log for each soil test boring on an approved
pro-forma. While carrying out standard penetration test the
contractor shall record the number of blows for each 150 mm of
penetration of the sampling split spoon. The first 15 cm of
penetration shall be considered as seating drive and the total
number of blows for the next 30 cm of penetration resistance at the
specified depth. Hammer used for driving the split spoon shall be
65 kg and a free drop of 750 mm shall be maintained. Records of
driving the sampler, number of blows and penetration shall be
maintained for each bore hole depth-wise. IS 2131 latest edition
should be followed for additional information.
The contractor shall furnish the complete bore log and records of
penetration duly verified and signed by the Engineer-in-charge at
site and submit them in duplicate to the Engineer-in-charge.
2.5.1.4 Direct Load Tests on Soils:
During the exploration the actual locations of the proposed tests
shall be agreed by the Engineer-in-charge. The tests shall be
carried out as described in IS 1888 latest revision "Method of Load
Tests on Soils" unless otherwise specifically directed. The
application of load may be by gravity or by reaction method. The
Bidder shall furnish in his bid the complete detail of the equipment
and method plate. However, the Contractor shall have to modify
the arrangement at his own cost if it is ultimately found to be
deficient.
The depth of soil for each test shall be 3.0m below ground level.
The excavation and side protection during the test and backfilling
after the test shall be carried out by the Contractor.
While releasing the loads the rebounds should be observed in the
similar manner as that for settlement observations. For load test
point, minimum five cycles of loading and unloading operations to
be done at each loading stage up to the anticipated design value of
yield value whichever reaches earlier. The observations shall be
recorded directly in log books, pro-forma of which has to be
approved by the Engineer-in-charge who shall also be present to
check the data. The Engineer-in-charge shall be notified well in
advance of the detailed programme of the test and shall also be
informed prior to start of releasing the load at each stage so that
the total settlement can be checked by him. The recorded
observations in duplicate shall be handed over to the Engineer-in-
charge.
2.5.1.5 Laboratory Test of Soil Samples:
Adequate number of test samples of soil shall have to be collected
from site and transported carefully to the approved laboratory for
carrying out necessary tests. The laboratory tests shall be carried
out as per standard practice or as decided by the Engineer-in-
charge. The method and procedure of testing to be followed shall
be submitted to the Engineer-in-charge in centuplicate (six copies)
duly signed by the laboratory in-charge.
2.5.1.6 Open Trial Pits:
The location of open trial pits will be decided after placement of
order in consultation with Engineer-in-charge. The excavation of
trial pits shall be up to a depth of 3 m or not below the ground water
table or as directed by the Engineer-in-charge . In no case the
depth shall be extended over 5 m. The size of pits shall be 1m x
1m or as directed by the Engineer-in-charge.
The Contractor shall provide a suitable access to the bottom of the
pit and undisturbed soil samples shall be taken wherever directed.
2.5.1.7 Report on Soil Investigation:
The Contractor shall make analysis of soil and water data as
collected by him in the field and approved by the Engineer-in-
charge as well as field tests and laboratory tests. A comprehensive
report shall have to be prepared by him finally incorporating all the
data collected in proper tabular forms along with specific
recommendations. The report shall be submitted in centuplicate
(six copies) to the Engineer-in-charge for his review and approval.
2.5.1.8 IS Codes: (All referred codes should be latest edition):

Important Relevant Codes for this section
IS: 1888 - Method of Load Tests on soils.
IS: 1892 Code of Practise for subsurface Investigation for
foundation.
IS: 1498 - Classification of soils.
IS: 2720 - Method of test for soils.
2.5.1.9 Tests to be conducted for Soil Investigation Work:
Conducting laboratory tests as per usual practice and relevant
Indian Standards including the following tests:
a) Natural moisture content
b) Particle size analysis
i) Sieve
ii) Mechanical (Hydrometer)
c) Wet and dry density
d) Index properties (liquid and plastic limits) wherever applicable
e) Unconfined compression test wherever applicable
f) Sheer tests by tri-axial compression whenever applicable
g) Consolidation test (Odometer) wherever applicable
h) Permeability test
i) Crushing strength of rock wherever applicable, shear strength &
RQD
j) Chemical analysis of soil samples collected from bore holes at
different depths to detect constituents like SO4, CL.
k) Chemical analysis of water samples collected from bore holes for
SO4, CL content.
l) Soil resistivity (ohm-mtr)
2.5.2.0 TECHNICAL SPECIFICATION FOR PREPARATION OF SITE

AND EARTH WORK IN FOUNDATION & TRENCHES:
2.5.2.1 Scope:
This shall include all works involved in grading, excavation shorting,
filling around foundations and disposal of spoil/soil to a place as
pre-determined or as directed including all leads lifts, etc.
Boring and subsurface data regarding nature of soil, sub-soil water
etc. shown drawings, or otherwise furnished to the Contractor shall
be taken for guidance only, and variation there from shall not affect
the terms of the contract. The Contractor must satisfy himself of the
character and volume of all works under this item and expected
surface, sub-surface and/or sub soil water to be encountered. He
must also satisfy himself about general conditions of site and
ascertain existing and future obstructions likely to come up during
the execution of the Contract to carry out work under this scope.
2.5.2.2 Grading Etc.:
The area to be excavated shall be cleared out of fences, trees,
logs, stumps, bush, vegetation, rubbish, slush etc. and levelled up.
Trees up to 30 cm girth shall be uprooted. Trees above 30 cm
girth, which are to be cut, shall be approved by the Engineer-in-
charge and then marked. Felling of trees shall include taking out
roots up to 60 cm below ground level or 15 cm below formation
level whichever is lower. After the tree is cut roots taken out, the
spot holes formed shall be filled with good earth in 25 cm layers
and consolidated unless directed by the Engineer-in-charge
otherwise. The trees shall be cut in suitable pieces as instructed by
the Engineer-in-charge.
Before earthwork is started, all the spoil and unserviceable
materials and rubbish shall be burned or removed from site to
approved disposal areas as may be specified. Ashes shall be
spread or removed. Useful materials, saleable timber, firewood etc.
shall be the property of the Owner and shall be stacked properly at
the work site in a manner as directed by the Engineer-in-charge.
2.5.2.3 Classification:
All earth work shall be classified under the following categories:
2.5.2.3.1 Ordinary Soil
This shall include all kinds of soil, dry or wet, which can generally
by excavated with spades, except soil containing 50% or more of
kankar, moorum and/or shingle and soft or hard rock.
2.5.2.3.2 Hard Soil
The soil, dry or wet, containing 50% or more of kankar, moorum
and/or shingle or other types of hard soil that usually require use of
pick axes shall be classified under this item. The decision of the
Engineer-in-charge in the matter of classification of this type of soil
shall be final and binding on the Contractor. This clause shall also
include excavation in consolidated brick ballast and mud concrete.
2.5.2.3.3 Soft and decomposed Rock
This shall include rock, boulders, chalk, slate, laterites and all other
materials which in the opinion of the Engineer-in-charge is rock, but
does not need blasting and could be removed with picks, crow bars
and wedges. The mere fact that the Contractor resorts to blasting
for reasons of his own, shall not mean the rock to be classified as
'hard rock'. This shall also include excavation in macadam and
tarred roads and paths.
2.5.2.3.4 Hard Rock
This shall include rock or boulders, which in the opinion of the
Engineer-in-charge, requires the use of blasting or chiselling for
excavation. This shall include cuttings of the existing structures
coming in the way of excavation.
In case of any dispute regarding classification, the decision of the
Engineer-in-charge shall be final or in case of dispute relevant IS
code shall be followed.
2.5.2.4 Excavation for Foundations and Trenches:
All excavations shall be done to the minimum dimensions as
required for safety and working facility. Prior approval of the
Engineer-in-charge shall be obtained by the Contractor, in each
individual case, for the method he proposes to adopt for the
excavation, including dimensions, side slopes, shoring, de-
watering, disposal etc. This approval however, shall not in any way
make the Engineer-in-charge responsible for any consequent loss
or damage. The excavation must be carried out in the most
expeditious efficient manner.
Prior to starting the excavation, the ground level at the location
shall be checked jointly with the Engineer-in-charge.
The rough excavation may be carried up to a maximum depth of
150 mm above the final level. The balance shall be excavated with
special care. If directed by the Engineer-in-charge soft and
undesirable sports shall be filled up as instructed by the Engineer-
in-charge.
If the excavation is done to a depth greater than that shown on the
drawing, or directed by the Engineer-in-charge, due to Contractor's
fault, the excess depth shall be filled up to the required level with
cement concrete not leaner than 1:4:8 ordinary concrete or richer
as directed by the Engineer-in-charge in each individual case.
2.5.2.5 Protection:
The Engineer-in-charge shall be notified by the Contractor as soon
as the excavation is expected to be completed in 24 hours time so
that it may be inspected by him at the earliest. Immediately after
approval of the Engineer-in-charge, the excavation must be
covered up in the shortest possible time. But, in no case the

excavation shall be covered up or worked on before approval by
Excavated materials shall be placed beyond 1.5 metres from the
edge of the pit or trench or half the depth of the pit or trench,
whichever is more or further away, if directed by the Engineer-in-
charge.
Excavation shall not be carried out below the foundation level of
structures close by until required precautions have been taken.
Adequate fencing shall be made enclosing the excavation.
2.5.2.6 Dewatering:
All excavations shall be kept free of water. Grading in the vicinity of
excavations shall be controlled to prevent surface water running
into excavated areas. The Contractor shall remove by pumping of
other means approved by the Engineer-in-charge any water
inclusive of rainwater and sub-soil water accumulated in excavation
and will keep the trench dewatered until the construction of
foundation structure is complete. Sumps made for dewatering must
be kept clear of the foundations. Method of pumping shall be
approved by the Engineer-in-charge but in any case, the pumping
arrangement shall be such that there shall be no movement of sub
soil or blowing in due to differential head of water during pumping.
2.5.2.7 Timber shoring:
2.5.2.7.1 General
Timber shoring shall be `close' or `open' type, on the nature of soil
and the depth of pit or trench and the type of timbering shall be
determined by the Engineer-in-charge It shall be the responsibility
of the contractor to take all necessary steps to prevent the sides of
trenches and pits from collapsing.
2.5.2.7.2 Close Timbering
Close timbering shall be done by completely covering the sides of
the trenches and pits generally with short, upright members called
`poling boards'. These shall be of minimum 25 cm x 4 cm sections
as directed by the Engineer-in-charge. The boards shall generally
be placed in position vertically in pairs, one board on each side of
cutting and shall be secured by horizontal walling of strong wood at
maximum 1.2 metres spacing, cross strutted with ballies or as
directed by the Engineer-in-charge. The length of the ballie struts
shall depend on the width of the trench or pit.
In case where the soil is very soft and loose, the boards shall be
placed horizontally against the sides of the excavation and
supported by vertical walling, which shall be strutted to similar
timber pieces on the opposite face of the trench or pit. The lowest
boards supporting the sides shall be taken into the ground. No
portion of the vertical side of the trench or pit shall remain exposed,
so that the earth is not liable to slip out.
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
proceed systematically to the other end. Concrete or masonry work
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.
2.5.2.7.3 Open timbering
In the case of open timbering, the entire surface of the side of
trench pit is not required to be covered. The vertical boards of
minimum 25 cm width and minimum 4 cm depth shall be spaced
sufficiently apart to leave unsupported strips of maximum 50 cm
average width. The detailed arrangements, sizes of the timber and
the distance apart shall be subject to the approval of the Engineer-
in-charge. In all other respects, specification for close timbering
shall apply to open timbering.
2.5.2.8 Backfilling around foundations in pits, trenches, plinth or
under floors:
2.5.2.8.1 Earth
Earth used for filling shall be free from silts, organic or other foreign
matter. All clods of earth shall be broken or removed. Material for
backfilling shall generally be obtained from the spoil of excavation,
but the Engineer-in-charge shall have the option, in case of
shortage of good selected earth obtained from excavation, to direct
the Contractor to get the filling materials from approved borrow pits.
Where the excavated materials is mostly rock, the boulders shall be
broken into pieces not bigger than 10 cm size in any direction,
mixed with fine material consisting of decomposed rock, moorum or
earth as available, so as to fill up the voids as far as possible and
then the mixture used for filling.
2.5.2.8.2 Filling in pits and trenches around structures
As soon as the work in foundations has been accepted and
measured, the spaces around the foundation structures in pits and
trenches shall be cleared of all debris, brick bats, mortar droppings
etc. 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 the
satisfaction of the Engineer-in-charge. Earth shall be rammed
preferably with approved compaction machine. Usually, no manual
compaction shall be allowed unless specifically permitted by the
Engineer-in-charge. The final surface shall be trimmed and
levelled to proper profile as desired by the Engineer-in-charge. In
case of black cotton soil the backfilling shall be done with sand at
the direction of the Engineer-in-charge.
2.5.2.8.3 Plinth Filling
The plinth shall be similarly filled with earth as described here in
before in layers not exceeding 15 cm watered and consolidated
with approved compaction machine or manually if specifically
permitted by the Engineer-in-charge. When the filling reaches the

finished level, the surface shall be flooded with water for at least 24
hours, allowed to dry and then rammed and consolidated, in order
to avoid any settlement at a later stage. The finished level of the
filling shall be trimmed to the slope intended to be given to the floor.
In case of black cotton soil replacement of top 1 metre soil with
approved soil/sand shall be done.
2.5.2.8.4 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.
Where the trenches are excavated in soil, the filling shall be done
with earth on the sides and top of pipes in layers not exceeding 15
cm, watered, rammed and consolidated, taking care that no
damage is caused to the pipe below. In case of excavation of
trenches in rock the filling up to depth of 30 cm or the diameter of
the pipe whichever is more, above the crown of pipe of barrel shall
be done with fine material such as earth, moorum pulverised
decomposed rock or ash according to the availability at site. The
remaining filling shall be done with rock filling of boulders of size
not exceeding 10 cm mixed with fine material as available to fill up
the voids, watered, rammed and consolidated.
2.5.2.8.5 Sand filling in Trenches and other places
At places backfilling shall be done with local sand if directed by the
Engineer-in-charge. The sand used shall be clean, medium
grained and free from impurities. The filled in sand shall be kept
immersed in water for sufficient time to ensure maximum
consolidation. The surface of the consolidated sand shall be
dressed to required level or slopes. Construction of floors or other
structures on sand fill shall not be started until the Engineer-in-
charge has inspected and approved the fill.
2.5.2.9 IS Codes (All referred codes should be latest edition):
Important relevant codes for this section
IS 1498 - Classification of soils for General Engineer-in-charge
purpose.
IS 7293 - Safety code for working with construction machinery.
2.5.2.10 In case of excavation more than described depth, the required level
of foundation will be brought out by filling P.C.C (1:4:8) as
approved by Engineer in charge.
2.5.3.0 TECHNICAL SPECIFICATION FOR FABRICATION OF

STRUCTURAL STEEL WORKS:
2.5.3.1 General:
2.5.3.1.1 Scope
This specification covers general requirements for supply,
fabrication and delivery at site of structural and miscellaneous
steel.
2.5.3.1.2 Steel Materials
Steel materials shall comply with the IS specifications (latest
editions) laid down elsewhere and/or as called for on the approved
design drawings.
Contractor shall furnish to Engineer-in-charge duplicate copies of
all mill orders, (un- priced) covering the material ordered by him for
this project and also the test reports received from the mills for
Engineer-in-charge's check and information.
2.5.3.1.3 Drawings
Engineer-in-charge reserves the right to make correction to
drawings. Revisions to drawings and any new drawings made to
include additional work shall be considered as a part of this
specification and the Owner shall entertain no extra claim on this
account.
Unless otherwise specified, the drawings and specifications are
intended to include everything obviously requisite and necessary
for the proper and entire completion of the work and the job shall
be carried out accordingly for the completeness as required.
In the case of variations in drawings and specification the decisions
of the Engineer-in-charge shall be final. Should Contractor in the
execution of his work, find discrepancies in the information
furnished by Engineer-in-charge, he shall refer such discrepancies
to the Engineer-in-charge before proceeding with such work or
where ever possible point out the discrepancies while submitting
his offer.
2.5.3.2 Fabrication:
2.5.3.2.1 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 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 view shall be neatly finished. Material
at the shops shall be kept clean and protected from weather.
2.5.3.2.2 Connections
Shop connections shall be either by welding; riveting, or high
strength bolts.
All major field connections shall be of high strength bolts, but
standard MS bolts (IS 1363- latest edition) may be used for fixed
connections of light members such as purlins, girts, staircase
stringers and landing beams, unless these bolts are permitted to be
used by Engineer-in-charge for other connection also. However,
site welding for fabrication is permitted.
High tensile bolts shall comply with the requirements of BS 1083
heat treated to quality or its equivalent in latest IS 1367. All
relevant IS Code (latest edition) for bolting and welding shall be
followed.
In all cases where bearing is critical, all members in the assembly
shall bear on the unthreaded length of the bolt. 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.
All members likely to collect rain-water shall have drain holes
provided.
Not more than one shop splice shall be provided to make up the full
length of a member. Splicing near the mid span of any beam
should be avoided. Splicing of joints shall be done after approval of
2.5.3.2.3 Straightening
Rolled material, before being worked, shall be straightened, unless
otherwise required/specified. If straightening or flattening is
necessary, it shall be done by methods that will not injure the
material. Long plates shall be straightened by passing through
angle or levelling rolls and structural shapes by the use of
mechanical or hydraulic bar straightening machine. Heating or
forging shall not be resorted to without the prior approval or
Engineer-in-charge in writing.
2.5.3.2.4 Cutting
Cutting may be by shearing, cropping, sawing or machine flame
cutting. All re-entrant corners shall be shaped notch-free to a
radius of at least 12 mm. Sheared or cropped edges shall be
dressed to a neat workmanlike finish and shall be free from
distortion and burrs.
The machine flame cut edges shall be properly cleaned. Where
machine flame cutting is permitted for high tensile steel, special
care shall be taken to leave sufficient material and all flame
hardened material shall be removed by machining/edge planning.
Hand flame cutting shall be undertaken only if so permitted by
Engineer-in-charge and shall only be carried out by an expert in
such work. Hand flame cut edges shall be ground smooth and
straight.
Edge planning of sheared, cropped or gas cut edges is not
intended unless the sheared, cropped or gas cut edges are such as
to warrant it or it is specifically required.
2.5.3.2.5 Rolling and Forming
Plates for circular bins, bunkers, hoppers 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 for
facilitating accurate assembly, welding and erection in the field.
2.5.3.2.6 Punching and Drilling
Holes in secondary members such as purlins, girts, lacing bars etc.
may be punched full size through material not over 12 mm thick.
Holes must be cleaned out, without burr or ragged edges. Holes for
all other connections shall be drilled accurately and the burrs
removed effectively. Where several parts are to be drilled, they
shall be first assembled, tightly clamped together and drilled
through.
Sub-punching may be permitted before assembly, provided the
holes are punched 3 mm smaller in diameter than the required size
and reamed after assembly to the full diameter. The thickness of
material punched shall not exceed 16 mm.
Holes for turned and fitted bolts shall be drilled to a slightly smaller
diameter and reamed to a diameter equal to the nominal diameter
of the shank or barrel subject to HB tolerance specified in IS 919
(latest edition).
Where reamed members are taken apart for shipping or handling,
the respective pieces reamed together shall be so marked that they
may be re-assembled in the same position in the final setting up.
No interchange of reamed parts will be permitted. Poor machining,
over drilling and equality in holes shall be cause for rejection.
Burning holes with gas is strictly prohibited.
2.5.3.3 Riveting:
All rivet steel used shall conform to either IS 1148 or IS 1119 (latest
edition) as may be applicable. The parts of riveted members shall
be well planned and firmly drawn together with bolts before riveting
is commenced. The drifting done during assembling shall be only
such as to bring the parts into position and be only such as to bring
the parts into position and shall not be such as to enlarge the holes
or distort the metal. Contact surfaces inaccessible after riveting
shall be painted before assembly prior to riveting. Rivets shall be
heated uniformly to a light cherry red (10850 C) and driven while
not. Rivets when heated and ready for driving shall be free from
slag, scale and carbon deposit. When driven, they shall completely
fill the holes. Rivet heads shall be full, neatly made, concentric with
the rivet holes and in full contact with the surface of the member,
gripping the members firmly. A driven rivet when struck sharply on

the head with a quarter pound rivet testing hammer shall be free
from movement and vibration. Loose, burnt or otherwise defective
rivets shall be replaced free of cost. In removing rivets, care shall
be taken not to injure the adjacent metal, and, if necessary, they
shall be drilled out or cut with a rivet buster or chisel.
Wherever practicable, machine riveting shall be carried out by
using machines of the steady pressure type. When necessary to
drive rivets with a pneumatic riveting hammer, a pneumatic bunker
shall be used for holding up, when practicable.
2.5.3.4 Bolting:
2.5.3.4.1 High Tensile Bolts
The material used for the manufacture of structural quality high
tensile steel bolts shall have a minimum tensile strength of 58
kg/mm2. Other mechanical properties shall conform to grade St-58-
HT of IS 961 (latest edition).
Bolts, nuts and washers and other fastening materials shall be
stored in racks off the ground with coating of suitable protective oil.
All bolts, nuts and washers shall conform to the relevant Indian
Standards.
Bolts shall be inserted in such a way that they may remain in
position under gravity even before fixing the nut. Bolted parts shall
fit solidly together when assembled and shall not be separated by
gaskets or any other interposed compressible materials. When
assembled, all joint surfaces, including those adjacent to the
washers, shall be free of scales except tight wall scales. They shall
be free of dirt, loose scales, burns, and other defects that would
prevent solid seating of the parts. Contact surfaces shall be free of
oil, paint and lacquer or galvanising.
All high tensile bolts conforming to HT-58 of IS 961 (latest edition)
shall be tightened to provide, when all fasteners in the joint are
tight, at least the minimum bolt-tension mentioned as per relevant
I.S (latest) is to be maintained:
Tightening shall be done by one of the following methods.
i) Turn-of nut method
When the turn off nut method is used to provide the bolt tension as
specified above, there shall first be enough bolts brought to a 'Snug
tight' condition to ensure that the parts of the joint are brought into
good contact with each other. "Snug tight' is defined as the
tightness attained by a few impacts of an impact wrench or the full
effort of a man using an ordinary wrench. Following this initial
operation, bolts shall be placed in any remaining holes in the
connection and brought to snug tightness. All bolts in the joint shall
than the tightened additionally by the applicable amount of nut
reaction with tightening progressing systematically from the most
rigid part of the joint to its free edges. During this operation there
shall be no rotation of the part not turned by the wrench.
Bolts may be installed without hardened washers when tightening
is done by the turn of nut method. However, normal washers shall
be used.
Bolts tightened by the turn-of-nut method may have outer face of
nut match marked with protruding bolt point before final tightening,
thus affording the inspector visual means of noting the actual nut
rotation. Such marks can be made by the wrench operator by
suitable means after the bolts have been brought up snug tight.
ii) Calibrated Wrench Tightening
When calibrated wrenches are used to provide the bolt tensions
specified earlier their setting shall be such as to include a bolt
tension 5% to 10% in excess of this value. These wrenches shall
be calibrated at least once each working day by tightening in a
device capable of indicating actual bolt tension, not less than three
typical bolts of each diameter from the bolts being installed. Power
wrenches shall be adjusted to stall or cut out at the selected
tension. If manual torque wrenches are used, the torque indication
corresponding to the calibrating tension shall be noted and used in
the installation of all bolts of the tested lot. Nuts shall be in
tightening motion when torque is measured. When using calibrated
wrenches to install several bolts in a single joint, the wrench shall
be turned to 'touch up' bolts previously tightened, which may have
been loosened to the prescribed tension. Bolts tightened by means
of a calibrated wrench shall be installed with a hardened washer
under the nut or bolt head, whichever is the element turned in
tightening.
In either of the above two methods, because of bolt entering and
wrench operation clearances, tightening may be done by turning
the bolt while the nut is prevented from rotating.
Impact wrenches, if used, shall be of adequate capacity and
sufficiently supplied with air to perform the required tightening of
each bolt in approximately ten seconds.
2.5.3.5 Welding:
2.5.3.5.1 General
Electrodes for shielded arc manual welds shall comply with the
requirements of IS 814 latest edition and shall be of an approved
make.
The electrodes shall be suitable for use in the position and type of
work as laid down in the above specifications and as recommended
by the manufacturers.
Electrodes flux covering shall be sound and unbroken. Broken or
damaged coating shall, cause the electrodes to be discarded.
Covered electrodes for manual arc welding shall be properly stored
in an oven prior to use in a manner recommended by the
manufacturer and only an hour's quota shall be issued to each

welder from the oven.
Electrodes larger than 5 mm diameter shall not be used for root-
runs in butt-weld.
Welding plant and accessories shall have capacity adequate for the
welding procedures laid down and shall satisfy appropriate
standards and be of approved make and quality. All the electrical
plant in connection with the welding operation shall be properly and
adequately earthed and adequate means of measuring the current
shall be provided.
All welds shall be made only by welders and welding operators who
have been properly trained and previously qualified by tests to
perform the type of work required as prescribed in the relevant
applicable standards.
All welds shall be free from defects like blow holes, slag inclusions,
lack of penetration, undercutting, cracks etc. All welds shall be
cleaned of slag of flux and show uniform sections, smoothness of
weld metal, feather edge without overlap and freedom from
porosity.
Fusion faces and surfaces adjacent to the joint for a distance of at
least 50 mm on either side shall be absolutely free from grease,
paint, loose scales, moisture or any substance which might
interfere with welding and shall be smooth, uniform and free from
notches etc. Faces shall be prepared in accordance with the
approved fabrication drawings by shearing, chipping, machining or
machine flame cutting except that sheering shall not be used for
thickness over 8 mm.
In the fabrication of cover 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 member. Wherever
weld reinforcement interferes with proper fit up between
components to be assembled for welding, these welds shall be
ground flush prior to assembly.
The members to be joined by fillet welding shall be brought and
held as close together as possible and in no event shall be
separated by more than 3 mm. If the separation is 1.5 mm or
greater the fillet weld size shall be increased by the amount of
separation. This shall only apply if the surfaces are completely
sealed by welds.
In all other cases the fit up shall be close enough to exclude water
after painting.
The separation between facing surfaces of lap joints and butt joints
with backing plate shall not exceed 1.5mm. Abutting parts to be
butt welded shall be carefully aligned and the correct root gap
maintained throughout the welding operation. Misalignments
greater than 25 % of the thickness of the thinner plate or 3 mm
whichever is smaller shall be corrected and in making the

correction the parts shall not be drawn into a slope sharper than 20
(1 in 27.5).
Pre-qualified welding procedure recommended by appropriate
welding standards and known to provide satisfactory welds shall be
followed. For non-standard procedures, qualification tests as
prescribed in IS 823 latest edition shall be made to verify the
adequacy of the procedures. Welding procedure shall be prepared
by contractor and submitted to Engineer-in-charge for approval
before start of welding. This shall include all details of welding
procedure with reference to provision of IS 823 and IS 4353 (latest
editions). Approval of the welding procedure by Engineer-in-charge
shall not relieve contractor of this responsibility for correct and
sound welding without undue distortion in the finished structure.
Submerged arc, automatic or semi-automatic welding shall
generally be employed, only where it is not practicable to use
submerged arc welding, manual arc welding may be resorted to.
Voltage and current (and polarity if direct current is used) shall be
set according to the recommendations of the manufacturer of the
electrode being used and suitability to thickness of material, joint
form etc.
The work shall be positioned for flat welding wherever practicable
and overhead weld shall be avoided.
No welding shall be done when the surface of the members is wet
nor during periods of high wind unless the welding operator and the
work are properly protected.
In joints connected by fillet welds, the minimum sizes of single run
fillet welds or first welds or first runs and minimum full sizes of fillet
welds shall conform to the requirements of IS 816 and IS 823
(latest edition).
All complete penetration butt welds made by manual arc welding,
except when produced with the aid of backing material or welded in
flat position, from both sides in square edge material not over 8 mm
thick with root opening not less than one half the thickness of the
thinner part joined, shall have the root of the initial layer gouged out
on the back side before welding is started from that side, and shall
be so welded as to secure sound metal and complete fusion
throughout the entire cross section.
Butt welds shall be terminated at the ends of joint in a manner that
will ensure their soundness, where abutting parts are 20 mm of
more in thickness run on and run off plates with similar edge
preparation and having a width not less than the thickness of the
thicker part joined shall be used. These extension places shall be
removed upon completion of the weld and the ends of the weld
made smooth and flush with the abutting parts. Where the abutting
parts are thinner than 20 mm the extension pieces may be omitted
but the ends of the butt welds shall then be chipped or gouged out
to sound metal and side welded to fill up the ends to the required
reinforcement.
Each layer of multiple layer weld including root and surface runs
may be moderately peered with light blows from a blunt tool. Care
shall be exercised to prevent scaling or flaking of weld and base
metal from over peering.
No welding shall normally be done on parent material at a
temperature below (-) 50 C. However, if welding is to be
undertaken at low temperatures, adequate precautions as
recommended in relevant Indian Standards shall be taken. When
the parent material is less than 40 mm thick and the temperature is
between (-) 50 C and 00 C, the surface around the joint to a
distance of 100 mm or four times the thickness of the materials,
whichever is greater, shall be preheated till it is hand warm. When
the parent material is more than 40 mm thick, the temperature of
the area mentioned above shall in no case be less than 200 C. All
requirements regarding preheating of the parent material shall be in
accordance with the relevant Indian standard.
Electrodes other than low hydrogen electrodes shall not be
permitted for thickness of 75 mm and above.
Before commencing fabrication of a member or structure in which
welding is likely to result in distortion and/or locked up stresses a
complete programme of fabrication, assembly and welding shall be
made and submitted to Engineer-in-charge for approval. Such a
programme shall include, besides other appropriate details, full
particulars in regard to the following:
i) Proposed preheating in component such as flanges and pre-
setting of joints to offset expected distortion.
ii) Make up of sub-assemblies proposed to be welded before
incorporation on final assembly.
iii) Proposed joint forms, classification of wire and flux or
covered electrodes, welding process including fitting and
welding sequences with directions in which freedom of
movement is to be allowed.
iv) Proposed number, spacing and type of strong backs and
details of jigs fixtures for maintaining proper fit up and
alignment during welding.
v) Any other special features like assembling similar back to
back or stress relief if so desired by Engineer-in-charge.
Welding shall be carried out at contractor's cost to establish
the efficiency of the proposed programme, with any
modification suggested by the Engineer-in-charge, in limiting
distortion or/and residual stress to acceptable levels.
2.5.3.5.2 Inspection of Welds

All welds shall be inspected for flaws by any of the methods
described under clause 'Inspection'. The choice of the method
adopted shall be determined by Purchaser/Engineer-in-charge.
The contractor shall carry out tests, which establish soundness of
welds. In case the tests uncover defective work such tests will be
at contractor's cost and the contractor shall correct such defects at
his own cost and prove the soundness of rectified work at his own
cost.
The correction of defective welds shall be carried out as directed by
Engineer-in-charge without damaging the parent metal. When a
crack in the weld is removed, magnetic particles inspection or any
other equally positive means as prescribed by Engineer-in-charge
shall be used to ensure that the whole of the crack and material up
to 25 mm beyond each end of the crack has been removed. Cost
of all such tests and operations incidental to correction shall be to
contractor's account.
2.5.3.5.3 Tolerances
The dimensional and weight tolerance for rolled steel shall be in
accordance with IS 1852 (latest edition).
No rolled or fabricated member shall deviate from straightness by
more than 1/1000 of the axial length or 10 mm whichever is
smaller.
The length of members with both ends finished for contact shall
have a tolerance of +1 mm. Members without ends finished for
contact bearing shall have a tolerance of + 1. 5 mm for members
up to 10 metres long and a tolerance of + 3 mm for members over
10 metres in length.
Lateral deviation between centreline of web plate and centreline of
flange plate at contact surface, in the case of built up sections shall
not exceed 3 mm.
The deviation from flatness of welded plate girder web in the length
between stiffeners or a length equal to the depth of the girder shall
not exceed 1/150th of such length.
Deviations from the specified depth of welded girders measured at
the centreline of the web shall not exceed 3mm up to depth of
1000 mm, 5 mm for depths above 1000 mm up to 2000 mm and
8 mm for depths over 2000 mm.
2.5.3.5.4 Site welding
Where site welding is approved by the Engineer-in-charge, all work
should conform fully to the specification.
2.5.3.5.5 End Milling
Column ends bearing on each other or resting on base plates and
compression joints designed for bearing shall be milled true and
square to ensure proper bearing and alignment. Base plates shall

also have their surfaces milled true and square.
2.5.3.5.6 Erection of Altered and Rectified Steel
This includes transportation of the rectified components to the site
of erection, lifting to the required position, aligning in position,
inclusive of all erection bolts, tack welding and final welding.
Alterations and rectification of fabricated steel or of dismantled
steel shall be deemed to be fabrication work involving change in
length of the member or in cross section, such as welding
additional flanges or web plates or cutting already welded plates
etc. Additions to fabricated steel such as additional cleat angles,
plugging drilled holes, drilling additional holes and additional
fabrication work of steel fabricated and stored at the fabrication
shop shall not be deemed to be included as 'alterations' and shall
be done by the contractor without any extra cost to the Purchaser.
However, if any re-fabrication/erection is due to the change
suggested by the Purchaser/Engineer-in-charge it shall be paid as
per Clause mentioned elsewhere.
2.5.3.6 Inspection:
2.5.3.6.1 General
Contractor shall give due notice to Engineer-in-charge/Purchaser in
advance of the materials or workmanship getting ready for
inspection. All rejected material shall be promptly removed from
the shop and replaced with new material for Engineer-in-
charge/Purchaser's approval of inspection. The fact that certain
material has been accepted at contractor's shop shall not invalidate
final rejection at site by Purchaser/Engineer-in-charge if it fails to be
in proper condition or has a fabrication inaccuracy, which prevents
proper assembly. No material shall be painted or despatched to
site without the inspection and approval of Purchaser/Engineer-in-
charge unless such inspection is waived in writing by Engineer-in-
charge.
Shop inspection by Engineer-in-charge or his authorised
representative or submission of test certification and acceptance
thereof by Engineer-in-charge shall not relieve contractor from the
responsibility of furnishing material conforming to the requirements
of these specifications nor shall it invalidate any claim which the
Purchaser may make because of defective or unsatisfactory
material or workmanship. Contractor shall provide all the testing
and inspection services and facilities for shop work.
For fabrication work carried out in the field the standard of
supervision and quality control shall be maintained as for shop
fabricated work. The inspection and testing be conducted in a
manner satisfactory to Engineer-in-charge.
2.5.3.6.2 Material Testing
The inspection and tests on structural steel shall be set forth below.
If mill test reports are not available for any steel materials the same
be got tested by the contractor to Engineer-in-charge's satisfaction
to demonstrate conformity with the relevant specification. The
costs of such tests will be borne by the contractor.
i) Test on Welds
Where root and intermediate passes of weld is examined by
magnetic particle testing such testing shall be carried out
throughout its entire length in accordance with ASTM specification
E-109. In the case of completed welds, such tests shall be carried
out in accordance with ASTM specification E-109 or E-136 as
decided by Engineer-in-charge.
If heat treatment is performed, the completed weld shall be
examined after the heat treatment. All defects shall be repaired
and re-tested. Magnetic particle tests shall be carried out using
alternating current. Direct current may be used with the permission
of Engineer-in-charge.
ii) Liquid Penetrate Inspection
In the case of welds examined by liquid Penetrate Inspection, such
tests shall be carried out in accordance with ASTM C-165 or IS
3658 (latest edition). All defects shown shall be repaired and
rechecked.
iii) Radiographic Inspection
All full strength butt welds shall be fully radio graphed in
accordance with the recommended practice for radiographic testing
as per ASTM -E-93 and part UW-51 of ASMD code Section-VIII.
iv) Dimensions, Workmanship and Cleanliness
The structural steel members shall be inspected at all stages of
fabrication and assembly to verify that dimensions, tolerance,
alignment and surface finish, painting where specified are in
accordance with the requirements shown on contractor's approved
shop drawings.
v) Inspection of Test Failure
In the event of any failure of structural steel members to meet an
inspection or test requirement; Contractor shall notify the Engineer-
in-charge or his authorised representative. Contractor must obtain
permission from the Engineer-in-charge before repair is
undertaken. The quality control procedures to be allowed to ensure
satisfactory repair shall be subject to approval by Engineer-in-
charge.
Engineer-in-charge has a right to specify additional inspection or
testing as he deems necessary, and the additional cost of such
testing will be borne by Contractor. Contractor shall maintain
records of all inspection and testing which shall be made available
to Engineer-in-charge or his authorised representative.
2.5.3.7 Miscellaneous Requirements:

2.5.3.7.1 Shop Matching
Some steelwork particularly columns along with the tie
beams/bracing may have to be shop assembled to ensure
satisfactory fabrication, obtaining of adequate bearing areas etc, if
so desired by Engineer-in-charge at no extra cost to owner.
2.5.3.7.2 Drilling Holes for Other Works
All holes for fixing equipment shall be shop drilled.
Holes in members required for installing equipment or steel
furnished by other manufacturers or other contractors shall be
drilled in contractor's shop as part of this contract.
2.5.3.7.3 Stairways, Intermediate Landings and Gratings
All stairways and intermediate landings shown on the drawings
shall be fabricated as a complete unit and shall include grating
treads, landings, hangers, brackets, struts, clips, bracings etc. as
detailed or as necessary for connections to structural steel framing
in places. Tread and landings shall be supplied with one piece
standard non-slip abrasive nosing of approved type. The maximum
width of openings in gratings shall not exceed 40 mm. The
minimum thickness of main bars shall be 5 mm. The usual span of
gratings will not generally exceed 1.5 metres.
2.5.3.7.4 Handrails
Handrails shall be provided on open sides of platform, stairways
and around all openings as shown on drawings. Handrails shall be
of standard weight galvanised steel pipe of flush welded
construction, and ground smooth using 32 mm nominal bore
medium class pipe provided with double rail, top rail about 1 metre
above platform level and pipe posts spaced not more than two
meters apart. Angle handrail posts may be provided if specifically
called for in design drawings. Handrails around openings should
have toe plates, 150 mm high.
Smooth uniform curves and bends shall be provided at stair return
and also wherever required. Posts connected to curb plates shall
have a neat closure at the bottom and 6mm thick plate neatly
welded to posts for attachments to curb plates. All necessary
fittings including inner dowels at splices, brackets, bolts, bends,
flanges and dowels and chains where ever required shall be
provided. Joints in rails shall be fully plugged and welded. A
minimum radius of 3 times the pipe diameter shall be provided at all
points of direction changes in the handrail.
2.5.3.7.5 Chequered Plate
Chequered plates used shall be 6mm thick cover plates or as
indicated on drawings. The chequered plate pattern shall be
approved by owner/Engineer-in-charge. Mild steel flats of suitable
size shall be welded to the bottom portion of chequered plates at a
designed spacing to stiffen chequered plates suitably. Chequered

plates shall be fixed by tack welding of suitable size.
2.5.3.7.6 Marking of Members
After checking and inspection, all members shall be marked for
identification during erection. This work shall correspond to
distinguishing marks on approved erection drawings and shall be
legibly pointed and stamped on. The erection mark shall be
stamped with a metal dye with figures at least 20 mm high and to
such optimum depth as to be clearly visible, even after a member is
galvanised.
All erection marks shall be on outer surface of all sections and near
one end, but clear of bolt holes. Marking shall be so stamped that
they are easily discernible when sorting out members. The
stamped marking shall be enriched boldly by a distinguishable paint
to facilitate easy location.
Erection marks on like pieces shall be in identical locations.
Members having lengths of 3.0 m or more shall have the erection
mark at both ends.
2.5.3.7.7 Errors
Any error in shop work which prevents proper assembling and
fittings up of parts in the field by moderate use of drift pins of
moderate amount of reaming will be classified by Engineer-in-
charge as defective workmanship. All charges incurred by
Purchaser/Engineer-in-charge either directly or indirectly because
of workmanship will be deducted from the amount due to contractor
before payment is made. The amount of such deduction will
consist of the sum total of the costs of labour direct or indirect,
material, plant, transportation, equipment rental and overhead
expenses.
In case Engineer-in-charge chooses to reject the material because
of poor workmanship of the cost of all handling for returning the
material of contractor, if he so desires, shall entirely be the
contractor's and in all such cases, the cost of handling, transport
and delivery to site shall be borne by contractor.
2.5.3.8 Surface Treatment:
2.5.3.8.1 Shop paint
After inspection and issue of test and acceptance certificate, all
steel surfaces are to be painted or otherwise treated shall be dried
and thoroughly cleaned by effective means of all loose mill scale
rust and foreign matter as per IS 1477 Part I (latest edition). The
following methods like wire brushings, scraping and chipping, sand
papering or cleaning, flame cleaning, sand blasting or shot blasting,
chemical rust removal may be adopted for preparing the steel
surface to be painted. Except where encased in concrete, all steel
work shall be given one coat of approved metal protection as may
be specified, applied thoroughly and evenly and well worked into
the joints and other open spaces. Materials shall be of best quality
available and procured directly from approved manufacturers.

Samples shall be submitted to the Engineer-in-charge for approval
before procurement.
Surfaces not in contact, but inaccessible after shop assembly, shall
receive two coats of shop paint, positively of different colours or
such materials to prove use of two coats before assembly. This
does not apply to the interior of sealed hollow sections.
Shop contact surfaces shall be cleaned by effective means before
assembly, but not painted.
In the case of surface to be welded, the steel shall not be painted
or metal coated within minimum 50 mm distance of any edges to be
welded, if the paint specified or the metal coating would be harmful
to welders or impair the quality of the welds. Welds and adjacent
parent metal shall not be painted prior to de-slugging, inspection
and acceptance.
Machine finished surfaces shall be protected against corrosion by a
suitable coating.
Primers should be applied by brushing. Red oxide shall be used as
shop painting. Where two coats are specified to be applied at shop
to in accessible parts, the second coat shall be red oxide zinc
chromate paint (Primer) conforming to IS 2075 (latest edition).
In areas which are difficult to reach either by brushing or spraying,
dibbers, mops or both may be used by dipping the same in paints
and pulling or pushing them through narrow spaces. Regarding the
methods of application of paint, whether by spraying or brushing,
the instructions of the manufacturers shall be followed.
2.5.3.8.2 Painting after Erection
Field painting shall only be done after the structure is erected,
levelled, plumbed and grouted in its final position and accepted by
the Engineer-in-charge. Painting shall not be done in frosty or
foggy weather, or when humidity is such as to cause condensation
on the surface to be painted. The air temperature should not be
less than 4.40 C and relative humidity greater than 80%.
Before painting, steel which is delivered only with shop primer shall
be dried and thoroughly cleaned from all loose scale and rust.
Painting shall be done by brushing or spraying. Steelwork that has
received a shop coat primer shall be cleaned with emery paper
followed by application of a second coat of primer. Damaged areas
shall be carefully cleaned and re-primed.
Painting shall proceed as soon as possible after cleaning and
before further deterioration of the surface occurs. Two coats of
approved paint shall be applied after approval of the Engineer-in-
charge and allowing a drying time according to the manufacturers
instructions. In the case of red lead, after the second coat of
primer, sufficient time shall be allowed for the red lead to dry
thoroughly.
All field rivets, field welds, and serious abrasions to the shop coat
shall be spot painted with the same paint used for the shop coat
where specified, surfaces which will be in contact after site
assembly shall receive a coat of paint (in addition to any shop
priming and shall be brought together while the paint is still wet.
Where the steel has received a metal coating in the shop, this
coating shall be completed on the site so as to be continuous over
any field welds, field rivets or bolts. Each coat of paint shall have
an optimum thickness. The overall paint thickness should not be
less than 100 microns.
2.5.3.9 Galvanizing:
2.5.3.9.1 General
Structural steel work for switchyard or other structures as may be
specified in the contract shall be hot dip galvanised in accordance
with the American Society for Testing and Materials Specification
ASTM-A 123 or equivalent Indian Standard Specifications. Where
the steel structures are required to be galvanised the field
connection materials like bolts, nuts and washers shall also be
galvanised, sherardized or Electro plated.
2.5.3.9.2 Surface Preparation
All members to be galvanised shall be cleaned, by the process of
picking, of rust, loose scale, dirt, oil, grease, slag and spatter of
welded areas and other foreign substances prior to galvanising.
Pickling shall be carried out by immersing the steel in an acid at a
suitable concentration and temperature. The concentration of the
acid and the temperature of the bath can be varied, provided that
the pickling time is adjusted accordingly.
The pickling process shall be completed by thoroughly rinsing with
water, which should preferably be warm, so as to remove the
residual acid.
2.5.3.9.3 Procedure
Galvanising shall be carried out by hot dip process in a proper and
uniformly heated bath. It shall meet all the requirements when
tested in accordance with IS 2633 (latest edition) - Methods of
testing weight, thickness and uniformity of coating on hot dipped
galvanised articles. The zinc coating shall be uniform, clean and of
a standard thickness on the entire surface of the material
galvanised. The acceptable values of the coating of zinc on the
steel materials shall be in accordance with relevant latest I.S code.
After finishing the threads of bolts, galvanising shall be applied over
the entire surface uniformly. The threads of bolts shall not be
machined after galvanising in order to preserve the integrity of the
zinc coating. Bolts shall preferably be Sherardized or Electro-plated
in order to maintain a better thread.
The threads of nuts may be tapped after galvanising but care shall
be taken to use oil in the threads of nuts during erection.
The surface preparation for galvanising and the process of
galvanising itself, shall not adversely affect the mechanical
properties of the materials to be galvanised. Where members are of
such lengths as to prevent complete dipping in one operation, great
care shall be taken to prevent warping.
Materials on which galvanising has been damaged shall be acid
stripped and re-galvanised unless otherwise directed, but if any
member becomes damaged after having been dipped twice, shall
be rejected. Special care shall be taken not to injure the skin on
galvanised surfaces during transport handling and erection.
Damages, if occur shall be made good in accordance with the
provisions of this specification or as directed by the Engineer-in-
charges.
2.5.3.10 Applicable Codes and Specifications (All referred codes
should be latest edition):
Unless otherwise specified therein, materials and workmanship
shall conform to the latest editions of the one or as many as
applicable of the following standards or their approved equivalents,
or as applicable, if not included in the list.
IS 808 - Rolled steel beam, Channel and angle sections.
IS 8500- Structural steel- Micro alloy (Medium and High strength
qualities).
IS 2062 Steel for General structure purpose.
IS 1977 - Structural steel (Ordinary quality) Low tensile.
IS 1148 - Hot-rolled rivet-bars (up to 40 mm diameter for structural
purposes.)
IS 1149 High tensile rivet bars for structural purposes.
2.5.4.0 TECHNICAL SPECIFICATION FOR ERECTION OF STRUCTURAL

STEEL WORK:
2.5.4.1 Scope:
This specification covers general requirements for erection of
structural and miscellaneous steel works.
2.5.4.2 Erection Scheme:
Each bid shall be accompanied by a broad erection scheme
prepared by the Bidder after a thorough study of the bid drawings
and the site conditions. The erection scheme shall describe the
methods proposed to be employed by the Contractor for unloading,
transporting within the site, handling, assembling, hoisting and
erection of the structural and miscellaneous steel components and
the type, capacity and quantity of equipment that the Contractor
proposes to bring to site for all these operations. The scheme shall
also indicate the strength and trade-wise compositions of the work
force and supervisory personnel that will be deployed by the
Contractor for the various operations.
2.5.4.3 Site Operations:
An experienced and qualified superintendent shall be in full time
charge of the job.
The Contractor shall complete the structural foundations and all
preliminary works on site well before the arrival of structural steel,
such as establishment of office, stores, unloading gantry, 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
part of his contract and any other work that may be necessary so
as to start erection immediately after the arrival of first batch of
steel at site.
The Contractor shall furnish at his own expense, the necessary
non-inflammable staging for hoisting materials or equipment
required for the erection work and shall remove and take them
away after completion of the job. The Contractor shall also provide
necessary passageways, offices, safety belts, helmets, lights and
other fittings to the satisfaction of the Owner/Engineer-in-charge
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 full period to maintain the Contractor's electrical equipment and
connections.
The Contractor shall protect all existing plant structures, piping,
conduits, equipment and facilities against damage during erection.
Any damage caused by the Contractor shall be repaired entirely at
the Contractor's cost to the satisfaction of the Owner/Engineer-in-
charge. If work has to be carried out adjacent to existing
switchyards or electrical installations, which are live, the Contractor
must ensure suitable safety precaution in consultation with the

Engineer-in-charge.
2.5.4.4 Handling and Storage:
No dragging of steel shall be permitted. All steel shall be stored
300 mm above ground on suitable packing to avoid damage, in the
order required for erection and with erection marks visible. All
storage areas shall be prepared and maintained by the Contractor.
Steel shall not be stored in the vicinity of areas where excavation or
grading will be done and if stored temporarily, this shall be removed
by the Contractor well before such excavation and/or grading
commences to a safe distance to avoid burial under debris.
2.5.4.5 Anchor Bolts and Foundations:
The Contractor shall carefully check the location and layout of
anchor bolts before the foundations are constructed to ensure that
the structures can be properly erected as shown in the drawings.
Anchor bolts may be provided with three nuts on upper threads
portion, one of which may be used for levelling the column base to
the required elevation and one will be a lock nut. All shim stock
required for erection shall be of good MS plates and shall be
supplied by the Contractor at his cost.
Cleaning of foundations and preparing the area is considered
normal and shall be carried out by the Contractor at no extra cost.
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 the Contractor
only after getting prior approval of the Engineer-in-charge.
2.5.4.6 Assembly and Connections:
Field connections may be effected either by riveting, bolting,
welding or by use of high strength bolts as shown on the design
and erection drawings subject to conditions as mentioned at
relevant clauses of Specification of structural steel works. Welding
shall only be permitted where the facilities available are equal to
shop fabrication and meet all the requirements.
In no circumstance shall the welding of structural steelwork onto
concrete reinforcement be permitted.
All welding shall be in accordance with IS 816 (latest edition) -
Code of Practice for use of Metal arc welding for General
Construction in mild steel and IS 823 (latest edition) - Code of
procedure for manual arc welding of mild steel.
All assembling shall be carried on a level platform.
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

Corrections of minor misfits and reasonable amount of remaining
and cutting of excess stock from rivet shall be considered as a part
of erection. Any error in shop which prevents proper fit on a
moderate amount of reaming and slight shaping or cutting shall be
immediately reported to the Engineer-in-charge and if required
replaced.
2.5.4.7 Erection:
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
permitted by the Engineer-in-charge in writing.
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.
Structural steel frames shall be erected plumb and line. 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.
As erection progresses, the work shall be securely bolted to take
care of all dead load, wind, seismic and erection stresses.
No riveting or welding or final bolting shall be done until the
structure has been properly aligned and approved by the Engineer-
in-charge. No cutting, heating or enlarging of the holes shall be
carried out without the prior approval of the Engineer-in-charge.
2.5.4.8 Inspection:
The Engineer-in-charge/Owner or their authorised representatives
shall have free access to all parts of the job during erection and all
erection shall be subject to their approval. In case of faulty erection
all such dismantling and re-erection required will be at the
Contractor's cost. No paint shall be applied to rivet heads or field
welds or bolts until these have been approved by the Engineer-in-
charge.
2.5.4.9 Tolerance:
The shift of column axis at column base from the marked axis shall
not exceed 5 mm. All column tiers shall be plumb within a
tolerance of 1 in 500 and the structure as a whole plumb within a
tolerance of 1 in 1000. In no case, however, shall the displacement
from plumb of column tiers exceed 10 mm and the total
displacement of the structure as a whole exceed 25 mm for
structures taller than 50 metres and additional displacement of 1
mm for every 2.5 metres additional height subject to a maximum

displacement of 50 mm. The actual levels of supports of trusses,
collar beams, roofing beams, purlin, etc. shall not vary by more
than 20 mm from their marked levels. The sweep of trusses,
beams, etc. in the horizontal plane shall not exceed 1/1500 of their
span subject to a maximum of 10 mm. Further, the deviation of the
upper chords of trusses from vertical plane through centres of
supports shall be within 1/250th of the truss height. Deviation in
spacing of purlins shall be within 5 mm.
2.5.5.0 TECHNICAL SPECIFICAION FOR EXCAVATION OF HARD ROCK
2.5.5.1 Scope:
The work covers all operations connected with excavation in Hard
Rock including all labour and material. The definition of Hard Rock
should be as specified in specification for preparation of site and
earth works in foundation and trenches. The disposal of excavated
material to a designated location is included.
2.5.5.2 General:
Excavation in hard rock shall generally be done by blasting. A valid
blasting licence shall be obtained by the Contractor from authorities
concerned. If the permission for blasting is refused by the
Engineer-in-charge for safety considerations the rock shall be
removed by wedging, picking, barring, burning and sudden
quenching or other approved means. All the excavation beyond
the minimum excavation limits shall be filled back with the same
class and type of material as proposed and approved by the
Engineer-in-charge. While blasting the Contractor shall take all
possible care to preserve rock below and beyond the lines of
excavation in the soundest condition possible.
2.5.5.3 Blasting:
For blasting operations required in case of excavation of rock, the
following points shall be observed:
The Contractor shall employ competent and experienced
supervisor and licensed blaster in-charge of each set of operations
and he will be held personally responsible to ensure that all safety
regulations are followed. Before any blasting is carried out, the
Contractor shall inform the Engineer-in-charge and obtain his
approval in writing for resorting to such operations. He shall
intimate the hours of firing charges, the nature of explosive and
extent to be used and the precaution to be taken for general safety.
The Contractor shall ensure that all workmen and the personnel at
site are excluded from the unsafe area, to be determined by the
Engineer-in-charge, at least 15 minutes before firing by sounding
warning siren. The area shall be encircled by red flags. Within 30
metres from structures no blasting shall be done without prior
approval of the Engineer-in-charge in writing. When blasting is
necessary adjacent to partially or completely built structures the
Contractor shall take all the precautions necessary to prevent flying
rock from causing damage to the structures.
The Contractor shall be responsible for all damage caused by
blasting and shall replace or repair the structures at his own cost.
All major blasting shall be completed prior to starting concrete work
on site.
2.5.5.3.1 Line Blasting
Line drilling for rock blasting if required shall be done as per

following methods. One line of holes is proposed to be drilled as
'line drilling' where rock has to be blasted, in case of uniform
excavation over the entire area. The maximum spacing of holes
shall be 150 mm and diameter of holes 48 mm. This line drilling will
be very close to the area excavated as directed by the Engineer-in-
charge, from the face of the excavation area. In addition to the
above the Engineer-in-charge may order further line drilling at
suitable location to facilitate safe excavation.
In case of uniform excavation over the entire area, the layout of the
interior blasting holes shall be carefully planned in such a way that
no interior hole is closer than 2.5 m to the line drilled holes. Only
light blasting is permitted in the interior holes, which are near the
line-drilled holes. The Contractor may carryout tests to determine
the amount of explosives required to ensure an even break at the
line drilled holes and that no damage occurs to the structures wall
and rock beyond excavation limits.
After the interior holes are blasted any irregularities in the vertical
face which was line drilled shall be removed and trimmed by
wedging, splitting, chiselling and barring. Excavation shall rock
from the centre to the outside.
2.5.5.3.2 Excavation by Blasting
The Contractor shall employ a competent and experienced

supervisor and licensed blaster in-charge of each set of operation
and he will be held personally responsible to ensure that all safety
regulations are carried out.
Before any blasting is carried out, the Contractor shall inform the
Engineer-in-charge and obtain his approval in writing for resorting
to such operation. He will intimate the hours of firing charges, the
nature of explosive to be used and the precautions to be taken for
general safety.
The Contractor shall ensure that all workmen and the personnel at
site are excluded from the area of 200 m radius from the firing
point, at least 15 minutes before firing time by sounding warning
siren. The area shall be encircled by red flags.
The blasting of rock near the existing buildings, equipment or any
other property shall be done under cover and the Contractor has to
make all such necessary muffling arrangements. Covering may
preferably be done by MS plates with adequate dead weight over it.
The blasting shall be done with small charge only and where
directed by the Engineer-in-charge; a trench shall have to be cut by
chiselling prior to the blasting operation separating the area under
blasting from the existing structures. The firing shall be supervised
by a Supervisor and not more than 6 holes at a time shall be set off
successively. If the blasts do not tally with the numbers fired, the
difference indicating the misfired shall be carefully located after half
an hour and when located shall be exploded by drilling a fresh hole
along the misfired hole (but not nearer than 600 mm from it) and by
exploding a new charge.
A wooden tamping rope shall be used to push cartridges home and
metal rod or rammer shall not be permitted on the site of work. The
charge shall be placed firmly into place and not rammed or
pounded. After a hole is filled to the required depth, the balance of
the hole shall be filled with stemming which may consist of sand or
stone dust or similar inert material.
The Contractor shall preferably fire the explosive electrically.
The explosive shall be exploded by means of a primer which shall
be fired by a detonator by a fuse instantaneous detonator (FID) or
other approved cables. The detonators with FID shall be
connected by special nippers.
In dry weather and normal dry excavation, ordinary low explosive
gunpowder may be used. In damp rock, high explosive like
gelatine with detonator and fuse wire may be used. In underwater
or excavation with substantial seepage causing accumulation,
electric detonation shall be necessary.
Holes for charging explosive shall be drilled with pneumatic drills,
the drilling pattern being so planned that rock piles after blasting
will be suitable for handling without secondary blasting.
When excavation almost reaches the level, hand trimming shall
have to be done for dressing the surface to the desired level. Any
extra excavation shall be filled up as instructed by the Engineer-in-
charge, preferably by cement concrete with a mix not leaner than
1:3:6.
The Contractor shall be responsible for any accident to workmen,
public or owners property due to blasting operations in absence of
adequate protection from his end. The Contractor shall also be
responsible for strict observance of rules, laid down by the
Inspector of Explosives, or any other Authority, duly constituted
under the State Government or the Union Government.
2.5.5.3.3 Procurement and Storage of Explosives
The Owner shall obtain for the Contractor necessary licence from
the authorities dealing with explosives, but fees, if any, required for
obtaining such licence shall be borne by the Contractor. The
Contractor shall have to make necessary storage facilities for the
explosives as per rules of local Authorities/Govt. of India.
Explosive shall be kept dry and shall not be exposed to direct rays
of sun or in the vicinity of fire, stoves, steam pipes or heated metal,
etc. No explosive shall be brought near the rock in excess of
quantity required for a particular amount of firing to be done. Any
surplus left after filling the holes shall be removed at least 400
metres from the firing point.
2.5.5.3.4 Limitations
For blasting, the following restriction will be in force. Blasting limits

and charges will be as follows:
1. Within 24 hours after concreting up to 100 m, no blasting is
permitted.
2. During concreting (any time) beyond 100 m blasting only within 2
kg/delays.
3. 24 hours after concreting beyond 100 m up to 14 kg/delay, or in
accordance with the following table:
Distance from Blasting limits

structures in kg per delay
metres
30 4
45 7
100 14
200 27
Within 30 metres from structures, no blasting shall be done without

prior approval of the Engineer-in-charge in writing.
When blasting is necessary, adjacent to partially or completely built
structures, the Contractor shall take all precautions necessary to
prevent flying rock from causing damage to the structures.
The Contractor shall be responsible for all damages caused by
blasting and shall replace or repair the structures at his own cost to
the satisfaction of the Engineer-in-charge. All major blasting shall
be completed prior to starting concrete work at site.
2.5.5.4 Owners Assistance:
In the event of any statutory limitation / other reason, if the
contractor is not entitled to obtain / procure the required
licence/explosives etc Owner shall arrange and provide blasting
materials and shall conduct the blasting operation on chargeable
basis. For such facilities extended by the Owner, Contractor shall
not be absolved from statutory/contractual obligations.
2.5.5.5 I.S Codes (All referred codes should be latest edition):
Important Relevant codes for this section:
I.S 4081 - Safety code for Blasting and Related Drilling operation.
I.S 6922 - Criteria for safety and design of structures subjected to
underground blasts.
2.5.6.0 TECHNICAL SPECIFICATION FOR CEMENT CONCRETE (PLAIN &

REINFORCED):
2.5.6.1 Scope:
This specification deals with cement concrete, Plain or Reinforced,
for general use, and covers the requirements for concrete
materials, their storage, grading, mix design, strength and quality
requirements, pouring at all levels, reinforcements, protection,
curing, formwork, finishing, painting, admixtures, inserts and other
miscellaneous works.
The provision of the latest revision of IS 456 shall be complied with
unless permitted otherwise and any other Indian standard code
(latest revision) shall form a part of this specification to the extent it
has been referred to or applicable within this specification.
2.5.6.2 Materials:
2.5.6.2.1 Cement
Cement used shall be ordinary Portland cement / Portland slag
cement. Rapid hardening Portland cement can be used under
special circumstances, if permitted by the Engineer-in-charge. Only
fresh cement shall be used.
2.5.6.2.2 Aggregates
All aggregates shall conform to all provisions and test methods of
IS 383 latest revision and/or IS 515 latest revision.
Samples of aggregates proposed to be used shall be submitted
free of charge in sufficient quantities to the Engineer-in-charge with
sieve analysis data for his approval. Approved samples will be
preserved by him for future reference. This approval will not in any
way relieve the Contractor or his responsibility of producing
concrete of specified qualities.
2.5.6.2.3 Coarse Aggregate
Coarse aggregates shall consist of uncoated, hard strong, dense
and durable pieces of crushed stone, and shall be free from
undesirable matters, viz. disintegrated stones, soft, flaky or
elongated particles, salt, alkali, vegetable matter or other
deleterious substances. The amount of different undesirable
substances in coarse aggregates shall not exceed the percentage
limits by weight as specified in relevant IS codes, but in no case,
the total amount of all the undesirable substances shall exceed 5%.
Aggregates other than crushed stone conforming to the provisions
of this specification may be used under special conditions, if
permitted by the Engineer-in-charge. Washing of aggregates by
approved means shall be carried out, if desired by the Engineer-in-
charge.
The maximum size of coarse aggregates shall be as follows:

For:
Reinforced concrete including foundations - 20 mm
Ordinary Plain concrete - 20 mm
Heavy mass concrete - 40 mm
Grading of coarse aggregate for a particular size shall generally
conform to relevant IS codes (latest edition) and shall also be such
as to produce a dense concrete of the specified proportions and/or
strength and consistency that will work readily into position without
segregation.
2.5.6.2.4 Fine Aggregates - Sand
Sand shall consist of siliceous material, having hard, strong,
durable, uncoated particles, free from undesirable amounts of dust,
lumps, soft or flaky particles or other deleterious substances. The
amount of different undesirable substances shall not exceed the
percentage limits by weight as specified in relevant IS codes (latest
edition) but in no case, the total amount of all undesirable
substances shall exceed 5% by weight.
Manufactured sand, other than natural sand, conforming to the
provision of this specification may be used under special
conditions, if permitted by the Engineer-in-charge. Washing of
aggregates by approved means shall be carried out, if desired by
the Engineer-in-charge at no extra cost to the Owner.
Coarse and fine sand shall be well graded within the limits by
weights as specified in relevant IS codes (latest edition). Fineness
modulus shall not vary by more than plus or minus 20 % from that
of the approved sample.
2.5.6.2.5 Water
Water shall be clean, fresh and free from organic or other
deleterious matters in solution or in suspension in such amounts
that may impair the strength or durability of the concrete. Potable
water is satisfactory.
2.5.6.2.6 Admixtures
The use of admixtures in concrete for promoting workability
improving strength, entraining air or for any other purpose may be
used only with the approval of the Engineer-in-charge.
2.5.6.2.7 Reinforcement
Reinforcing steel shall be clean and free from loose mill scales,
dust, loose rust and coats of paints, oil grease or other coatings,
which may impair or reduce bond. It shall conform to the following
I.S specifications:
i) Mild steel and medium tensile steel bars and hard drawn
steel wire conforming to IS 432. (latest edition)
ii) Deformed bars conforming to IS 1139. (latest edition)

iii) Cold twisted steel bars conforming to IS 1786. (latest edition)
iv) Structural steel sections conforming to IS 226 (latest edition)
or IS 2062. (latest edition)
All steel reinforcement including and above 8 mm diameter shall
necessarily be of tested quality.
2.7.6.2.8 Formwork
Formwork shall be composed of steel and/or best quality shuttering
wood of non-absorbent type. Timber shall be free from knots and
shall be of medium grain as far as possible. Hard woods shall be
used as caps and wedges under or over posts. Plywood or
equivalent shall be used where specified to obtain. Ballah shall be
of mild steel tubes, and strong Sal Ballah 150 mm in diameter or
above. Bamboo, small diameter Ballah etc. shall not be used
unless approved by the Engineer-in-charge in specific cases.
2.7.6.2.9 Storage of Materials
All materials shall be stored to prevent deterioration or intrusion of
foreign matter and to ensure the preservation of their quality and
fitness for the work. Any material, which has been rejected by the
Engineer-in-charge, shall not be used for concrete and shall be
removed from site immediately, failing which the Engineer-in-
charge shall be at liberty to get the materials removed and the cost
thereof shall be realised from the Contractor's dues.
2.5.6.3 Concrete Mixes:
2.5.6.3.1 General
Concrete shall be either ordinary or controlled and in grades
designated as M-20, M-25 or even richer mixes as specified in
IS 456 (latest edition) as per the scope of work defined elsewhere.
Lean concrete shall be 1:4:8 mix with aggregate of nominal size 40
mm maximum with minimum thickness of 75mm or as indicated in
drawings.
2.5.6.3.2 Ordinary Concrete
Ordinary concrete is recommended only when accuracy is
impracticable and not necessary. However, if ordinary concrete is
allowed by the Engineer-in-charge, it shall be used only in the
concrete of grade M-20. Ordinary concrete does not require
preparation of trial mixes.
Concrete mix proportions for ordinary concrete shall be as per IS
456(latest edition) Table 9 (Clauses 9.3 & 9.3.1)
In proportioning concrete the quantity of cement shall be
determined by actual weight. The quantities of fine and coarse
aggregate must be determined by weight for structural works. If the
aggregates are moist allowance shall be made for bulking in case
of volume batching and in accordance with IS 2386 (Part-III) (latest
edition). Allowance shall also be made for surface water present in
the aggregates where computing the water content. The amount of

surface water shall be determined by one of the field methods
described in IS 2386 (Part-III) (latest edition). All the above data
shall be maintained properly to the satisfaction of Engineer-in-
charge.
The water cement ratio shall not be more than those specified. The
cement content of any nominal mix proportion specified above shall
be increased if the quantity of water in a mix has to be increased to
overcome the difficulties of placement and compaction, so that the
water cement ratio specified above for a particular mix is not
exceeded. No extra payment shall be made to the Contractor for
use of the extra cement.
If ordinary concrete made in accordance with the proportions given
above for a particular grade does not yield the specified strength
and fails to satisfy the requirements of Acceptance Criteria for
concrete as specified in IS 456(latest edition), the cement content
shall be increased as directed by the Engineer-in-charge to obtain
a specified strength at no extra cost to the owner. This richer mix
shall continue until the Engineer-in-charge instructs otherwise.
Ordinary concrete proportioned for a given grade specified above
shall not, however, be classified as a higher grade on the ground
that the test strength were found higher than the minimum
specified.
2.5.6.3.3 Controlled Concrete
Controlled concrete shall be used on all concrete works, except
where specified otherwise. Controlled concrete for use in plain and
reinforced concrete structure shall be in grade M-20, M-25, or even
richer mixes.
The mix proportions for all grades of concrete shall be designed to
obtain strengths corresponding to the values specified hereinafter
for respective grades of concrete. Preliminary tests, as specified in
the IS code and required by the Engineer-in-charge, shall be
carried out sufficiently ahead of the actual commencement of the
work with different grades of concrete made from representative
samples of aggregates and the water cement ratio required to
produce a concrete of specified strength and desired workability.
The minimum cement content, Maximum Water-Cement ratio &

Minimum Grade of Concrete for different exposures with Normal
Weight Aggregates of 20 mm Nominal Maximum size & other than
20 mm Nominal Maximum size shall be in accordance to Table 5 &
Table 6 of I.S 456 latest edition.
At least 4 trial batches are to be made and 7 test cylinders taken for
each batch noting the slump on each mix. These cylinders shall
then be properly cured and two cylinders for each mix shall be
tested in a testing laboratory approved by the Engineer-in-charge at
7 days and others at 28 days for obtaining the ultimate

compressive strength. The test reports shall be submitted to the
Engineer-in-charge. The cost of the mix design and testing shall be
borne by the Contractor.
On the basis of the preliminary test reports for trial mix, a proportion
of mix by weight and water cement ratio, approved by the
Engineer-in-charge, which will be expected to give the required
strength, consistency and workability and the proportions so
decided for different grades of concrete shall be adhered to during
all concreting operations. If, however, at any time, the Engineer-in-
charge feels that the quality of materials, being used has changed
from those used for preliminary mix design, the Contractor shall
have to run similar trial mixes to ascertain the mix proportions and
consistency. It will be within the competency of the Engineer-in-
charge to reduce the number of trial batches and then number of
test specimens mentioned above. Further, the Engineer-in-charge
can also allow adoption of the mixes already tried and found
satisfactory, with similar materials, for other jobs at the same site,
without any fresh design of the mix.
The mixes once approved must not be varied without prior approval
of the Engineer-in-charge. Should however, the Contractor
anticipate any change in the quality of future supply of materials
than that has been used for preliminary mix design, he shall inform
the same to the Engineer-in-charge and bring fresh samples
sufficiently ahead to carry out fresh trial mixes.
If permitted by the Engineer-in-charge, the Contractor may use
concrete cube specimens in place of cylinder specimens.
In designing the mix proportions of concrete, the quantity of both
cement and aggregate shall be determined by weight. The
Engineer-in-charge may allow the quantity of aggregates to be
determined by equivalent volume basis after the relationship
between the weight and volume is well established by trial and the
same shall be in calibrated tanks or weighed. All measuring
equipment shall be maintained in a clean and serviceable
condition, and their accuracy periodically checked.
To keep the water cement ratio to the designed value, allowance
shall be made for the moisture contents in both fine and coarse
aggregates and determination of the same shall be made as
frequently as directed by the Engineer-in-charge. The
determination of moisture contents shall be according to IS 2386
(Part-III) (latest edition).
2.5.6.3.4 Strength Requirements
Where ordinary Portland cement conforming to IS 269/8112/12269

(latest edition) or Portland blast furnace slag cement conforming to
IS 445 (latest edition) is used, the compressive strength
requirements for various grades of concrete shall comply with the
requirements mentioned in I.S 456 latest edition. Where rapid

hardening Portland cement is used, the 28 day compressive
strength requirements specified shall be met in 7 days. The
strength requirements specified shall apply to both controlled
concrete and ordinary concrete.
The acceptance of strength of concrete shall be as per clause 16
Acceptance Criteria' of IS 456 (latest edition) subject to stipulations
and / or modifications stated elsewhere in this specification.
Concrete work found unsuitable for acceptance shall have to be
dismantled and replacement to be done as per specification by the
Contractor. No payment for the dismantled concrete, the relevant
formwork and reinforcement, embedded fixtures, etc, wasted in the
dismantled portion shall be made. In the course of dismantling, if
any damage is done to the embedded items or adjacent structures,
the same shall be made good free of charge by the Contractor to
satisfaction of the Engineer-in-charge.
Other requirements of concrete strength as may be desired by the
Engineer-in-charge shall be in accordance with Indian Standard IS
456 (latest edition). In the event of the concrete failing to gain the
required strength cores shall be taken or load tests performed.
In exceptional circumstances, the Engineer-in-charge may accept a
concrete of lower strength than specified and which is otherwise
unacceptable according to the 'Acceptance Criteria' of IS 456
(latest edition), provided the strength is never less than 80% of the
specified strength. All concrete having a strength less than 80% of
that specified shall always be rejected.
With permission of the Engineer-in-charge, for any of the above
mentioned grades of concrete, if the water has to be increased in
special cases, cement shall also be increased proportionately to
keep the ratio of water to cement same as adopted in trial mix
design for each grade of concrete. No extra payment for the
additional cement will be made.
2.5.6.3.5 Workability
The workability of the concrete shall be checked at frequent

intervals by slump test. Where facilities exist and if required by the
Engineer-in-charge, alternatively, the compacting factor test in
accordance with IS 1199 (latest edition) shall be carried out.
2.5.6.4 Workmanship:
2.5.6.4.1 General
All workmanship shall be according to the latest and best possible
standards.
Before starting a pour, the Contractor shall obtain the approval of
the Engineer-in-charge in a pour card maintained for this purpose.
He will obtain complete instructions about the material and
proportion to be used, slump workability, quantity of water per unit
of cement, number of test cylinders to be taken, type of finishing to

be done, any admixture to be added, etc.
2.5.6.4.2 Concrete
Generally a special system shall be instituted to identify the grade

of concrete during mixing, transport and placing so as to ensure
that only the correct grade of concrete is used in each position.
i) Mixture of Concrete
The proportions of fine and coarse aggregate, cement and water
shall be as determined by the preliminary tests or according to fixed
proportions in case of ordinary concrete and shall always be
approved by the Engineer-in-charge. The quantities of fine and
coarse aggregates shall be determined as specified herein before.
The quantity of cement shall always be determined by weight.
Water shall be measured accurately after giving proper allowance
for surface water present in the aggregate for which regular checks
shall be made by the Contractor. Due allowance shall be made for
bulking in case of volume batching in accordance with IS 2386
(Part-III). Concrete shall always be mixed in a mechanical mixer
unless specifically approved by the Engineer-in-charge for concrete
to be used in unimportant structures. Water shall not be poured
into the drum of the mixer until all the cement and aggregates
constituting the batch are already in the drum and mixed for at least
one minute. Mixing of each batch shall be continued until the mix is
uniform in colour and consistency, but in no case shall mixing be
done for less than two (2) minutes and at least forty (40) revolutions
after all the materials and water are in the drum. When absorbent
aggregates are used or when the mix is very dry, the mixing time
shall be extended as may be directed by the Engineer-in-charge.
Mixers shall not be loaded above their rated capacity as this
prevents thorough mixing.
The entire contents of the drum shall be discharged before the
ingredients for the next batch are fed into the drum. No partly set
remixed or excessively wet concrete shall be used and it shall be
immediately removed from site. Each time the work stops, the
mixer shall be thoroughly cleaned and when the next mixing
commences, the first batch shall have 10% additional cement at no
extra cost to the Owner to allow for loss in the drum.
When hand mixing is permitted by the Engineer-in-charge for
concrete to be used in unimportant structures it shall be carried out
on a watertight platform and care shall be taken to ensure that
mixing is continued until the mass is uniform in colour and
consistency. In case of hand mixing, extra cement @ 10% shall be
added to each batch at no extra cost to the owner.
ii) Conveying Concrete
Concrete shall be handled and conveyed from the place of mixing
to the place of final laying as rapidly as practicable, by approved
means, before the initial setting of the cement starts. Concrete

should be conveyed in such a way as will prevent segregation or
loss of any of the ingredients. If segregation does occur during
transport, the concrete shall be remixed. During very hot or cold
weather, if directed by the Engineer-in-charge, concrete shall be
transported in deep containers which will reduce the rate of
evaporation and loss of heat. Conveying equipment for concrete
shall be well maintained and thoroughly cleaned before
commencement of concrete mixing. Such equipment shall be kept
free from set concrete.
iii) Placing Concrete
Formwork and reinforcement shall be approved in writing by the
Engineer-in-charge before concrete is placed. The forms shall be
well wetted and all shavings dirt and water that may have collected
at the bottom shall be removed before concrete is placed.
Concrete shall be deposited in its final position without segregation,
re-handling or flowing. The interval between adding the water to
the dry materials in the mixer and the completion of the final placing
inclusive of compaction of the concrete shall be well within the
initial setting time for the particular cement in use or as directed by
the Engineer-in-charge. As far as possible concrete shall be
placed in the formwork by means approved by the Engineer-in-
charge and shall not be dropped from a height or handled in a
manner which may cause segregation. Any drop over 180 cm shall
have to be approved by the Engineer-in-charge. Once the concrete
is deposited in its final position, it shall not be disturbed.
After the concrete has been placed, it shall be spread and
thoroughly compacted by approved mechanical vibration to a
maximum subsidence without segregation and thoroughly worked
around reinforcement or other embedded fixtures into the correct
form and shape. Vibrators shall not be used for pushing and
shovelling concrete into adjoining areas. Vibrators must be
operated by experienced men and over-vibration shall not be
permitted. Hand tamping in some cases may be allowed subject to
the approval of the Engineer-in-charge. Care must be taken to
ensure that the inserts, fixtures, reinforcement and formwork are
not displaced or distorted during placing of concrete. No concrete
shall be placed in open, while it rains. If there has been any sign of
washing of cement and sand, the concrete shall be removed
immediately. Suitable precautions shall be taken in advance to
guard against rains damaging the fresh concrete. No accumulation
of water shall be permitted on or around freshly laid concrete.
Slabs, beams and similar members shall be poured in one
operation normally, under special circumstances, with the approval
of the Engineer-in-charge these can be poured in horizontal layers
not exceeding fifty (50) cm in depth. When poured in layers, it must
be ensured that the under layer is not already hardened. Bleeding
of under layer, if any, shall be effectively removed. Moulding,
throttling, drip course, etc. shall be poured as shown on the
drawing or as desired by the Engineer-in-charge. Holes shall be

provided and bolts, sleeves, anchors, fastenings or other fixtures
shall be embedded in concrete as shown on the approved drawings
or as directed by the Engineer-in-charge. Any deviation there from
shall be set right by the Contractor at his own expense as
instructed by the Engineer-in-charge.
iv) Construction Joints
When the work is to be interrupted, the concrete shall be rebated at
the joint to such shape and size as may be required by the
Engineer-in-charge or as shown on the drawing. All vertical
construction joints shall be made with stop boards, which are rigidly
fixed and slotted to allow for the passage of the reinforcing steel. If
desired by the Engineer-in-charge, keys and/or dowel bars shall be
provided at the construction joints. In the case of water retaining
structures, water stop of approved material shall be provided if so
specified on the drawing or desired by the Engineer-in-charge.
Construction joints shall be provided in positions as shown or
described on the drawings. Where it is not described the joints
shall be in accordance with the following:
In a column, the joint shall be formed about 75 mm below the
lowest soffit of the beams framing into it.
Concrete in a beam shall be placed throughout without a joint, but if
the provision of a joint is unavoidable, the joint shall be vertical and
at the middle of the span. A joint in a suspended floor slab shall be
vertical, at the middle of the span and at right angle to the principal
reinforcement.
In forming a joint, concrete shall not be allowed to slope away to a
thin edge. The locations of construction joints shall be planned by
the Contractor well in advance of pouring and have to be approved
by the Engineer-in-charge.
Before fresh concrete is placed, the cement skin of the partially
hardened concrete shall be thoroughly removed and surface made
rough by hacking, sand blasting, water jetting, air jetting or any
other method as directed by the Engineer-in-charge. The rough
surface shall be thoroughly wetted for about two hours and shall be
dried and coated with 1:1 freshly mixed cement sand slurry
immediately before placing the new concrete. The new concrete
shall be worked against the prepared surface before the slurry sets.
Special care shall be taken to see that the first layer of concrete
placed after a construction joint is thoroughly rammed against the
existing layer.
Cold joints during pour shall be treated with 1:1 freshly made
cement sand slurry only after removing all loose materials.
v) Protection and Curing of Concrete
Newly placed concrete shall be protected by approved means from
rain, sun, and wind. Concrete placed below the ground level shall
be protected from falling earth during and after placing. Concrete

placed in ground containing deleterious substances shall be kept
free from contact with such ground or with water draining from such
ground during placing of concrete and for a period of at least three
days or as otherwise instructed by the Engineer-in-charge. The
ground water around newly poured concrete shall be kept to an
approved level by pumping or other approved means of drainage.
Adequate steps shall be taken to prevent flotation or flooding.
Steps, as approved by the Engineer-in-charge, shall be taken to
protect immature concrete from damage by debris, excessive
loading, vibration, abrasion, mixing with earth or other deleterious
materials, etc. that may impair the strength and durability of the
concrete.
As soon as the concrete has hardened sufficiently for the surface to
be marked, it shall be covered either with sand, Hessian, canvas or
similar materials and kept continuously wet for at least seven (7)
days after final setting. This period may be extended, at the
discretion of the Engineer-in-charge, up to fourteen (14) days.
vi) Control Tests on Concrete
For the concrete of a particular specified strength, at least six (6)
test cylinders, for each type of mix, shall be taken by the Contractor
for each 8 hours or less work for each medium sized mixing plant.
If the volume of concrete poured is less than 20 m3 on any day per
mixing plant, the Engineer-in-charge may exempt or reduce the
number of test specimens at his discretion based on the test
reports. The sampling of concrete, making the test specimens,
curing and testing procedure shall be as specified in IS 456 (latest
edition). The test specimens shall be 150 mm diameter and 300
mm high. The Contractor shall get the specimens tested in a
laboratory approved by the Engineer-in-charge and submit to the
Engineer-in-charge the test results in triplicate within three (3) days
of the test. The Contractor shall carryout the sampling and testing
according to the provisions of this specification at his own cost. No
payment shall also be made for the concrete used in specimen. To
control the consistency of concrete from mixing plant, slump tests
shall be carried out by the Contractor free of charge every two
hours or as directed by the Engineer-in-charge. The amount of
mixing water shall not be changed without approval of the
Engineer-in-charge. Slumps corresponding to the test cylinder
shall be recorded for reference.
Before commencing the work or during the progress of the work,
the Engineer-in-charge, if he so desires, may order tests to be
carried out on cement, sand or coarse aggregates, water,
reinforcing steel or transverse tests on concrete specimens, or any
other relevant tests in accordance with IS recommendations. The
Engineer-in-charge can suspend the work during the testing of any
doubtful material. No claim for any consequent loss arising out of
such suspension shall be entertained.
For testing concrete, if permitted by the Engineer-in-charge, cube

specimens may be tested in place of cylinder specimens.
2.5.6.4.3 Reinforcement
i) Shop Drawings Bar Bending Schedules

The Contractor shall prepare and furnish bar bending schedules
with working drawings for all RCC work, for review by the Engineer-
in-charge.
ii) Cleaning
All steel for reinforcement shall be free from loose scale, oil,
grease, paint or other harmful matters immediately before placing
the concrete.
iii) Bending
Unless otherwise specified, reinforcing steel shall be bent in
accordance with procedure specified in IS 2502 (latest edition) or
as approved by the Engineer-in-charge. Bends and shapes shall
comply strictly with the dimensions in the approved Bar Bending
Schedule. Bending schedule shall be re-checked by the Contractor
before bending and he shall be entirely responsible for its
correctness. Only correctly bent bars shall be used.
No reinforcement shall be bent when in position in the work without
approval of the Engineer-in-charge, whether or not it is partially
embedded in concrete. Bars shall not be straightened in a manner
that will injure the material. Re-bending can be done only if
approved by the Engineer-in-charge. Reinforcement bars shall be
bent by machine or other approved means producing a gradual and
even motion. All the bars shall be cold bent unless otherwise
approved. Bending hot at a cherry red heat (not exceeding 8450 C)
may be allowed in very exceptional cases except for bars whose
strength depends on cold working. Bars bent hot shall not be
cooled by quenching.
iv) Placing in Position
All reinforcements shall be accurately fixed and maintained in
position as shown on the drawings by such approved means as
mild steel chairs and/or concrete spacer block. Bars intended to be
in contact, at crossing points, shall be securely bound together at
all such points by No. 20G annealed soft iron wire or by tack
welding as may be directed by the Engineer-in-charge. Binders
and the like shall tightly embrace the bars with which they are
intended to be in contact and shall be securely held. The vertical
distance between successive layers of bars shall be maintained by
provision of mild steel spacer bars. They should be so spaced that
the main bars do not sag perceptibly between adjacent spacers.
Welding by gas or electricity may be permitted by the Engineer-in-
charge under suitable conditions and with suitable safeguards in
accordance with relevant Indian Standards for welding of mild steel
bars used in reinforced concrete construction. Welding between

ends of a bar in a line, whereby stress is transferred across the
section may be allowed for mild steel bars only. In the case of bars
of mild steel, which have their strength increased by cold twisting
(like cold twisted bars), the stress at the weld shall be limited to
strength of mild steel.
As a consequence, if any additional steel is required to be provided
in the member, it shall be to the Contractor's account.
Welding of structural steel, plates, gussets, etc. to reinforcement
involving the cutting back of hardened concrete to expose the
reinforcement, will not be permitted under any circumstances.
The placing of reinforcements shall be completed well in advance
of concrete pouring. Immediately before pouring, the reinforcement
shall be examined by the Engineer-in-charge for accuracy of
placement and cleanliness and necessary corrections as directed
by him shall be carried out. The cover for concrete over the
reinforcements shall be as shown on the approved drawings unless
otherwise directed by the Engineer-in-charge. Where concrete
blocks are used for ensuring the cover and positioning
reinforcement, they shall be made of mortar not leaner than one (1)
part cement to two (2) parts sand by volume and cured for at least
seven (7) days. The sizes and locations of the concrete blocks
shall be approved by the Engineer-in-charge. Laps and anchorage
lengths of reinforcing bars shall be in accordance with IS 456
(latest edition), unless otherwise specified. If the bars in a lap are
not of the same diameter, the smaller will guide the lap length. The
laps shall be staggered as far as practicable and as directed by the
Engineer-in-charge.
2.5.6.4.4 Formwork
i) General
If it is so desired, the Contractor shall prepare, before
commencement of actual work, design and drawings for formwork
and centring and get them approved by the Engineer-in-charge.
The formwork shall conform to the shape, lines and dimensions as
shown on the drawings.
The centring shall be true, rigid and thoroughly braced both
horizontally and diagonally. The forms shall be sufficiently strong
to carry without undue deformation, the dead weight of the concrete
as a liquid as well as working load. Where the concrete is vibrated,
the formwork shall be strong enough to withstand the effects of
vibration without appreciable deflection, building, distortion or
loosening of its components. The joints in the formwork shall be
sufficiently tight to prevent any leakage of mortar. The formwork
shall be such as to ensure a smooth uniform surface free from
honeycombs, air bubbles, bulges, fins and other blemishes. Any
blemish or defect found on the surface of the concrete must be
brought to the notice of the Engineer-in-charge immediately and

rectified free of charge as directed by him. To achieve the desired
rigidity, tie bolts, spacer blocks, tie wires and clamps as approved
by the Engineer-in-charge shall be used but they must in no way
impair the strength of concrete or leave stains or marks on the
finished surface. Where there are chances of these fixtures being
embedded, only mild steel or concrete of adequate strength shall
be used. Bolts passing completely through liquid retaining
walls/slabs for the purpose of acquiring and aligning the formwork
should not be used unless effective precautions are taken to
ensure water tightness after removal.
For exposed interior and exterior concrete surfaces of beams,
columns, and walls, plywood or other approved forms, thoroughly
cleaned and tied together with approved corrosion resistant devices
shall be used. Rigid care shall be exercised in ensuring that all
columns are plumb, true and thoroughly cross braced to keep them
so. All floor and beam centring shall be crowned not less than 8
mm in all directions for every 5 m span. Unless described on the
drawing or elsewhere to the contrary, bevelled strips 25 mm by 25
mm shall be provided, without any extra charge, to form angles and
in corners of columns and beam boxes for chamfering of corners.
Temporary openings for cleaning, inspection and for pouring
concrete shall be provided at the base of vertical forms and at other
places, where they are necessary and as may be directed by the
Engineer-in-charge. The temporary openings shall be so formed
that they can be conveniently closed when required and must not
leave any mark on the concrete.
ii) Cleaning and treatment of Forms
All forms shall be thoroughly cleaned of old concrete, wood
shavings, saw dust, dirt and dust sticking to them before they are
fixed in position. All rubbish, loose concrete, chippings, shavings,
sawdust, etc. shall be scrupulously removed from the interior of the
forms before the concrete is poured. Along with wire brushes,
brooms, etc. compressed air jet and/or water jet shall be used for
the cleaning, if directed by the Engineer-in-charge.
Before shutter is placed in position, the form surface in contact with
concrete shall be treated with approved non-staining oil
composition. Care shall be taken that the oil or composition does
not come in contact with reinforcing steel or existing concrete
surfaces; they shall not be allowed to accumulate at the bottom of
the shuttering.
The formwork shall be so designed and erected that the forms for
slabs and the sides of beams, columns and walls may be removed
first, leaving the shuttering to the soffits of beams and their
supports in position. Re propping of beams shall not be done
except with the approval of the Engineer-in-charge, and props can
be reinstated in anticipation of abnormal conditions. If formwork for
column is erected for the full height of the columns, one side shall
be left open and built up in sections, as placing of concrete

proceeds. Wedges, spacer bolts, clamps or other suitable means
shall be provided to allow accurate adjustment of the formwork and
to allow it to be removed gradually without jarring the concrete.
iii) Removal of forms
Forms for various types of structural components shall not be
removed before the minimum specified days in accordance with I.S
which shall also be subject to the approval of the Engineer-in-
charge.
In normal circumstances & where ordinary Portland cement is used,
forms may generally be removed after the expiry of the following
periods:
Type of Formwork Minimum period
before
striking Formwork
a) Vertical formwork to columns, beams 16-24 hours
b) Soffit formwork to slabs (Props to be
refixed immediately after removal of
form work) 3 days
c) Soffit formwork to beams (Props to be
refixed immediately after removal of
form work) 7 days
d) Props to slab:
1) Spanning up to 4.5 m 7 days
2) Spanning over 4.5 m 14 days
e) Props to beams & arches:
1) Spanning up to 6 m 14 days
2) Spanning over 6 m 21 days
- For other types of cement, the stripping time recommended for
ordinary Portland cement may be suitably modified. If Portland
pozzolana or low heat cement has been used for concrete, the
stripping time will be 10/7of the period stated above.
- The number of props left under, their sizes and disposition shall
be such as to be able to safely carry the full dead load of the slabs,
beam or arch as the case may be together with any live load likely
to occur during or further construction.
- For rapid hardening cement, 3/7 of above periods will be
sufficient in all cases except for vertical side of slabs, beams &
columns which should be retained for at least 24 hours.
-In case of cantilever slabs and beams, the centring shall remain
till structures for counter acting or bearing down have been erected
and have attained sufficient strength.
-Proper precautions should be taken to allow for the decrease in
the rate of hardening that occurs with all types of cement in cold
weather and accordingly stripping time shall be increased.
- Work damaged through premature or careless removal of forms
shall be reconstructed.
The Contractor shall record on the drawing or in other approved
manner, the date of which the concrete as placed in each part of
the work and the date on which the formwork is removed there from
and have this record checked and countersigned by the Engineer-
in-charge. The Contractor shall be responsible for the safe removal
of the formwork, but the Engineer-in-charge may delay the time of
removal if he considers it necessary. Any work showing signs of
damage through premature removal of formwork of loading shall be
entirely re-constructed without any extra cost to the Employer.
Before removing any formwork, the Contractor must notify the
Engineer-in-charge well in advance to enable him to inspect the
concrete, if he so desires.
iv) Tolerance
The formwork shall be so made as to produce a finished concrete
true to shape lines, levels, plumbs and dimensions as shown on the
drawings. The formwork shall be designed and constructed so as to
remain sufficiently rigid during placing &compaction of concrete,
and shall be such as to prevent loss of slurry from the concrete. For
further details regarding design, detailing, etc. reference may be
made to I.S 14687(latest edition). The tolerance on the shapes,
lines & dimensions shown in the drawing shall be within the limits
given below:
a) Deviation from specified dimensions of cross section - 6 mm
of columns & beams +12mm
b) Deviation from dimensions of footings
1) Dimensions in plan -12 mm
+50mm
2) Eccentricity 0.02 times the width of the footing in the
direction of deviation but not more than
50 mm
3) Thickness + 0.05 times the specified thickness.
v) Re-use of forms
Before re-use, all forms shall be thoroughly scraped cleaned, joints,
etc. examined, and when necessary repaired, and in-situ used/re-
used, if declared unfit or unserviceable by the Engineer-in-charge.
2.5.6.4.5 Classification of Concrete Finishes
i) Ordinary
This shall be used in places where ordinary surface finish is
required and shall be composed of steel and or approved good
quality seasoned wood.
ii) Plywood
This shall be used on exposed surfaces, where a specially good
finish is required and shall be made mostly of approved brand of
heavy quality plywood to produce a perfectly level, uniform and
smooth surface. Re-use may only be permitted after special
inspection and approval by the Engineer-in-charge. He may also
permit utilisation of used plywood for the 'ordinary' class.
iii) Imperfect Surfaces
a) Interior
Imperfect surfaces, where strength is not the criteria shall be
patched and rubbed smooth with carborundum stone. Immediately
after the formwork is stripped off, fins and projections shall be
removed and the concrete surface affected thereby shall be rubbed
smooth to satisfaction of the Engineer-in-charge.
b) Exterior
Imperfect surfaces shall not be patched, but shall be repaired by
removal and replacement of the member or as directed by the
Engineer-in-charge. Small voids shall be filled with 1:2 cement
mortar pressed into holes and floated smooth. Plastering and steel
towelling of surfaces shall not be allowed except in exceptional
cases as may be directed by the Engineer-in-charge. Fins and
projections shall be treated as above.
2.5.6.4.6 Slip Formed Concrete
Silos and other suitable tall structures may be constructed by slip

form construction methods, subject to the approval of the Engineer-
in-charge.
Slip forming in general provides an acceptable finish and will be
encouraged, but it does require considerable resources and very
good organisation on the part of the Contractor. The Contractor
shall therefore make a detailed application for approval if he wishes
to use this method, covering, inter alias:
a) Past experience in slip forming;
b) Resources available in plant and equipment
c) Resources available in Engineer-in-charge, supervisors and
skilled operatives;
d) Method statement for the work, including;
Outline programme;
Proposals for shutters and shutter jacking
Proposals for concrete production;
Proposals for reinforcement supply and fixing;
Proposals for finishing and curing;
Contingency plans for dealing with any breakdown or interruption to
the work in progress.
2.5.6.4.7 Anchor Bolts, Anchors, Openings, Sleeves, Inserts and Other Built-
In-Fixtures
i) The Contractor shall provide openings, grooves, chases, etc, in

concrete work as required for erection of equipment and structures.
He shall build into concrete work all the materials noted below and
shall embed and secure the same as and when required. The
material shall be of best quality available of approved manufacture
and shall be up to satisfaction of the Engineer-in-charge. Exposed
surfaces of embedded materials are to be painted with one coat of
approved anti-corrosive paint and/or bituminous paint without any
extra cost to the owner.
ii) Materials to be embedded
a) Inserts hangers, anchors, openings, frames, manhole cover
frames, floor clips, sleeves and conduits.
b) Anchor bolts and plates for machinery, equipment and for
structural steel work.
c) Dowel bars, etc. for concrete work.
d) Lugs or plugs for door and window frames occurring in
concrete work.
e) Flashing and jointing in concrete work.
f) Any other built in fixtures as may be required.
Correct location, exact alignment, etc. of all these shall be entirely
the responsibility of the Contractor.
2.5.6.4.8 Joints, etc.
i) Expansion and Isolation Joints

Expansion joints in concrete structures shall be provided at
specified places as indicated on the drawings. The materials and
types of joints shall be as specified below. In case of liquid
retaining structures, additional precaution shall be taken to prevent
leakage of liquids as may be specified on the drawings or as
directed by the Engineer-in-charge.
All materials to be procured from reliable manufacturers and shall
have approval of the Engineer-in-charge. The Engineer-in-charge
may demand test certificates for the materials and/or get them
tested.
ii) Bitumen Board
Bitumen impregnated fibreboards of approved manufacture as per
IS 1838 shall be used as fillers for expansion joints. It must be
durable and waterproof. It shall be compressible and possess a
high degree of recovery after compression is released. At the
exposed end, the joint shall be sealed with approved sealing
compound to a depth of 25 mm after application of an approved
primer. The sealing compound and the primer shall be applied as
specified by the manufacturer.
iii) Bitumen compound
The gap for expansion joints shall be thoroughly cleaned and the
bitumen compound laid as per manufacturer's specifications. The
compound to be used shall be of approved manufacturer and shall
conform to the requirements of IS 1834 (latest edition).
iv) Separation Joints
Strong and tough alkathene sheet or equivalent of about 1 mm
thickness as approved by the Engineer-in-charge shall be used. It
shall be fixed by an approved sticker to the cleaned surface of the
already set concrete to cover it fully. Fresh concrete shall be laid
against the sheet, care being taken not to damage the sheet in any
way.
v) Rubber Pad
Hard foundation quality rubber pads of required thickness and
shape shall be put below machine or other foundations where
required as shown on the drawings or as desired by the Engineer-
in-charge. The rubber shall be of best quality of approved
manufacture, durable, capable of absorbing vibration and must be
chemically inert and in contact with moist or dry earth under normal
conditions.
2.5.6.4.9 Pressure Grouting
Pervious rock, fissures, etc, under foundations shall be grouted and

sealed, if required. Grout shall be composed of cement and water,
except that for wider seams, sand or 6mm down stone chips may
have to be used in the mixture as directed by the Engineer-in-
charge. The mix for grouting shall be 1 part cement and 1 part
sand. The location and depth of grout holes shall be as directed by
the Engineer-in-charge. Grout shall be placed at pressure up to 14
kg/cm2 or as required by approved grouting machine.
2.5.6.5 Pre-cast Concrete:
The specification for pre-cast concrete will be exactly similar as for
the cast in place concrete. All pre-cast work shall be carried out in
a yard made for the purpose. This yard shall have a hard and
levelled platform made of concrete or grouted brick soling finish

smooth with neat cement plaster overlaid by a layer of GI plain
sheets, curing tank and such other facilities. The moulds shall
preferably be of steel or of wood lined with GI sheet metal. The
yard shall preferably be fenced.
Lifting hooks shall be embedded in correct position of the unit to
facilitate erection, even though they may not be shown on the
drawings, and shall be burnt off and finished after erection.
Pre-cast concrete planks after 28 days' of casting and curing ready
for erection shall be transported to site by suitable means approved
by the Engineer-in-charge. All care shall be taken that no damage
occurs during transportation. All adjustments, levelling and
plumbing shall be done by providing instruments, materials and
men to the Engineer-in-charge for checking the proper erection of
the pre-cast units. The joint between pre-cast planks shall be
pointed with 1 cement and 2 sand mortar where called for on the
drawing.
2.5.6.6 Waterproofing Of Concrete Structures:
The materials shall conform to the respective IS code wherever
applicable. The Engineer-in-charge's approval to the materials shall
be obtained by the Contractor before procurement. If desired by
the Engineer-in-charge, test certificates for the materials shall be
submitted by the Contractor and samples for testing by the
purchaser shall be supplied free. The materials shall be of best
quality available indigenously, fresh and thoroughly clean.
2.5.6.6.1 Water stops
i) Ribbed Rubber Water stop

The material must be very durable and tough. The ribs shall be
work sufficient to ensure bond with concrete. The width shall be
minimum 100 mm and thickness minimum 3 mm. The rubber water
stop must be used in long lengths to avoid splicing as far as
possible, which shall have at least 230 mm overlaps and stuck with
a reliable sticker compound, or vulcanised.
ii) GI Strips
GI strip shall be minimum 22 gauge and 230 mm in width. It shall
be strong and durable. Longest lengths available shall only be
procured. At joints strips shall be lapped 150 mm and brazed
thoroughly to prevent any leak.
These shall be placed in position very securely so as not to get
dislodged or distorted during placing of concrete. GI strips to be
used in construction joints.
iii) PVC Sealing Strips
PVC sealing strips shall be used for Expansion joints. The
minimum thickness of PVC sealing strips will be 5 mm and the
minimum width 150 mm. The actual size and shape will have to be
specified in drawings. The material should be of good quality
Polyvinyl chloride highly resistant to tearing, abrasion and
corrosion. The physical properties will generally be as follows:
Specific gravity : 1.3 to 1.35
Shore hardness : 60A to 80A
Tensile strength : 100-150
kg/m2
Minimum safe continuous temperature : 700 C
Ultimate elongation : Not less than 275%
2.5.6.6.2 Admixtures
i) In Plaster
The plaster shall be made of cement, sand and the approved
waterproofing admixture as per manufacturer's specification. The
admixture shall be 'IMHERMO' or equivalent as approved by the
Engineer-in-charge. The concrete surface to be plastered shall be
hacked to form a key to Engineer-in-charge's satisfaction. If
desired by the Engineer-in-charge, the Contractor shall have the
work supervised by the manufacturer's supervisor at no extra cost
to the owner.
ii) In Concrete
The admixture shall be the right variety of Lilax, Silvicon, 'ICICO' or
equivalent water proofing cement additive, which conforms to IS
2645 (latest edition). Water proofing additive shall be as far as
possible free from aggressive chemicals like chloride sulphides,
etc. which can cause corrosion of steel reinforcement in RCC.
iii) Other Admixture in Concrete
The Engineer-in-charge may at his discretion instruct the
Contractor to use any admixture in the concrete.
2.5.6.6.3 Surface Treatments
i) Bituminous Coating
Surface to be waterproofed shall be absolutely dry, clean and dust
free. The surface shall be completely coated with hot coal tar pitch
as per IS 216 (latest edition) (not heated above 3750 F) using not
less than 2 kg/m2 or with hot asphalt i.e. bitumen according to IS 73
(latest edition) (not heated above 4000 F) using not less than
1.5 kg/m2. When the first coat has completely dried up and passed
by the Engineer-in-charge, the second coat shall be applied in the
same manner using not less than 1.25 kg/m2 in case of coal tar and
1 kg/m2 in case of asphalt. Immediately after application of the
second coat and before it is dried up, sand requires to be spread
on the surface to cover it completely. Sufficient time shall be
allowed after spreading of sand before backfilling is done in order

to allow the final coat to dry up completely. Coal tar or asphalt to
be used shall be of approved manufacture and of the best quality
available.
ii) Bitumen Felt
If specified or desired by the Engineer-in-charge, structures shall
be made damp proof by courses of bitumen felt and blown bitumen.
The Contractor shall entrust the work to a specialist firm approved
The materials shall conform to IS 1322 (latest edition), and the
workmanship to IS: 1609 (latest edition). The bitumen felt shall be
of Hessian based. If demanded by the Engineer-in-charge, tests as
specified in IS codes shall be organised by the Contractor without
charging any extra to the purchaser.
Cleaning the surface, keeping it dry, providing necessary corner
fillets and cement rendering and cutting chases shall be carried out.
Protective brickwork, concrete sub-bases or walls are to be
included in the bid.
The specification shall cover laying the damp proof course on the
outside and inside of the walls and bases of structures. Unless
otherwise specified elsewhere, 10 years guarantee for perfect
performance shall be given by the Contractor individually and
collectively.
iii) Damp Water Proofing
Multiple layer damp water proofing treatment for basement and
structure below GL shall be done in accordance with IS 1609 and
IS 3067 (latest editions). The type of treatment shall depend upon
the depth of the structures below subsoil water level and shall be
as shown on the drawing or as decided by the Engineer-in-charge.
2.5.6.7 Acceptance of Structures:
2.5.6.7.1 Inspection
Immediately after stripping the formwork, all concrete shall be
carefully inspected and any defective work or small defects should
either be removed or made good before concrete has thoroughly
hardened.
In case of doubt regarding the grade of concrete used either due to
poor workmanship or based on results of cube strength tests,
compressive strength tests of concrete on the cores taken from the
suspect concrete and/ or load test may be carried out.
2.5.6.7.2 Core test
The points from which cores are to be taken and the number of
cores required shall be as per discretion of the Engineer-in-charge
in charge and shall be representative of the whole of concrete
concerned. In no case, however, shall fewer than three cores be

tested.
Cores shall be prepared and tested as described in IS 516(latest
edition).
The concrete in the member represented by a core test shall be
considered acceptable if the average equivalent cube strength of
the cores is equal to at least 85 % of the cube strength of the grade
of concrete specified for the corresponding age and no individual
core achieve strength less than 75 %.
In case the core test results do not satisfy the requirements or
where such tests have not been done, load test may be resorted to.
2.5.6.7.3 Load tests on parts of structures

Load tests should be carried out as soon as possible after expiry of
56 days from the time of placing of concrete.
Load test of structural members may be required by the Engineer-
in-charge when the strength of job control cylinders/cubes fall
below the required strength and is not acceptable as per
'Acceptance Criteria' of IS 456 (latest edition). If the load testing is
decided by the Engineer-in-charge, the member under
consideration shall be subject to a superimposed load equal to one
and a quarter (1) times the specified one and superimposed load
used for design and this load shall be maintained for a period of 24
hours before removal. The detailed procedure of the test is to be
decided by the Engineer-in-charge.
If the member shows evident failure, such changes as are
necessary to make the structure adequately strong shall be made
by the Contractor free of cost to the owner. On the other hand the
Engineer-in-charge, under special circumstances (with the approval
of the designer), can retain the portion of the structure under test,
provided suitable modification for strengthening and/or dispersion
of design load is feasible. Cost of such modification or dispersion
of load shall be borne by the Contractor.
If the deflection exceeds 'D' in the above formula and the member
does not recover at least 75% of observed deflection within 24
hours of removal of load, the test loading shall be repeated after a
lapse of at least 72 hours and the member shall be considered to
have failed to pass the test, if the recovery after the second test
loading is not at least 75% of the deflection shown during the
second test.
If the maximum deflection in mm, shown during 24 hours under
load is less than 40 L /D, where L is effective span in metres and D
the overall depth of the section in mm, it is not necessary the
recovery to be measured and the recovery provision will not apply.
Other non-destructive test methods may be adopted, in which case
the acceptance criteria shall be agreed upon between the
Engineer-in-charge in charge and the Contractor and the tests shall

be done under expert guidance.
The entire cost of load testing shall be borne by the Contractor. If a
portion of the structure is found to be unacceptable, it shall be
dismantled and replaced by a fresh structure as per specification.
The cost of dismantling and the cost of concrete, formwork and
reinforcement involved in the dismantling in case any damage is
done to the embedded items and or other adjacent structures, the
same shall be made good free of charge by the Contractor to the
2.5.6.8 Codes of Practice (All referred codes should be latest edition):

I.S 269 Portland cement 33 grade.
I.S 8112- Portland cement 43 grade.
I.S 12269- Portland cement 53 grade.
I.S 455- Portland slag cement.
I.S 8041 - Rapid hardening Portland cement.
I.S 383 - Specification for coarse and fine aggregates.
I.S 432 - (All parts)-Specifications for mild steel and medium tensile
steel bars and hard-drawn steel wire for concrete reinforcement.
I.S 456 - Code of practice for plain and reinforced concrete.
I.S 516 - Methods of tests for strength of concrete.
I.S 1199 - Method of sampling and analysis of concrete.
I.S 1200 - Method of measurement of building and Civil
Engineering work.
I.S 1322 - Specification for bitumen felts for water proofing damp
proofing.
I.S 1566 - Specification for hard drawn steel wire fabric for concrete
reinforcement.
I.S 1786 - High strength deformed steel bars and wires for concrete
reinforcement.
I.S 2062- Structural steel conforming to Grade A.
I.S 1833 - Performed fillers for expansion joints in concrete non-
extruding and resilient type (Bitumen Impregnated fibre).
I.S 1834 - Specification for hot applied sealing compounds for joints
in concrete.
I.S 2386 Methods of test for aggregate for concrete.
I.S 2502 - Code of practice for bending and fixing of bars for
concrete reinforcement.
I.S 2751 - Code of practice for welding of mild steel plain and
deformed bars for reinforced concrete construction.
I.S 2911 - Code of practice for design and construction of pile
foundation.
I.S 3067 - Code of practice of general design details and
preparatory work for damp proofing and water proofing of
building.
I.S 3370 - (Part-I & II)-Code of practice for concrete structure for the
storage of liquids.
2.5.7.0 TECHNICAL SPECIFICATION FOR BRICKWORK:
2.5.7.1 Scope:
This specification covers the construction of brick masonry in
foundations, arches, walls, etc, at all elevations. Only masonry with
first class burnt clay brick is dealt with in this section.
The provision of the latest revision of IS 2212(latest edition) shall
be complied with unless permitted otherwise and any other IS
Codes (latest revision) shall form a part of this specification to the
extent it has been referred to or applicable with this specification.
2.5.7.2 Materials:
2.5.7.2.1 Bricks
Bricks shall conform to the requirements of IS 1077(latest edition)

specification for common burnt clay building bricks, and shall be of
the first class quality. Alternatively Fly ash bricks conforming to I.S
12894 (latest edition), Clay Fly ash bricks conforming to I.S 13757
(Latest edition) or Calcium silicate (Fly ash sand lime) bricks
conforming to I.S 4139 (Latest edition) may be permitted as per
acceptance of Engineer-in-charge.
Bricks shall be of uniform deep red, cherry or copper colour,
thoroughly burnt, without being verified, regular in shape and size
and shall have sharp and square sides, edges and parallel faces to
ensure uniformity in the thickness of the course of brickwork.
Bricks shall be free from cracks, chips, flaws, stones or lumps of
any kind. They shall not show any signs of efflorescence either dry
or subsequent to soaking in water.
Bricks shall be sound, hard and homogeneous in texture. The
same will emit a clear ringing sound on being struck.
Fly Ash Lime Bricks (FALG Bricks) shall conform to I.S 12894
(Latest edition). Visually the bricks shall be sound, compact &
uniform in shape free from visual cracks, warpage, flaws and
organic matter. The bricks shall be solid and with or without frog on
one of its flat side.
Fly ash shall conform to grade 1 or grade 2 of I.S 3812 (Latest
edition).
This item will be operated only for load bearing structure up to
2storeys & for non-load bearing walls 23 cm thick for multi-storeyed
buildings.
Bottom ash used as replacement of sand shall not have more than
12% loss on ignition when tested.
Deleterious materials, such as clay & silt in the sand shall
preferably be less than 5%. Lime shall conform to class C hydrated
lime of I.S: 712 (Latest edition). Any suitable additive considered
not detrimental to the durability of the bricks may be used.
Clay fly ash bricks conforming to I.S 13757 (Latest edition) shall be
sound, compact & uniform in shape & colour. Bricks shall have
smooth rectangular faces with sharp & square corners. The bricks
shall be free from visible cracks, flaws, warpage, nodules of free
lime and organic matter. The bricks shall be hand or machine
moulded. The bricks shall have frog of 100 mm in length 40 mm
width and 10 to 20 mm deep on one of its flat sides. If made by
extrusion process may not be provided with frogs. Fly ash should
conform to grade 1 or grade 2 of I.S 3812 (Latest edition).
Calcium Silicate bricks conforming to I.S 4139 (Latest edition) shall
be sound, compact and uniform in shape. The bricks shall be free
from visible cracks, warpage, organic matter, large pebbles and
modules of free lime Bricks shall be solid and with or without frog.
The bricks shall be made of finely grounded sand siliceous rock &
lime. In addition limited quantity of fly ash conforming to I.S 3812
(latest edition) may be used in the mix.
Bricks shall be of the local standard size. Any other similar size
may be accepted, but no dimension shall vary more than 3mm from
the accepted size.
All bricks which absorb water more than 30% of their own dry
weight after being immersed in water for 24 hours shall be rejected.
All bricks shall have to be approved by the Engineer-in-charge.
Any lot of bricks found not up to the specification, must be removed
from the site immediately at the Contractor's own cost.
Representative samples of bricks to be used shall be submitted to
the Engineer-in-charge and his approval taken before bulk
purchase.
The samples shall be kept sealed with the Engineer-in-charge for
future reference and comparison. All bricks supplied shall conform
to these approved samples in all respects.
Bricks shall be carefully and systematically stacked at locations as
directed in an approved manner. Each stack shall contain equal
numbers of bricks preferably not more than 3,000.
2.5.7.2.2 Water
Water shall be clean and free from deleterious matter such as oil,
acid, alkali, salt and vegetable growth.
2.5.7.2.3 Cement
Cement conforming to Indian Standard specification and elaborated

in concrete works shall be used. Cement shall be stored in
weatherproof sheds on dry platforms and protected from rain and
moisture. Cement which has set or partially set shall not be used.
2.5.7.2.4 Sand
Sand shall conform to IS 383 (latest edition), 100% of the sand

shall pass through IS Sieve No.240 and not more than 15% to 35%
through IS Sieve No.30. Sand shall have a fineness module

between 2.1 and 2.5. Sand shall be clean and free from dirt, clay
or other impurities.
Percentage of clay or total impurities shall not be more than 5 by
weight.
2.5.7.3 Mortar:
Mortar for brick work except for half brick or lower thickness walls
shall be 1 part cement and 6 parts sand by volume. Mortar for half
brick and lower thickness brick walls shall be 1 part cement and 3
parts sand by volume.
The unit of measurement for cement shall be a bag of cement
weighing 50 kg and this shall be taken as 0.035 m3. Other
ingredients in specified proportions shall be measured in boxes of
suitable size. Sand shall be measured on the basis of its dry
volume. In case of damp sand, its quantity shall be increased
suitably to allow for bulkage.
Cement and sand shall be mixed dry thoroughly on clean approved
platform and water shall then be added to obtain a mortar of the
consistency of a stiff paste, care being taken to add just sufficient
water for the purpose.
Mortar shall be used as soon as possible after mixing and within 2
hours after the cement is mixed wet. Mortar unused for more than
2 hours shall be rejected and removed from the site of work.
Mixture of lime putty and sand can be kept for a period of 72 hours,
provided it is kept damp and not allowed to dry.
2.5.7.4 Workmanship:
All workmanship shall be of best standard as approved by the
Engineer-in-charge.
2.5.7.4.1 Laying
Bricks shall be soaked in water before use for at least six (6) hours.
The Contractor shall provide tanks of sufficient capacity to allow the
specified immersion. Bricks shall be laid in water by hand and not
thrown. The bricks shall not be too wet at the time of use, as they
are likely to slip on the mortar bed and there will be difficulty in
ensuring plumb ness of the wall.
Bricks shall be laid with a shore joint in full mortar beds and
thoroughly flushed up with mortar at every course. Face bricks
shall be laid on full, mortar beds and have all vertical joints
completely filled with mortar. All brickwork shall be plumb, square
and true to dimensions shown on drawings and in approved bond.
All brickwork shall be built tightly against columns, floor slabs or
other structural parts, around window and door frames with proper
distance to permit caulked joint. Where drawings indicate that
structural steel columns and beams are to be partly or wholly
covered with brickwork, the bricks shall be built closely against all
flanges and webs with all spaces between the steel and the
brickwork filled solid with setting mortar with not less than 10 mm in
thickness.
Bricks shall be laid in joints not more than 12 mm thick. Where
stucco finish is specified, the joints of brickwork shall be raked to a
minimum depth of 10 mm to ensure good bond of stucco with
brickwork.
2.5.7.4.2 Raking Out Joints
Joint of brickwork shall be raked out to a depth of 12 mm at the

time of lying and face of brickwork shall be kept clear of all mortar.
2.5.7.4.3 Corbelling Cornices String Courses
Corbelling shall be effected by 1/4 brick projection for ordinary work
and 1/8 brick projection required from consideration of strength.
2.5.7.4.4 Reinforcing and Anchorage
For external walls, the anchors in the form of flats or rods from
spandrel beams and columns and any other anchoring and
reinforcement as shown on drawing shall be adequately embedded
in the masonry.
2.5.7.5 Brick-On-Edge Coping, Plinth Projection & Cut Brick Corners:
The top course of all plinths, parapets, steps and tops of walls
below RCC slabs, beams, etc shall be laid with brick-on-edge,
unless specified otherwise. Care shall be taken that bricks forming
the top corners and ends of walls shall be properly radiated and
keyed into position as specified in IS 2212 (latest edition).
Plinths of all buildings shall be protected by brick on edge paving of
minimum width of 750 mm, inter-spaces filled with cement mortar
(1:6).
2.5.7.6 Curing and Protection:
Masonry during and after construction shall be kept moist and
cured properly as per relevant IS codes (latest editions) or as
directed by the Engineer-in-charge. The brickwork shall be kept
moist for period of at least 10 days.
2.5.7.7 Scaffolding:
Double scaffolding having two sets of vertical supports shall be
provided except in case of building up to two storeys where single
scaffolding may be used if permitted by the Engineer-in-charge.
The supports shall be sound and strong and of steel tubular
construction unless otherwise permitted by the Engineer-in-charge.
The vertical posts shall be tied together with horizontal pieces over
which the scaffolding planks shall be fixed. In cases where single
scaffolding has been allowed by the Engineer-in-charge, the inner
ends of horizontal scaffolding poles shall rest in a hole provided in
the header course only. One header for each hole shall be left out.
Such holes, however, shall not be allowed in pillars less than one
metre in width, or immediately neat the skew backs of arches. The
holes left in masonry work for supporting the scaffolding shall be
immediately filled and made good before plastering.
Important Relevant Codes for this section:
I.S 383 Specification for coarse and fine aggregate.
I.S 1077 - Specifications for common burnt clay building bricks.
I.S 2212 - Code of practice for Brickwork.
2.5.8.0 TECHNICAL SPECIFICATION FOR FINISH TO MASONRY AND

CONCRETE:
2.5.8.1 Code:
This specification covers repairing, finishing, curing, testing,
protection, maintenance till handing over of finishing items for
masonry and concrete.
Before commencing finishing items the Contractor shall obtain the
approval of the Engineer-in-charge regarding the scheduling of
work to minimise damage by other trades. He shall also undertake
normal precaution to prevent damage or disfiguration to work of
other trades or other installations.
2.5.8.2 Preparation of Surface:
All joints in masonry walls shall be raked out to a depth of at least
10 mm with a hooked tool made for the purposes while the mortar
is still green. Walls shall be brushed down with stiff wire brush to
remove all loose dust from joints and thoroughly washed with
water. All laitance shall be removed from concrete to be plastered.
For all types of flooring, skirting, and dado work, the base cement
concrete slab or masonry surface shall be roughened by chipping
and cleaned of all dirt, grease or loose particles by hard brush and
water. The surface shall be thoroughly moist to prevent absorption
of water from the base course. Any excess of water shall be
mopped up.
At any point, the level of base shall be lower than the theoretical
finished floor level by the thickness of floor finish. Any chipping or
filling to be done to bring the base to the required level shall be
brought to the notice of the Engineer-in-charge and his approval
shall be taken regarding the method and extent of rectification work
required.
Prior to commencement of actual finishing work, the approval of the

Engineer-in-charge shall be taken as to the acceptability of the
base.
2.5.8.3 Plastering:
2.5.8.3.1 Mortar
Mortar for plastering shall be as specified in the schedule of items.
For sand cement plaster, sand and cement in the specified
proportion shall be mixed dry on a watertight platform and minimum
water added to achieve working consistency.
For lime gauged plaster, lime putty or hydrated lime, sand in the
required proportion shall be mixed on a watertight platform with
necessary addition of water and thoroughly ground in mortar mill.
This mix shall then be transferred to a mechanical mixer to which
the required quantity of cement is added and mixed for least 3
minutes.
No mortar which has stood for more than half an hour shall be
used. Mortar that shows tendency to become dry before this time
shall have water added to it.
2.5.8.3.2 Application of Plaster

Plaster, when more than 12 mm thick, shall be applied in two coats
with a base coat followed by the finishing coat. Thickness of the
base coat shall be sufficient to fill up all unevenness in the surface;
no single coat, however, shall exceed 12 mm in thickness. The
overall thickness of the coats shall not be less than the minimum
thickness shown on the drawings. The undercoat shall be allowed
to dry and shrink before applying the second coat of plaster. The
undercoat shall be scratched or roughened before it is fully
hardened to form a mechanical key. The method of application
shall be thrown on rather than 'applied by trowel'.
To ensure even thickness and true surface, patches of plaster
about 100 mm to 150 mm square or wooden screed 75 mm wide
and of the thickness of the plaster, shall be fixed vertically about
2000 mm to 3000 mm apart, to act as gauges. The finished wall
surface shall be true to plumb, and the Contractor shall, without any
extra cost to the owner, make up any irregularity in the brickwork
with plaster. All vertical edges of brick pillars, door jambs etc. shall
be chamfered or rounded off as directed by the Engineer-in-charge.
All drips, grooves, mouldings and cornices as shown on drawing or
instructed by the Engineer-in-charge shall be done with special
care to maintain true lines, levels and profiles. After the plastering
work is completed all debris shall be removed and the area left
clean. Any plastering that is damaged shall be repaired and left in
good condition at the completion of the job.
2.5.8.3.3 Finish
Generally, the standard finish shall be used unless otherwise
shown on drawing or directed by the Engineer-in-charge.
Wherever any special treatment to the plastered surface is
indicated, the work shall be done exactly as shown on the
drawings, to the entire satisfaction of the Engineer-in-charge
regarding the texture, colour and finish.
a) Standard Finish
Wherever punning is indicated, the interior plaster shall be
finished rough. Otherwise, the interior plaster shall generally
be finished to a smooth surface. The exterior surface shall
generally be finished with a wooden float.
b) Neat Cement Finish
Immediately after achieving a true plastered surface with the
help of a wooden straight edge, the entire area shall be
uniformly treated with a paste of neat cement at the rate of 1
kg/m2 and rubbed smooth with a trowel.
c) Coloured Plaster Finish
This shall be done in the same way as specified in clause (b)
using coloured cement in place of ordinary cement. When
coloured plastering is specified in more than one coat, the
top coat only shall be made with coloured cement.
Coloured cement shall be either ready mixed material or
may be obtained by mixing pigments and cement at site, as
approved by the Engineer-in-charge. The pigments to be
mixed with cement shall conform to appendix A of IS 2114
latest edition. Samples of colouring material shall be
submitted conform in all respects to the approved samples,
which shall remain with the Engineer-in-charge. All coloured
cement and or pigments shall be stored in an approved
manner in order to prevent deterioration.
d) Pebble Dash Finish
Mortar of required thickness consisting of 1 part cement and
4 parts sand by volume shall be applied in the usual manner
as described under plastering clause. While the mortar is
still plastic small pebbles or crushed stone of size generally
from 10 mm to 20 mm as approved by the Engineer-in-
charge shall be thrown on the plastered surface. The
aggregate shall be lightly tapped into the mortar with a wood
float or the flat end of a trowel, in order to ensure satisfactory
bond between the dashing and the mortar.
e) Rough-Cast Finish
A wet plastic mix of 3 parts coloured cement 6 parts sand
and 4 parts aggregate by volume (gravel or crushed stone of
size from 6 mm to 12 mm as approved by the Engineer-in-

charge) shall be thrown and left in the rough condition.
f) Scraped Finish
Ordinary plaster as described above shall, after being
levelled and allowed to stiffen for a few hours, be scraped
with a steel straight edge to remove the surface skin. The
pattern shall be as approved by the Engineer-in-charge.
g) Textured Finish
Mortar consisting of 1 part cement and 3 parts sand by
volume shall be applied in a manner as specified under
'Plastering' clause. Ornamental treatment in the form of
horizontal or vertical rib texture, fan texture etc. shall be
applied by means of suitable tools to the freshly applied
plastered surface as approved by the Engineer-in-charge.
2.5.8.3.4 Curing
All plastered surfaces after laying shall be watered, for a minimum
period of seven days, by an approved method, and shall be
protected from excessive heat and sunlight by suitable approved
means. Moistening shall commence, as soon as soon as the
plaster has set sufficiently and not susceptible to damage. Each
individual cost of plaster shall be kept damp continuously for at
least two days, and then dried thoroughly before applying the next
coat.
2.5.8.3.5 Pointing to Masonry

All joints of brickwork shall be raked out to a depth of 10 mm with a
hooked tool made for the purpose while the mortar is still green.
The brickwork shall then be brushed down with a stiff wire brush,
so as to remove all loose dust from the joints and thoroughly
washed with water. Mortar consisting of 1 part cement and 3 parts
clean, sharp well graded sand by volume shall be pressed carefully
into the joints and finished with suitable tools to shape as shown on
the drawings. Any surplus mortar shall be scraped off the wall face
leaving the surface clean.
The pointed surface shall be kept wet for at least three days for
curing.
2.5.8.3.6 Plaster with Metal Lath
The supports, hangers, brackets, cleats, etc. shall be as shown on
drawings and/or as approved by the Engineer-in-charge. These
shall have a coat of prime paint before and another coat of
approved paint after erection.
The metal lath shall be expanded metal, with 12 mm x 38 mm
mesh, 16 BG thick and 3 mm wide strands. Side laps shall be
minimum 12 mm and end laps 25 mm minimum. The plastering

shall be minimum 20 mm thick measured from the back of lath and
applied in two layers. The mortar for plastering shall consist of 1
part cement, 1/2 part lime and 4 parts sand by volume, or 1 part
cement and 4 parts sand by volume mixed as specified for
plastering. The application, finish, etc. shall be as specified under
relevant clause above. Where called for in the schedule of items, a
2 mm Plaster of Paris punning shall be applied over plaster as a
finishing coat to give perfectly smooth and even finish.
2.5.8.3.7 Lime Punning
For plastered surfaces, where an even smooth surface is specified,
lime punning with 5 parts of shell lime properly slaked, strained and
aged, mixed with 1 part clean, washed, sieved, fine sand by volume
shall be done. The thickness of lime punning shall be not less than
2 mm and more than 3 mm. The plastered surface shall be
saturated with water before application of the lime punning. The
punning shall be applied by skilled workmen and given a smooth
and even finish free from undulations, cracks, etc and to the
2.5.8.3.8 Plaster of Paris Punning
Plastered surfaces, where specified shall be finished with plaster of
Paris punning. The material shall be from approved manufacturers
and approved by the Engineer-in-charge. The thickness of the
punning shall be 2 mm and shall be applied by skilled workmen.
The finish shall be smooth, even and free from undulation, cracks,
etc.
Before bulk work is taken in hand a sample of punning shall be
done on roughly 10 m2 areas and approval of the Engineer-in-
charge taken. The work shall then be taken in hand as per
approved sample.
2.5.8.3.9 Stone Facing

Stone facing where specified shall be done as shown on design
drawings and approved working drawings. The stone shall be
specified on drawings and/or schedule of items.
Sample of stone shall be submitted to the Engineer-in-charge for
approval and then bulk purchase made. The Contractor shall
submit three copies of working drawing for the Engineer-in-charge's
approval before commencing the work.
The thickness of facing stone shall not be less than 25 mm unless
otherwise specified on drawings.
The stone slabs shall be cut and finished to sizes as per pattern
shown on drawings. They shall be fastened to wall with suitable
non-corrodible anchorage as approved by the Engineer-in-charge.
Where mild steel clamps, stays etc. are used for anchorage, they
shall be galvanised (weight of zinc coating shall not be less than
700 g/m2 of surface) to prevent rust stains developing on the
finished surface. There shall be at least 12 mm gap between the
stone and masonry, which shall be filled up and packed by a mortar
of 1 part cement and 2 parts of sand by volume. After the mortar is
set and cured for at least four days, the exposed surface shall be
neat, of uniform texture and acceptable to the Engineer-in-charge.
Where pointing is specified on drawings it shall be done by mortar
as specified on drawings and/or schedule of items.
2.5.8.4 Acceptance Criteria:
Finish to masonry and concrete shall fully comply with the
drawings, specifications, approved samples and instructions of the
Engineer-in-charge with respect to lines, levels, thickness colour,
texture, pattern and any other special criteria as mentioned in the
body of the specification or as shown on drawings.
Important relevant code for this section:
I.S 1661 - Code of practice for cement and cement lime plaster
finish on walls and ceilings.
I.S 4101 - Code of practice for external facings and veneers.
2.5.9.0 TECHNICAL SPECIFICATION FOR SUPPLYING AND LAYING OF

RCC PIPES:
2.5.9.1 Scope:
This specification covers the supply and laying of RCC Hume Pipes
as may be required. The entire work shall be carried out as per
latest editions of Indian Standards I.S 458(latest edition) and I.S
783(latest edition).
2.5.9.2 Supply of Pipes:
The Contractor shall supply the RCC Hume Pipes of various
diameters along with complete fittings required for carrying out the
work. RCC Hume pipes should conform to class NP 3 or NP 2 of
I.S 458(latest edition), as may be required and should be in good
condition. The Contractor must furnish on being demanded by the
Engineer-in-charge, manufacturer's certificates and/or test.
2.5.9.3 Alignment, Levels and Grade:
The work shall be carried out in conformance to the alignments,
levels and grades specified in the drawings. The layout and levels
should be made by him at his own cost from one reference grid and
bench mark given by the Engineer-in-charge. He shall give all help
in instruments, materials and men to the Engineer-in-charge for
checking the detailed layout and levels as and when required.
Making of reference layout and level pillars along the pipeline route
and maintaining them up to completion of the work shall be the
responsibility of the Contractor.
No extra payment shall be made for these.
2.5.9.4 Laying Of Pipes:
2.5.9.4.1 General
The laying of RCC pipes shall conform to clause 9 of IS 783(latest
edition).
2.5.9.4.2 Conditions for Laying

The conditions for laying of pipes to suit the conditions at site
and/or as per drawings and instruction of the Engineer-in-charge
shall be as classified below:
i) Culvert condition
In this condition the pipe is laid under embankment and may project
wholly or partly above the original ground surface.
ii) Trench condition
In this condition the pipe is laid in a trench excavated for the
purpose. The trench shall be refilled with thoroughly tamped earth
after laying and jointing of pipes in approved manner.
iii) Open condition

In this condition the pipe is laid such that it projects wholly or partly
above original ground surface, there being no superimposed
overburden on the pipe.
iv) Bedding and supports
a) Culvert condition
In this condition the pipes shall be laid generally on First class
Bedding' as per clause 4.3.3 of IS 783(latest edition), unless
directed otherwise.
b) Trench condition
In this condition the pipes shall be laid generally on 'First class
Bedding' as per clause 4.2.3 of IS 783(latest edition), unless
directed otherwise.
c) Concrete Cradle Bedding

If required by the drawing or so instructed by the Engineer-in-
charge, the pipes shall be laid on concrete cradles. Conforming to
clause 4.2.4 of IS 783(latest edition) in case of trench condition and
conforming to clause 4.3.4 of IS 783(latest edition) in case of
culvert condition.
d) Open condition
In open condition the pipeline shall be supported over rigid
pedestals constructed at intervals not greater than the length of one
individual piece of pipe, as per drawings and instructions of the
Engineer-in-charge. In no case shall joint between two pipes shall
lie at centre of the span between two supports, the pedestals shall
be of rubble masonry or brick masonry or plain/reinforced concrete
with a properly shaped out top to receive the pipe.
2.5.9.4.3 Jointing of Pipes
Clause 10 of I.S 783(latest edition) shall be applicable for jointing of

pipes and every possible care shall be taken by the Contractor to
ensure that the joints made are leak proof. Curing of joints shall be
done for a period of 10 days. No extra payment shall be made for
making and curing of joints.
2.5.10.0 TECHNICAL SPECIFICATION FOR PAINTING, WHITE WASHING,

POLISHING ETC.:
2.5.10.1 Scope:
This specification covers painting, white washing, polishing, etc. of
both interior and exterior surfaces of masonry, concrete, plastering,
plaster of Paris, false ceiling, structural and other miscellaneous
steel items, rain water down comer, floor and roof drains, soil waste
and service water pipes and other ferrous as well as non-ferrous
metal items as shown on drawings or as directed by the Engineer-
in-charge.
If surface to be finished cannot be put in suitable condition for
painting by customary preparatory methods, the Contractor shall
notify the Engineer-in-charge in writing or assume responsibility for
and rectify any unsatisfactory finishing that results.
Before commencing painting, the Contractor shall obtain the
approval of the Engineer-in-charge in writing regarding the
scheduling of work to minimise damage disfiguration or staining by
other trades. He shall also undertake normal precautions to
prevent damage, disfiguration or staining to work of other trades of
other installations.
2.5.10.2 Materials:
Materials shall be highest grade products of well-known approved
manufacturer and shall be delivered to the site in original sealed
container, bearing brand name, manufacturer's name and colour
shade, with labels intact and seals unbroken. All materials shall be
subject to inspection, approved by the Engineer-in-charge. It is
desired that materials of one manufacturer only shall be used as far
as possible and paint of one shade be obtained from the same
manufacturing batch. All paints shall be subjected to analysis from
random samples taken at site from painters bucket, if so desired by
All prime coats shall be compatible to the material of the surface to
be finished as well as to the finishing coats to be applied.
All unspecified materials such as shellac, turpentine or linseed oil
shall be of the highest quality available and shall conform to the
latest I.S standard. All such materials shall be made by reputable
recognised manufacturers and shall be approved by the Engineer-
in-charge.
All colours shall be per painting schedule and tinting and matching
shall be done to the satisfaction of the Engineer-in-charge. In such
cases, where samples are required, they shall be executed in
advance with the specified materials for the approval of the
Engineer-in-charge.
2.5.10.2.1 White Wash

White washing shall be done from pure shale lime or fat lime or a
mixture of both as instructed by the Engineer-in-charge and shall
conform to I.S 712 (latest edition). Samples of lime shall be
submitted to the Engineer-in-charge for approval and lime as per
approved sample shall be brought to site in un-slaked condition.
After slaking, it shall be allowed to remain in a tank of water for two
days and then stirred up with a pole, until it attains the consistency
of thin cream. 100 grams of gum of indigo or synthetic ultramarine
blue shall be added to the lime.
2.5.10.2.2 Water Proof Cement Paint
Paint shall be made from best quality white cement and lime
resistant colours with accelerators, waterproofing agents and
fungicides. The paint shall conform to I.S 5410(latest edition).
2.5.10.2.3 Acrylic Emulsion Paint
It should be water based acrylic copolymer emulsion with rutile
titanium dioxide and other selected pigments and fungicide. It shall
exhibit excellent adhesion to plaster and cement surface and shall
resist deterioration by alkaline salts. The paint film shall allow the
moisture in wall to escape without peeling or blistering. The paint,
after it is dried, shall be able to withstand washing with mild soap
and water without spalling or any deterioration in colour.
2.5.10.2.4 Synthetic Enamel Paint
Painting shall be made from synthetic resins and drying oil with
rutile titanium dioxide and other selected pigments to give a
smooth, hard, durable and glossy finish to all exterior and interior
surfaces. White and pastel shades shall resist yellowing and
darkening with ageing. The paint shall conform to I.S 2932(latest
edition) and I.S 2933(latest edition).
2.5.10.3 Storage:
The Contractor shall arrange for safe and proper storage of all
materials and tools. Paints shall be kept covered at all times and
mixing shall be done in suitable containers. All necessary
precautions shall be taken by the Contractor to prevent fire.
2.5.10.4 Preparation of surface:
Before starting the work the Contractor shall obtain the approval of
the Engineer-in-charge regarding the soundness and readiness of
the surface to be painted on.
2.5.10.4.1 Masonry, Concrete and Plastered surface
Surface shall be free from all oil, grease, efflorescence, mildew,
loose paint or other foreign and loose materials. Masonry cracks
shall be cleaned out and patch filled with mortar similar to the
original surface and uniformly textured. Where this type of
resurfacing may lead to the finishing paint being different in shade
from the original surfaces, the resurfaced area shall be treated with
minimum one coat of cement primer which should be continued to
the surrounding area from a distance of minimum 100 mm.
Surface with mildew or efflorescence shall be treated as below:
2.5.10.4.2 Mildew
All mildew surfaces shall be treated with an approved fungicide
such as ammonical wash consisting of 7 gm. of copper carbonate
dissolved in 80 ml liqueur ammonia and diluted to 1 litre with water,
or 2.5 % magnesium silica fluoride solution and allowed to dry
thoroughly before paint is applied.
2.5.10.4.3 Efflorescence
All efflorescence shall be removed by scrubbing effected surfaces
with a solution of muriatic acid in water (1:6 to 1:8), and washed
fully with clear and allowed to dry thoroughly.
2.5.10.4.4 Metal
All metal surfaces shall be absolutely clean, dry and free from wax,
grease or dried soap films. All steel and iron surfaces in addition
shall be free from rust. All galvanised iron surfaces shall be pre-
treated with a compatible primer according to the manufacturer's
direction. Any abrasion in shop coat shall be touched up with the
same quality of paint as the original coat.
2.5.10.5 Application:
2.5.10.5.1 General
The method of application shall be as recommended by the
manufacturer. In case of selection of special shades and colour
(not available in standard shades) the Contractor shall mix different
shades and prepare test panels of minimum size 1 metre square as
per instruction of the Engineer-in-charge and obtain his approval
prior to application of finishing paints. Proper tools and implements
shall be used. Scaffoldings if used shall be independent of the
surface to be painted to avoid shade differences of the freshly
repaired anchor holes.
Painting shall be done by skilled labour in a workmanlike manner.
All materials shall be evenly applied so as to be free of sags, runs,
crawls or other defects. All coats shall be of proper consistency. In
case of application by brush no brush marks shall be visible. The
brushes shall be clean and in good condition before application of
paint.
All priming undercoats for painting shall be applied by brush only.
Rollers, spray equipment etc, shall not be used.
No work shall be done under conditions that are unsuitable for
production of desired results. No painting shall be done when
plastering is in progress or is drying. Application of paint which
seals the surface to moisture shall only be done after the moisture
on and below the surface has dried out.
All coats shall be thoroughly dry before being sand papered or
before the succeeding coat is applied. Coats of paint as specified
are intended to cover surfaces perfectly. In case the surface is not
covered properly by applying the specifying number of coats,
further coats shall be applied by the Contractor when so directed by
All primers and undercoats shall be tinted to approximate the colour
of the finishing coat. Finished coats shall be of exact colour and
shade as per approved samples and all finish shall be uniform in
colour and texture. All parts of mouldings and ornaments shall be
left clean and true to finish.
2.5.10.5.2 White Washing

The surface where white washing is to be applied shall be cleaned
of all loose materials and dirt. All holes and irregularities of the
surface shall be filled up with lime putty and be allowed to dry up
before application of the lime solution.
One coat of white wash shall consist of one stroke from top
downwards, another from bottom upwards over the first stroke and
another from left to right before the previous one dries up. Second
coat shall be applied after the first coat dries up completely and
similarly third coat shall be applied and in case the Engineer-in-
charge feels that one or more coats are required the Contractor
shall do so without any extra coat to the Owner.
No brush marks shall show on the finished surface. The inner
plastered surfaces of walls shall be given 3 or more coats of white
washing.
2.5.10.5.3 Waterproof Cement Paint
Surface to be coated with cement paint shall be washed and
brushed down. As soon as the moisture has disappeared the
surface shall be given one coat of paint. Care shall be taken so
that the paint does not dry out too rapidly. After 4 to 6 hours, the
water shall be sprinkled over the surface to assist curing and
prevent racking. After the first coat has dried (24 to 48 hours), the
second coat shall be applied in similar manner. The finished
surface shall be kept moist by occasional sprinkling with water for
seven days after painting.
2.5.10.5.4 Acrylic Emulsion Paint

Lime gauged cement plastered surface shall not be painted for at
least one month after plastering. A sample patch shall be painted
to check alkali reaction if so desired by the Engineer-in-charge.
Painting shall be strictly as per manufacturer's specification.
2.5.10.5.5 Synthetic Enamel Paint

Such paint shall be applied on properly primed surface.
Subsequent coat shall not be applied till the previous coat is dry.
The previous coat shall be lightly sand papered for better adhesion
of subsequent coats.
2.5.10.5.6 Cleaning Up
The Contractor shall, upon completion of painting, etc. remove all
marks and make good surfaces, where paint has been spilled,
splashed or splattered, including all equipment, fixtures, glass,
furniture fittings etc. to the satisfaction of the Engineer-in-charge.

a) All painted surfaces shall be uniform and pleasing in
appearance.
b) The colour, texture, etc. shall match exactly with approved
samples.
c) All stains, splashes and splatters of paints shall be removed
from surrounding surfaces.

Important relevant I.S codes for this section are listed below:
I.S 1477 (I & II) - Code of practice for painting of ferrous metals in
building.
I.S 2395 (I & II) - Code of practice for painting, concrete, masonry
and plaster surface.
I.S 2932 - Specification for enamel, synthetic exterior type-I.
I.S 2933 - Specification of enamel, synthetic exterior, type-II.
I.S 5410 - Specification for cement paint, colour as required.
2.5.11.0 TECHNICAL SPECIFICATION FOR DRAINAGE AND SANITARY

FIXTURES:
2.5.11.1 Scope:
This section covers the layout and construction of drains for pour
water, surface water and sewage together with all fittings and
fixtures and inclusive of ancillary works related to drainage and
sanitary works for the whole plant.
2.5.11.2 Design Requirements:
2.5.11.2.1 General
All pipelines, location of fittings and fixtures etc. shall be as per
drawings or as directed by the Engineer-in-charge. Correctness of
lines, plumb, orientation, symmetry and levels shall be strictly
ensured. All items shall be fully secured against movement in any
direction and selected as to allow easy maintenance where desired
by the Engineer-in-charge. Suitable workers are to be provided for
underground and concealed pipelines and other items.
All pipelines and fittings, fixtures shall be installed leak proof. When
the work under scope of this specification connected with others
the connection shall be such as to prevent any splashing or spilling
or emission of foul odour and gases.
2.5.11.2.2 Rainwater down Comers
Rainwater down comers shall be standard cast iron pipes.
Rainwater down comers shall run along and be secured to walls,
columns etc. Where desired by the Engineer-in-charge these may
have to be installed in chases cut in the structure. All pipes shall
be well secured and supported by adequately strong brackets. The
brackets may be wrought iron clevis type, split ring type or
perforated strap iron type as approved by the Engineer-in-charge.
For vertical runs each pipe shall hang freely on it bracket fixed just
below the socket. Suitable space blocks shall be provided against
the vertical surface to which the pipe is fixed.
All bends and junctions shall be supplied with watertight cleanouts.
Roof and floor drains and yard gullies shall be installed if required,
but where cutting into the structure is necessary it must be grouted
with M-20 cement concrete. All gutters shall be provided with
removable gratings.
All horizontal pipes shall have a minimum fall of 1 in 100.
2.5.11.2.3 Gutters
The gutters shall be made of GI or AC. All gutters shall be supplied
by reputable specialised firms. Each section shall be sufficiently
rigid, edges and corners straight and the slopes perfectly uniform.
The GI Gutters shall have the edges strengthened by suitable
means.
Unless noted otherwise the gutters shall have minimum fall of 1 in

120. Adequate number of strong supports shall be provided so that
there is no deflection even when the gutter is full. Each joint must
have a support. Unless otherwise specified the supports shall be
fabricated MS brackets. All junctions shall be thoroughly
watertight. The joints may be made by riveting, bolting or
soldering. All joints between successive lengths of gutters shall
have an overlap of at least 5 cm. The drop in the overlap shall
always be in the direction of the fall of the gutter. Ends of gutters
shall be closed watertight. Junction with rainwater down comers
shall be made fully watertight and secured.
2.5.11.2.4 Soil and Drainage Pipes (within Buildings)
If not specified the minimum gradients of soil and drainage
pipelines shall be as follows:
100 mm nominal diameter: 1 in 35.
2.5.11.2.5 Relation with Water Supply Pipelines
Under no circumstances unless specifically cleared by the
Engineer-in-charge, any drainage and soil pipes shall be allowed to
close to water supply pipelines.
2.5.11.3 Installation:
2.5.11.3.1 Laying
Each separate pipe shall be individually set for line and for level.
Where lengths of sewer or drain pipes are laid in a trench, properly
painted sight rails shall be fixed across the trench at a height, equal
to length of the boning rod to be used, above the required invert
level of the drain of sewer at the point where the sight is fixed.
More sight rails shall be required of manholes, change of gradient
and intermediate positions if the distance for sighting is top far,
which shall not be more than 50 ft apart. The excavation shall be
boned in at least once in every 6 ft. the foot of the boning rod shall
be set on a block of wood of the exact thickness of the wall of the
pipe. Each pipe shall be separately and accurately boned between
sight rails.
2.5.11.3.2 Support and protection to pipelines
All pipes shall be laid with sockets leading uphill. Preferably the
pipe shall rest on solid and even foundations for the full length of
the barrel. However the pipe manufacturer's instruction as
approved by the Engineer-in-charge shall be followed in the matter
of support and jointing.
For others, to achieve full and continuous support, concrete for
bedding and packing is the best. Where pipes are not bedded on
concrete, the floors shall be left slightly high and carefully bottomed
up as pipe laying proceeds so that the pipe barrels rest on
undisturbed ground. If anywhere the excavation has been carried
too low the packing shall be done in concrete. Where laid on rock
or very hard ground that cannot be easily excavated to a smooth
surface, the pipes shall be laid on a cradle of fine concrete floor or
floor of gravel and crushed stone bed only as desired by the
Engineer-in-charge so as to install even bearing. PVC or similar
pipes shall be laid directly on stable soil and packed with selected
soil.
The minimum support and protection for glazed stone water pipes
shall be as follows:
a) When cover is less than 1 metre below ground level and
where pipes are unavoidably exposed above ground
surface, the pipes shall be completely encased or
surrounded with concrete.
b) Where the pipes are laid on a soft soil with the maximum
water table lying at the invert of the pipe, the pipe sewer
shall be bedded on concrete.
c) Where the pipes have to be laid on a soft soil with the
maximum water table rising above the invert of the pipe, but
below the top of the barrel, the pipe sewer shall be
haunched.
d) Where the maximum water table is likely to rise above the
top of the barrel or wherever the pipe is laid on soft soil the
pipe sewers shall be completely encased or surrounded with
concrete.
Vitrified clay pipes shall be laid on a bed of 150 mm thick
cement concrete (1:3:6 nominal mix by volume).
Cast iron pipes and concrete pipes may be supported on
suitable concrete or brick support, where specified. The
supports shall be unyielding and strong enough. At least
one support shall be located close to each joint. Spacing of
intermediate supports shall be as directed by the Engineer-
in-charge. Pipes shall be secured to the supports by
approved means.
Anchoring of pipes where necessary shall be achieved by
suitable concrete encasing designed for the specified thrust.
2.5.11.3.3 Entry into Structures
For entry of the pipe lines into the building suitable conduits under
the structure or sleeves shall be used. The conduits and sleeves
shall be such as to allow easy repairs and replacement of the
pipes. When openings or chases are required to be made in the
structure for entry of pipelines, locations and sizes shall be marked
by the Engineer-in-charge. After laying of the pipeline the openings
and chases shall be mentioned.
2.5.11.3.4 Ducts
Where soil, waste and ventilating pipes are accommodated in
ducts, access to cleaning eyes shall be provided. Connection, to
drain shall be through a gully with sealed cover to guard against
ingress of sewer gas, vermin or backflow.
2.5.11.3.5 Traps and Ventilating Pipes
Pipes for carrying off the waste from water closets and waste water
and over flow water from baths, wash basins, sinks to drains shall
be trapped immediately beneath such fixtures. Traps shall have
minimum water seal of 50 mm and shall be ventilated wherever
such ventilation is necessary to maintain water seal of the trap.
Ventilating pipes shall be carried up vertically from the drain to a
height of at least 600 mm above the outer covering of the roof of
the building or as shown on drawings. All vertical ventilating, anti-
siphonage and similar pipe shall be covered on top with a cowl.
The cowl shall be made of CI unless desired otherwise by the
Engineer-in-charge.
2.5.11.3.6 Manholes and Inspection Chambers
The maximum distance between manholes shall be 30 metre
unless specially permitted otherwise. In addition, at every change
of alignment gradient or diameter there shall be a manhole or
inspection chamber. Manhole shall be constructed so as to be
watertight under test. The benching at the sides shall be carried
out in such a manner as to provide no lodgement for any splashing
in case of accidental flooding of the chamber. The channel or drain
at the bottom of chamber shall be plastered with 1:2 (cement, sand
mortar) and finished smooth to the grade. The channels and drains
shall be shaped and laid to provide smooth flow. Connection to
existing sewer lines shall be through a manhole.
Manholes shall be provided with standard covers, usually cast iron
or as desired by the Engineer-in-charge. The covers shall be close
fittings so as to prevent gases coming out.
2.5.11.3.7 Cutting of Pipes
Manufacturer's instruction shall be followed for cutting of pipes
where necessary. Suitable and approved tools shall be used for
the cutting so as to leave clean and square surface to the exit of
the pipe.
2.5.11.3.8 Jointing
Jointing of laid pipes shall be so planned as to avoid completely
any movement or strain to the joints already made. If any joint is
suspected to be damaged it shall be opened out and redone.
All joints between pipes, and fittings and manholes shall be gas-
tight when above ground and watertight when underground.
Method of jointing shall be as per instruction of the pipe and fittings
manufacturer and as approved by the Engineer-in-charge.
However, in the absence of any instruction available from the

manufacturer the methods as detailed here under shall be used.
i) Cast Iron Pipes
Socket and spigot pipes shall be joined by cast lead joints. The
spigot shall be centred in the socket of the next pipe by tightly
caulking in sufficient turns of tarred gasket or hemp yarn to have
unfilled half the depth of socket. When the gasket or hemp yarn has
been caulked tightly a jointing ring shall be placed round the barrel
and tight against the face of the socket to prevent airlock. Molten
lead shall then be poured in to fill the remainder of the socket and
caulked with suitable tools right round the joint to make up for
shrinkage of the molten metal on cooling and shall be finished 3
mm behind the socket face.
Joints in cast iron pipes with special jointing arrangements like
'Tyten' joints etc. shall follow the instructions of the manufacturers.
In special cases, if flanged joints are accepted by the Engineer-in-
charge, the joints shall be made leak proof by inserting approved
type of rubber or other gaskets. The bolts shall be secured in
stages to avoid uneven strain.
ii) Concrete Pipes
Care shall be taken to place the collar centrally over the joint.
iii) Glazed Stoneware Pipes
Tarred gasket or hemp yarn soaked in thick cement slurry shall first
be placed round the spigot of each pipe and the spigot shall than
be placed into the socket of the pipe previously laid. The pipe shall
then be adjusted and fixed in the correct position and the gasket
caulked tightly so as not to fill more than 1/4 of the total depth of
the socket. The remainder of the socket shall be filled with a stiff
mixture of cement mortar of 1:1 proportion. When the socket is
filled, a fillet shall be formed round the joint with a trowel, forming
an angle of 450 with the barrel of the pipe. The newly made joints
shall be protected, until set, from sun and rain and shall be covered
with damp sacking or other suitable materials.
iv) Vitrified Clay Pipes
These shall be made from refractory clay mixed with crushed
pottery and stone and burnt at a high temperature. These shall be
hard, compact and glazed to make them sold resistant and
impervious, and shall be obtained from approved manufacturers.
Being very brittle special care shall be taken in handling these
pipes. The pipes shall not be jointed until the earth has been partly
refilled over the portion of the pipe between the joint holes. Before
laying the second pipe, the socket of the first pipe laid shall be
thinly painted all round on the inside with cement slurry (1 part of
cement and 2 parts of clean, sharp sand). A ring of rope yarn
(closely twisted hemp or jute) dipped in neat cement paste or tar or
bitumen, shall be inserted in the socket of the pipe and driven

home with caulking tools. The rope shall fully encircle the spigot
with a slight overlap and shall not occupy more than one fourth of
the total depth of the socket. The joint shall then be completely
filled with cement mortar (1:1) which shall have very little water and
levelled to form a splayed fillet at an angle of 450 with the outside
pipe. Special care taken so that any excess mortar, etc. left inside
the pipe joint is neatly cleaned off immediately each joint is made.
A semi-circular wooden scraper or a rubber disc can be used to
which a long handle is fixed.
v) Lead Pipes
The joints in lead pipes shall be made as wiped solder joint. The
minimum and maximum length of the wiped solder joints shall be 8
cm and 9 cm respectively. The solders shall generally consist of
two parts of lead and one part of tin.
vi) Polythene Pipes
The joints shall be thermal welded or bolted as per manufacturer's
instruction.
vii) Jointing Cast Iron Pipes with Stoneware Pipes
Where any cast iron soil pipe, waste pipe, ventilating pipe or trap is
connected with stoneware or semi vitrified waste pipe or drain
communicating with a sewer, the beaded spigot end of such cast
iron pipe, shall be inserted into a socket of such stoneware pipe or
drain and the joint made with mortar consisting of one part of
cement and one part of clean, sharp sand after placing a tarred
gasket of hemp yarn soaked in neat cement slurry round the joint
and inserted in it by means of a caulking tool.
viii) Jointing Stoneware with Cast Iron Pipes
Where any water closet pan or earthenware trap connected to such
a pan is to be jointed with a cast iron soil pipe, the joint between the
stoneware spigot and the cast iron socket shall always be of a
flexible nature. Such joint shall be made with a mixture of bitumen
and chopped mineral fibre, or preferably using a purpose made
rubber gasket.
2.5.11.4 Trenches and Other Excavations
Width of the trench at the bottom shall be such as to provide 200
mm clearance on either side of the pipe for facility of laying and
jointing.
Excavated material shall be stacked sufficiently away from the
edge of the trench and the side of the spoil bank shall not be
allowed to become such as to endanger the stability of the
excavation. Spoil may be carted away and used for filling the
trench behind the work.
Turf, topsoil or other surface material shall be set aside, turf being
carefully rolled and stacked for use in reinstatement.
All excavations shall be properly timbered, where necessary.

Efficient arrangements for dewatering during excavation and
keeping it dry till backfilling done shall be made to the satisfaction
of the Engineer-in-charge. Sumps for the dewatering shall be
located clear of pipe layout.
When the excavation proceeds through roads, necessary
permissions shall be secured by the Contractor from the
appropriate authorities.
Special care shall be taken not to damage underground services,
cables etc. These when exposed shall be kept adequately
supported till the trench is backfilled.
The backfilling shall be done only after the pipeline has been tested
and approved by the Engineer-in-charge. Special care shall be
taken to hand pack under and at sides of the pipe thoroughly with
selected material. If the pipeline is being laid in black cotton soil, it
shall be ensured that at least 300 mm of sand bed is provided for
the pipeline in addition to backfilling the sides at least 200 mm on
sides and topping with minimum 300 mm of sand cushion.
Consolidation shall be done in 150 mm layers. The surface water
shall be prevented from getting into the filled up trench. Traffic
shall not be inconvenienced by heaping up unduly the backfilling
material to compensate for future settlement. All future settlements
shall be made good regularly to minimise inconvenience of traffic
where applicable.
2.5.11.5 Fixtures and Fittings:
The tenderer shall mention in his bid the type and manufacture of
the fixtures he intends to use enclosing manufacturer's current
catalogues. In the absence of any such agreement the Engineer-in-
charge shall be at liberty to choose any type and manufacture.
All fixtures and fittings shall be of approved quality and type by
well-known manufacturers. All items brought to the site must bear
identification marks of the type and manufacturer. Procurements
shall be made well in advance and got inspected and approved
immediately by the Engineer-in-charge. All fixtures shall be
adequately protected by covering and plugging until handed over.
All fittings, gratings, fasteners, unless specified otherwise, shall be
chromium plated. The connecting lead pipes and bends shall
weigh at least 3 kg per 25 mm diameter per meter length. Where
PVC or similar pipes are allowed the Contractor shall produce the
test reports and convince the Engineer-in-charge about their
durability. Unless specified in the Contract the fixtures shall be as
specified hereinafter.
2.5.11.5.1 Water Closet

i) Raised Type
It shall include glazed stoneware basin with siphon, open front solid
plastic seat plastic cover, low level glazed stoneware flushing
cistern with valve less fittings, supply connections and necessary
fittings. All fittings shall be chromium plated. Colour of basin,
cistern, seat and cover shall be as desired by the Engineer-in-
charge.
ii) Squatting Type
It shall include glazed stoneware pan with foot rests and high level
cast iron flushing cistern with valve less fittings supply connections
and necessary fittings. All fittings shall be chromium plated. The
footrests shall be made of white glazed stoneware with chequered
surface. The flushing cistern shall be painted as desired by the
Engineer-in-charge.
2.5.11.5.2 Urinals
It shall consist of wall type glazed stoneware urinals, cast iron
automatic flushing cistern complete with supply connections, flush
pipe, lead pipes, gratings traps and all other necessary fittings.
Automatic flushing shall be approximately once every five minutes.
A number of urinals located together may be served by one cistern
of adequate capacity. All fittings shall be chrome plated.
2.5.11.5.3 Wash Basins
It shall be made of glazed stoneware. The basin shall be flat back,
wall hung by painted cast iron brackets and complete with pattern
with hot and cold brass faucets with nylon washers, chain waste,
waste washers, lead waste pipe with traps, perforated waste
complete with necessary fittings. All fittings including faucets shall
be chromium plated.
2.5.11.5.4 Sink
It shall be made of glazed stoneware. It shall be wall hung by
painted cast iron brackets and complete with one brass faucets
with nylon washers, chain waste, waste washers, lead pipe with
traps perforated waste with necessary fittings. All fittings including
faucets shall be chromium plated.
2.5.11.5.5 Bathroom Mirror
It shall be made of the best quality 6mm thick indigenous glass and
produced by a reputable mirror manufacturer. It shall be wall
mounted with adjustable revolving brackets. The brackets, screws
and other fittings shall be chromium plated.
2.5.11.5.6 Glass shelves

Glass shelves shall consist of 6 mm thick clear glass with guard
rails and shall be wall mounted with brackets. All brackets, guard
rails and screws shall be chromium plated.
2.5.11.5.7 Towel Rail
Towel rails shall be 20 mm diameter chromium plated MS pipes
wall mounted with chromium plated screws.
2.5.11.5.8 Liquid Soap Dispenser
It shall be round and easily revolving with removable threaded
nozzle. The body, bracket for wall mounting and screws shall be
chromium plated.
2.5.11.5.9 Toilet Roll Holder
It shall be made of strong members with suitable cover cum cutter.
The whole item including wall mounting screws shall be chromium
plated.
2.5.11.5.10 Installation
All plumbing fittings and fixtures shall be installed in a most
workmanlike manner by skilled workers. These shall be perfect in
level, plumb, plane, location and symmetry. All items shall be
securely anchored to walls and floors. All cuttings in walls and
floors shall be made good by the Contractor.
2.5.11.6 Septic Tank and Effluent Disposal:

2.5.11.6.1 Septic Tank
Septic Tank shall consist of the tank itself with inlet and outlets
therefore complete with all necessary earthwork and backfilling.
The details of septic tank shall be as shown on drawings. This item
shall also include ventilating pipe of at least 100 mm diameter
whose top shall be provided with a suitable mosquito proof wire
mesh and cowl. Ventilating pipe shall extend to a height of about 2
metre when the septic tank is at least 15 metre away from the
nearest building and to a height of 2 metre above the top of building
when it is located closer than 15 metre. Ventilating pipes can be
connected to the normal soil ventilating system of the building
where allowed.
2.5.11.6.2 Effluent Disposal

The effluent from the septic tank shall be disposed by allowing it
into an open channel or a body of water if the concerned authority
approves, or into a soak pit for absorption by soil, or shall be
allowed to be absorbed by soil through open jointed SW pipes laid
in a trench filled with broken bricks.
2.5.11.6.3 Soak pit

The soak pit shall be complete as per approved drawing. In
absence of a detailed drawing it shall consist of a 900 mm diameter
pit 1000 mm in depth below the invert level of the inlet pipe. The pit
shall be lined with stone, brick or concrete blocks set in cement
mortar (1:6) and filled with brickbats. Inlet pipe shall be taken down
to a depth of 900mm from the top as an anti-mosquito measure.
2.5.11.6.4 Open jointed SW Pipe
Minimum diameter of the SW pipes shall be 200 mm nominal. The
trench for laying the pipes shall be minimum 600 x 600 mm size.
The joints of the pipes shall be left unsealed.
2.5.11.6.5 Commissioning Septic Tank
After the septic tank has been proved watertight and the sewage
system is checked the tank shall be filled with water to its outlet
level before the sewage is let into the tank. It shall be seeded with
well digested sludge obtained from septic tank or sludge digestion
tank. In the absence of digested sludge a small quantity of
decaying organic matter such as digested cow dung may be
introduced.
2.5.11.7 Testing and Acceptance:
2.5.11.7.1 Inspection before installation
All pipes, fittings and fixtures shall be inspected before delivery at
the site to see whether hey conform to accepted standard. The
pipes shall again be inspected on site before laying by sounding to
disclose cracks. All defective items shall be clearly marked and
forthwith removed from the site.
2.5.11.7.2 Testing of Pipelines
Comprehensive tests of all pipelines shall be made by simulating
the conditions of use. The method of actual tests shall be decided
by the Engineer-in-charge. All test data shall be recorded and
submitted to the Engineer-in-charge for review and instruction. The
Engineer-in-charge's discretion regarding tolerance shall be final.
General guidance for the tests is given below.
i) Smoke Test
All soil pipes, waste pipes and vent pipes and all other pipes when
above ground shall be approved gaslight by a smoke test
conducted under a pressure of 25 mm of water and maintained for
15 minutes after all trap seals have been filled with water. The
smoke is produced by burning oily waste or tar paper of similar
material in the combustion chamber of a smoke machine.
Chemical smokes are not satisfactory.
ii) Water Test
a) For Pipes Other than Cast Iron Glazed ware and concrete pipes
shall be subjected to a test pressure of at least 1.5 m head of water
at the highest point of the section under test. The tolerance figure
of two litres per centimetre of diameter per kilometre may be
allowed during a period of 10 (ten) minutes. The test shall be
carried out by suitably plugging the low end of the drain and the
ends of connections, if any, and filling the system with water. A
knuckle bend shall be temporarily jointed in at the top end and a
sufficient length of the vertical pipe jointed to it so as to provide the
required test head. The top end 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.
Subsidence of test water may be due to one or more of the
following causes:
i) Absorption by pipes and joints
ii) Sweating of pipes or joints
iii) Leakage at Joints or from Defective Pipes
iv) Trapped Air
Allowance shall be made for by addition of water until absorption
has ceased and after which the test proper should commence. Any
leakage and the defective part of the work shall be cut out and
made good.
a) For Cast Iron Pipes
Cast iron sewers and drains shall be tested as for glazed ware and
concrete pipes. The drain plug shall be suitably structured to
prevent their being forced out of the pipe during the test.
iii) For Straightness
a) By inserting at the high end of the sewer or drain a smooth ball of a
diameter 13 mm less than the pipe bore. In the absence of
obstruction, such as yarn or mortar projecting through the joints,
the ball will roll down the invert of the pipe and emerge at the lower
end; and
b) By means of a mirror at one end of the line and a lamp at the other
end. If the pipe is straight, the full circle of light may be observed,
the mirror will also indicate obstruction in the barrel if the pipe line
is not straight.
2.5.11.7.3 Testing Septic Tank
The septic tank shall be tested for water tightness. It shall be filled
up with water and allowed to stand for 24 hours. Then, it shall be
topped up and allowed to stand again for 24 hours and loss of level
recorded. The fall shall not be more than 15mm.
2.5.11.7.4 Fixtures etc.

All fixtures and fittings shall be connected by watertight joints. No
dripping shall be accepted.

Important relevant IS codes for this specification are listed below:
I.S 1172 - Code of basic requirements for water supply, drainage
and sanitation.
I.S 1239 - Mild steel tubes and mild steel tubular and (Pt .I & II)
other wrought steel pipe fittings.
I.S 1536 - Centrifugally cast (spun) iron pressure pipes for water
gas and sewage.
I.S 1537 - Vertically cast iron pressure pipe for water gas and
sewage.
I.S 3486 - Cast Iron Spigot & Socket drain pipes.
I.S 3589 - Electrically welded steel pipe for water, gas and sewage
(200 mm to 2000 mm nominal diameter).
I.S 1742 - Code of Practice for building drainage.
I.S 5329 - Code of practice for sanitary pipe work above ground for
building.
I.S 2470 - Code of practice for design and construction of (Pt I & II)
septic tank for small and large installation.
I.S 3076 - Low density polyethylene pipes for potable water
supplies.
I.S 4984 - High density polyethylene pipes for water supplies.
I.S 1538 - Cast iron fittings for pressure pipes for water, gas and
sewage.
I.S 3989 - Centrifugally cast (spun) iron spigot & socket soil waste
and ventilating pipes, fittings and accessories.
I.S 1230 - Cast iron rainwater pipes and fittings.
I.S 1729 - Sand cast iron spigot and socket soil waste and
ventilating pipes, fittings and accessories.
I.S 1626 - Asbestos cement building pipes, gutters & fittings (spigot
& socket types).
I.S 458 Pre-cast concrete pipes (with and without reinforcement).
I.S 783 - Code of practice for laying of concrete pipes.
I.S 651 - Salt glazed stoneware pipes and fittings.
I.S 4127 - Code of practice for laying of glazed stoneware pipes.
I.S 1726 Cast iron manhole covers and frame.
IS 1729- Cast Iron/Ductile Iron Drainage pipes and pipe fittings for
over ground non pressure pipe line socket and spigot series.
I.S 5219 - (Part-I)-'P' & 'S' traps, cast copper alloy.
I.S 771 - Glazed fire clay sanitary appliance.
I.S 772 - General requirements of enamelled cast iron sanitary

appliances.
I.S 774 - Flushing cistern for water closets & urinals (valve less
siphonic type).
I.S 775 - Cast iron brackets and supports for wash basins and
sinks.
I.S 2548 - Plastic seats and covers for water closet.
I.S 2527 - Code of practice for fixing rainwater gutters & down
pipes for roof drainage.
I.S 784 - Pre-stressed concrete pipe.
2.5.12.0 TECHNICAL SPECIFICATION FOR PLANT AREA ROADS &

DRAINS:
2.5.12.1 Scope:
This specification covers all work required for cutting, filling,
compacting, levelling and dressing, box cutting, soiling, edging etc.
required for the construction of R.C.C roads, RCC drains, pipe
culverts etc.
2.5.12.2 General:
2.5.12.2.1 Work to be provided for by the Contractor
The work to be provided for by the Contractor, unless otherwise
specified, shall include but not be limited to the following:
i) Furnishing all labour, supervision, services, materials,
scaffolds, earthmoving equipment, tools and plants,
transportation, water supply, necessary approaches etc.
required for the work.
ii) Submit to the Engineer-in-charge progressively, the results of
tests undertaken to assess the degree of compaction in the
backfilling if required by the Engineer-in-charge.
2.5.12.2.2 Information on Site Conditions
The Contractor must satisfy regarding the character and volume of
all work under this item and expected surface, sub-surface and/or
sub-soil water to be encountered. He must also satisfy himself
about general conditions of site and ascertain the existing and
future obstruction likely to come up during the execution of the
Contract to carry out the work under this scope.
2.5.12.2.3 Codes and Standards
All work under this specification, unless specified otherwise, shall
conform to the latest revision of Indian Standard specifications and
codes of practice relevant to the work under the scope of this
specification. For road works and concrete pavement for vehicular
movement, MORT&H specification is to be strictly followed.
If any particular aspect of work is not covered specifically by I.S
Codes (latest edition) or this specification, any other standard
practice as may be specified by the Engineer-in-charge shall be
followed.
2.5.12.2.4 Conformity with Design
Contractor shall carry out the work only as per the approved
drawings prepared by him based on the design drawings issued to
him from time to time or the detailed drawings issued to him and/or
as directed by the Engineer-in-charge.
2.5.12.2.5 Classification
Classification as indicated in specification, Preparation of site and
Earthwork in foundations and Trenches given in this document
shall be used.
2.5.12.2.6 Materials to be used
All materials required to carry out the work under the scope of this
contract to the satisfaction of the Engineer-in-charge shall be of
best quality and shall be supplied by the Contractor.
2.5.12.2.7 Borrow Materials

Borrow materials required for backfilling shall be excavated from
approved locations and shall consist of granular material free from
roots, vegetation, decayed organic matter, harmful salts and
chemicals free from lumps and clods and shall be of uniform
quality.
Arrangement for borrow materials from areas, stacks and/or
sources other than plant property limit shall be done by the
Contractor at his own cost.
2.5.12.2.8 Quality Control
The Contractor shall establish and maintain quality control
procedures for the various aspects of the work, methods, materials
and equipment used. The quality control operation shall include
but not be limited to the following items of work:
i) Lines, levels, grades - Periodic surveys, establishment of
markers and boards.
ii) Backfilling - Checking the quality of the fill material, checking
the degree of compaction by standard test, checking moisture
content of soil.
2.5.12.3 Execution:
2.5.12.3.1 Setting Out
The Contractor shall set out the work as per the approved drawings
and as desired by the Engineer-in-charge and carry the Bench
Mark from a known reference as shown by the Engineer-in-charge
to the place of his work and fix permanent points, and markers for
future reference. To show the correct formation level, necessary
profiles with pegs, bamboo and strings etc. shall be made prior to
the starting of the work. The permanent points and markers shall
be checked by the Engineer-in-charge and certified by him, after
which the Contractor will proceed with the work. Before starting
any work on excavation or back filling, the existing ground levels
shall be jointly recorded by the Engineer-in-charge and the
Contractor and certified by the Engineer-in-charge and plotted on
plans for the purpose of record and measurement. The levels
should preferably be taken at an interval of 3 m. in two
perpendicular directions but depending on the topography, the
Engineer-in-charge may instruct the Contractor to take levels at any

interval, the magnitude of which will be decided by the Engineer-in-
charge. It should be noted that the checking by the Engineer-in-
charge shall in no way absolve the Contractor of his responsibilities
of carrying out the work to true lines, levels, grades and
subsequent correction at his own cost in case any error is noticed
at any time.
2.5.12.3.2 Clearing and Grubbing
The area to be excavated or filled up with earth shall be cleared out
of fences, tree, roots, logs, stumps, bushes, vegetation, rubbish,
slush, etc. and levelled up. The Engineer-in-charge may at his
discretion instruct certain trees or vegetation to be retained from
aesthetic or other point of view. The Contractor shall take due care
and protect these while clearing the rest of the area.
2.5.12.4 Earthwork:
2.5.12.4.1 Cutting
The earthwork in cutting for roads shall be done wherever
necessary up to the finished road top level, maintaining proper
gradient and camber as shown on drawings. Then, the cutting for
berms shall be done to a depth as shown on drawings. The side
slopes are to be kept as per the drawing or as instructed by the
Engineer-in-charge. The side slopes are to be dressed neatly to
give a pleasing appearance. Any cutting done below the required
levels and profile shall be filled back at the Contractor's cost with
suitable materials with proper watering and ramming as decided by
2.5.12.4.2 Filling
The earthwork in filling for embankments shall be done wherever
necessary with the spoils obtained from the earthwork in cutting.
The filling shall be done in layers of 150 mm. All big lumps, clods,
etc. shall be broken with mallets or approved appliances. Every
layer of 150 mm shall be roughly levelled, compacted and
thoroughly consolidated with proper ramming and watering before
starting the next layer of filling. The Contractor shall take all
possible care for proper consolidation of the embankment. A
compaction of 95% of the maximum density shall be obtained at
optimum moisture.
Top width of embankments shall be as shown on drawings. The
side slopes shall be as per the drawing or as instructed by the
Engineer-in-charge. Allowance for shrinkage shall be kept at the
rate of 10 mm extra height for every one metre depth of filling.
Roots of trees, branches, leaves and other organic and deleterious
materials shall be removed from the areas to be filled and from the
excavated spoils, before filling is started.
Any damage to the embankments due to rains shall be made good
by the Contractor at his own cost.
The sequence of cutting and filling shall be as instructed by the

Engineer-in-charge.
The tenderer shall mention the method of consolidation he wants to
adopt for the execution of the contract. Consolidating by
mechanical equipment is required.
2.5.12.4.3 Surplus Spoils
If, after filling of the embankments with spoils from cutting, there is
any surplus spoil, such surplus spoil shall be transported within a
distance of 150 m and utilised in filling up of low areas within the
plant area, as instructed by the Engineer-in-charge. The filling shall
be done in layers of 150 mm, clods and lumps shall be broken and
consolidation done along with watering and ramming to the
2.5.12.4.4 Lead
Excavated earth shall be disposed in areas within 150 metres of
lead which shall be measured by the shortest route as a crow files.
2.5.12.4.5 Lift
Scope shall include work in all lifts.
2.5.12.5 Box Cutting:
2.5.12.5.1 Excavation
After the earthwork in cutting, and the earthwork in embankments
have been done properly up to the final level with gradient and
camber as per drawings and proper consolidation of the filling is
completed, earthwork in box cutting shall be taken in hand. Before
starting of box cutting, the Contractor shall obtain Engineer-in-
charge's approval of cutting and embankment work.
The box cutting shall be done in such a way, that the width of
cutting is exactly the clear distance between the edging blocks.
The depth of cutting shall be the total thickness of consolidated
soling and road metalling. The formation shall have the same
profile and camber as shown on drawings.
The excavated spoils shall be transported and utilised in filling of
low areas within the plant areas, or as directed by the Engineer-in-
charge. The filling shall be done in layers of 150 mm, clods and
lumps shall be broken and consolidation done to the satisfaction of
In case of presence of weak soil pockets below the formation, the
Contractor shall excavate to remove such soil to an extent as
instructed by the Engineer-in-charge. The extra depth shall then be
filled up with 38 mm down stone metal and voids in metal shall be
filled up with moorum. Then, the filling shall be rammed and rolled
uniformly with a road roller of 8 tonnes minimum weight. These
operations of removing weak soil pockets and filling with stone
metal shall be done by the Contractor and paid at the earthwork
rates plus the cost of stone metal only.
If by mistake the depth of box cutting is made more than required

the Contractor shall make up the extra depth by metal
consolidation, as specified above, at his own cost.
2.5.12.5.2 Rolling
After the box cutting is completed, the formation shall be rolled with
a road roller of 8 tonnes minimum weight, maintaining proper
gradient and camber. Care shall be taken to avoid excessive rolling
of the formation.
If, after rolling, the formation is higher than required, the excess
earth shall be removed by carefully cutting and dressing and the
formation shall be rolled as specified above. In case after rolling
the formation is depressed below the required level, the Contractor
shall continue the process of filling and rolling as above till the
correct level is attained up to a limit as decided by the Engineer-in-
charge.
2.5.12.6 Edging:
2.5.12.6.1 Materials
The edging shall be of bricks as per the approved drawings during
execution. The bricks shall be as per clause 2.7.7.2.1.
2.5.12.7 Laying:
After rolling of the box cutting is completed, trenches shall be cut
for edging. The width of the trenches shall be minimum and just
sufficient to insert the edging bricks. The clear width between the
inside faces of the edging bricks shall be exactly the same as
shown on drawing. The inside faces shall be in plumb and the gap
between the bricks shall not be more than 10 mm. The top of the
edging shall be at the same level as shown on drawings and the
inside face shall be in a neat line.
The edging bricks shall be thoroughly packed with a mixture of
stone chips (50%) and moorum (50%) at the outside face. The
laying and packing shall be done in a proper workmanlike manner
acceptable to the Engineer-in-charge.
2.5.12.8 Soling:
The material to be used for the work shall be natural sand,
moorum, gravel, crushed stone, or combination thereof depending
upon the grading required. Materials like crushed slag, crushed
concrete, brick metal and kankar may be allowed with the specific
approval of Engineer-in-charge. The material shall be free from
organic or other deleterious constituents and conform to clause 401
under section 400 of MORT&H specification. Moorum and sand mix
bedding is to be provided below soling.
2.5.12.9 Laying:
The soling shall be laid on its narrowest side closely on the
formation, so that minimum voids are left between the adjacent
blocks. The bigger voids shall be filled up by wedging in smaller

blocks of suitable size with a hand hammer. The laying of blocks
and wedging smaller blocks shall be such that the soling shall be a
compact mass with minimum voids and shall not move when being
rolled for consolidation. Then the blinding material (50%) small
stone plus 50% moorum, shall be spread over the soling and
worked into the voids by brooms. The blinding materials shall be
sufficient to fill up all voids and to produce an even surface after
rolling. Excess use of blinding material shall be avoided.
2.5.12.10 Rolling:
The soling shall be thoroughly consolidated with power roller of
minimum 8 tonnes weight, starting at edges and working towards
the centre.
The rolling shall be done in such a way that the whole soling shall
give a compact base without any voids. After initial rolling is done,
inspection shall be made to see if voids are still left in the soling. If
all voids are not filled up, further blinding material shall be added.
The rolling shall be continued till there is no settlement or voids,
and the surface is true and even. The finished soling shall give the
correct thickness, gradient and camber as specified on drawings.
2.5.12.11 Bad Workmanship:
If the Engineer-in-charge finds that the soling done is not up to the
specifications, the whole soling over the defective portion shall be
taken out, re-laid and compacted with specified roller as specified
above by the Contractor at his own cost.
2.5.12.12 Metalling:
The road metal shall conform to requirement specified in clause
404 under section 400 of MORT&H specification. The metal shall
be of tough, durable and hard texture and shall not flake or crush
under pressure. The metal shall be of granite, basalt or equivalent
quality with high density and shall not absorb, when immersed in
water for 24 hours, more than 1 % of own weight. In general,
unless otherwise specified, the metal shall conform to the
standards laid down by the MORT&H specification regarding
toughness, abrasion, co-efficient of hardness attrition loss and
cementation values. The grading of the metal shall be such that
not more than 5% by weight shall be retained on 38 mm sieve and
not more than 50% to 65% retained on 25 mm sieve, not more than
10 to 15% by weight retained on 20 mm sieve, but 100% shall be
retained on 12 mm sieve.
Metal shall be screened, if so desired by the Engineer-in-charge
and fines from 12 mm to dust screened out and may be used as
bondage if found suitable by the Engineer-in-charge.
2.5.12.13 Laying:
The metal shall be laid to camber and profile in such a way that the
total thickness of loose metal over stone soling is not less than 150
mm but more shall be used, if required to make the consolidated
thickness at least 100 mm after rolling. While spreading the metal,
proper profile and camber shall be maintained and checked with
templates at every 6 to 7 metres.
No rolling shall be done until laying has been approved by the
Engineer-in-charge.
2.5.12.14 Rolling:
2.5.12.14.1 Dry Rolling
After metals have been laid and dressed as above, metal shall be
rolled dry with a Road Roller of 8 tons minimum weight until well
compacted and there is no appreciable movement of the stone or
wave in front of the advancing roller is noticed and no lines of roller
are left on the surface. Excessive dry rolling should also be
avoided.
When the desired degree of compaction has been obtained by dry
rolling, screening of approved chipping 12 mm down in size should
be spread uniformly over the surface by brooming and this should
be pushed into the interstices by rolling, successive layers of
screening being added till no more chippings are being taken up by
the surface. Any unevenness observed shall be rectified by
removing stones up to a depth of 50cm to 75cm, refilling the same,
hand packing and re-rolling. No watering should be done till this
process is complete. The amount of screening used should not be
less than 1 m3 per 100 m2 of road surface (3 1/2 ft3 per 100 ft2).
Rolling operation has to be very carefully carried out.
Rolling should be done commencing from the edges of the road
and working towards the centre. Roller should be passed equal
and sufficient number of times on the metal spread at every stage
so as to secure equal and thorough compaction. Speed of roller
has to be very slow and uniform and reversing shall be quick and
free from jerks. As far as possible, the reversing process should be
at different sections of the length rolled during each successive trip.
2.5.12.14.2 Wet Rolling (Water Bound Macadam)
When the dry rolling has been completed to the satisfaction of the
Engineer-in-charge the surface is to be watered and kept saturated
and rolled a few turns as specified above. Approved quality binder
(moorum) shall then be spread uniformly over the surface to a
thickness of 20 mm to 12 mm. The roller wheels as well as the
road surface should be constantly watered during wet rolling
process. The rolling should be continued until slurry is formed over
the entire surface and the same moves in the form of a wave in
front of the roller when the rolling operation may end and the
surface is allowed to dry. The finished metalling shall be minimum
100 mm thick. The finished surface shall be smooth and uniform,

free from waviness and corrugations and as per specified profile
and camber.
After 24 hours of rolling, the surface shall be sprinkled with a thin
layer of sand not less than 2 ft3 per 100 ft2 or 56 m3 per 100 m2 of
road surface.
Traffic shall be allowed after four days from the day of sprinkling
the sand or as approved by the Engineer-in-charge.
2.5.12.15 Bad Workmanship:
The compaction and finish shall be as per specifications and to the
satisfaction of the Engineer-in-charge. If the Engineer-in-charge so
desires, the defective portions shall be removed, metal and
compacted as specified above by the Contractor at his own cost.
2.5.12.16 Concrete pavement:
Concrete pavement as a finishing course in ramp and other
vehicular movement surface as per scope of work defined earlier
should comply with the requirements laid down in section 600 of
MORT&H specification.
2.5.12.17 Road Side Pucca Drains:
2.5.12.17.1 Formation of Drains
The roadside pucca drains shall be made in sizes and slopes as
shown on drawings and/or as instructed by the Engineer-in-charge.
The minimum side slope shall be 1 vertical to 1 horizontal or as
instructed by the Engineer-in-charge. The sides of the bottom shall
be neatly dressed after excavation. Proper connections shall be
made to the culverts, as per instructions of the Engineer-in-charge.
The excavated spoils shall be transported and filled in low areas
within the plant area or in embankments within 150 m lead and in
all lifts as instructed by the Engineer-in-charge. The filling shall be
done in 150 mm layer. Lumps and clods shall be broken and then
compacted properly.
2.5.12.18 Culverts:
2.5.12.18.1 General
Excavation in trenches for foundation of culverts and wing walls
shall be done with side slopes of one vertical to 1/2 horizontal after
clearing the site, etc. as per specifications of earthwork. Backfilling
with ramming and watering shall be done after construction of the
foundations.
2.5.12.18.2 Brickwork Culvert
i) Materials and Workmanship
All bricks shall be of Ist class common burnt clay / fly ash lime
bricks/Clay fly ash bricks/ Fly ash sand lime bricks (as approved),
well-shaped. Bricks shall be soaked in water for at least one hour
prior to use and shall be laid truly horizontal and vertical in headers
and stretchers with cement mortar consisting of one part of cement

and four parts of sand in layers not exceeding 60" in height. Each
layer shall be allowed at least 24 hours to settle itself before
another layer is placed on it and every layer cured with water until
the starting of next layer above it.
Materials for mortar such as sand and cement shall be of standard
specifications. Mortar shall be well mixed, first dry mixed and then
by adding water slowly to have a thick workable consistency.
Mortar shall be mixed in small batches consistent with the rate of
consumption so that no mortar is used after one hour of mixing.
Mortar joints should be 10mm thick and all joints should be full of
mortar. Brickwork shall be carried up regularly in plumb every
course being horizontal. No vertical joints shall come directly over
one another.
Joints of the brickwork shall be raked 12 mm deep. The brickwork
shall be kept moist for 14 days.
ii) Plaster to Brickwork
Brickwork shall be plastered with cement mortar 1 part by volume
of cement to 4 parts by volume of clean, sharp, all graded sand.
The thickness of the plaster shall be 2 0mm and shall be done after
cleaning and wetting the brick joints. Plaster shall be cured for 14
days. All plaster work shall correspond to I.S 1661 - latest edition.
2.5.12.18.3 Pipe Culverts
i) Materials
Pipe culverts shall be made of reinforced concrete pipe (Hume
pipe) and shall be of class No. 3. All pipes shall meet the
requirements of I.S 458 (latest edition) and shall be procured from
approved manufacturers with collars as per manufacturers'
standard specifications. The tenderer shall specifically mention the
particular manufacturer's product he proposes to use.
Cement shall be conforming to the I.S listed in concrete work
specification & duly accepted by the Engineer-in-charge.
Aggregates shall be as per I.S 383 - latest edition. Maximum size
shall not exceed one third of the thickness of the pipe or 20 mm
whichever is smaller. For bedding concrete for laying the pipes, the
maximum size of aggregate shall be 38 mm.
Fine aggregates for concrete shall be as per I.S 383-Latest Edition.
ii) Laying
Laying of concrete pipes shall correspond to I.S 783-Latest edition
and to specification given below:
a) The excavation for laying pipes and foundations of drop wall
should be made as shown on drawings. Side slopes of
excavation shall be the vertical to half horizontal. Half metre
of working space shall be allowed on either side of pipe

exterior. Side slope, shoring, bailing out water, etc. as
required shall be done by the Contractor.
Side slips, if there by any, shall be removed by the Contractor
without any extra cost to the Owner. After laying of the pipes
are completed, backfilling of the trenches shall be done in
layers of 150 mm, clods and lumps broken, watered and
compacted with iron rammers to the satisfaction of the
Engineer-in-charge. The surplus spoils shall be transported
and filled in low areas within other plant area, as instructed by
the Engineer-in-charge. The filling shall be done as already
specified earlier.
b) Pipe bedding shall be first class projection bedding as per IS
783 (latest edition) having a projection ratio of not greater
than 0.70, in which the pipe is carefully bedded on fine
granular materials in an earth foundation carefully shaped to
fit the lower part of the pipe exterior for at least ten per cent of
its overall height; and in which earth filling material is
thoroughly rammed and tamped in layers not exceeding 150
mm in depth, around the pipe for the remainder of the lower
30 % of its height.
c) The drop walls shall be first class brickwork in 1:4 cement
mortars as already specified under clause "Brickwork".
d) The pipe culverts shall be made with proper care regarding
the invert of the pipe, gradient, if any, etc. as specified on
drawings and/or as instructed by the Engineer-in-charge.
2.5.13.0 TECHNICAL SPECIFICATION FOR FLOOR FINISHING AND

ALLIED WORKS:
2.5.13.1 Scope:
This specification covers furnishing, installation, finishing, curing,
testing, protecting, maintenance till handing over the various types
of floor finishes and allied items of work as listed below:
2.5.13.1.1 In situ finishes:
i. Integral finish to concrete base
ii. Red oxide of iron finish
iii. Terrazzo finish
iv. Granolithic finish
v. Patent stone
vi. Metallic hardware like 'Ironite finish
vii. Mastic asphalt finish
viii. Chemical resistant finish
2.5.13.1.2 Tile finishes:
i. Terrazzo tile
ii. Chequered tile
iii. Glazed tile
iv. Tesserae (mosaic, etc.)
v. Chemical resistant
vi. Rubber, vinyl, etc.
vii. Stone slab.
2.5.13.1.3 Base
The base to receive the finish is covered under other relevant
specification.
2.5.13.1.4 Sequence
Commencement, scheduling and sequence of the finishing works
shall be planned in detail and must be specifically approved by the
Engineer-in-charge keeping in view the activities of other agencies
working in the area. However, the Contractor for the finishing items
shall remain fully responsible for all the normal precautions and
vigilance to prevent any damage whatsoever till handing over.
2.5.13.2.1 Special Materials
Special materials required for individual finishing items are
specified under respective items. In general, all such materials shall
be as per relevant IS codes (latest editions) where available. In all
cases these materials shall be of the best quality available

indigenously unless specified otherwise.
The materials for finishing items must be procured from reputable
specialised manufacturers and on the basis of approval of samples
by the Engineer-in-charge. The materials shall be ordered,
procured and stored well in advance to avoid compulsion to use
substandard items to maintain the construction schedule.
2.5.13.2.2 Workmanship
Only workers specially experienced in particular items of finishing

work shall be engaged. Where such workers are not readily
available, with the Engineer-in-charge's permission, experienced
supervisors recommended by the manufacturer shall be engaged.
In particular cases where the Engineer-in-charge desires the
Contractor shall get the finishing items installed by the
manufacturer.
2.5.13.2.3 Preparation of base Surface
The surface to be treated shall be thoroughly examined by the

Contractor. Any rectification necessary shall be brought to the
notice of the Engineer-in-charge and his approval shall be taken
regarding method and extent of such rectification work. For all
types of flooring, skirting, dado and similar locations, the base to
receive the finish shall be adequately roughened by chipping,
raking out joints and cleaning thoroughly all dirt, grease etc, with
water, hand brush and detergent, if required, unless otherwise
directed by the manufacturer of any special finishing materials, or
specifically indicated in this specification under individual item.
To prevent absorption of water from the finishing treatment the
base shall be thoroughly soaked with water and all excess water
mopped up.
The surface shall be bone dry where adhesives are used for fixing
the finishes.
Prior to commencement of actual finishing work use approval of the
Engineer-in-charge shall be taken as to the acceptability of the
surface.
2.5.13.3 In-Situ Finishes:
2.5.13.3.1 Integral finish to concrete base
While the surface of the concrete laid as per specification for

'Cement concrete' has been fully compacted and levelled but the
concrete is still 'green' a thick slurry made with neat cement shall
be applied evenly and worked in with iron floats. When the slurry
starts to set, it shall be pressed with iron floats to have a firm
compact smooth surface without any trowel mark or undulations.
This finish shall be as thin as possible by using 2.2 kg of cement
per m2 of area.
The surface shall be kept in shade for 24 hours and then cured for
at least 7 days continuously by flooding with water. The surface
shall not be subjected to any load or abrasion till 21 days after
laying.
If required by the Engineer-in-charge the surface, while still 'green'
shall be indented by pressing strings. The markings shall be of
even depth, in straight lines and the panels shall be of uniform and
symmetrical patterns.
2.5.13.3.2 Red Oxide of Iron Finish

It shall consist of an under bed and a topping over already laid and
matured concrete base.
i) Thickness
Unless otherwise specified the total thickness of the finish shall be
minimum 40 mm for horizontal and 25 mm for vertical surface of
which the topping shall not be less than 10 mm. While the topping
shall be of uniform thickness the under bed may vary in thickness
to provide necessary slopes. The vertical surface shall project out
6mm from the adjacent plaster or other finishes. Necessary cutting
into the surface receiving the finish shall be done to accommodate
the specified thickness. All junctions of vertical with horizontal shall
be rounded neatly to uniform radius of 25 mm.
ii) Mix
a) Underbed:
The underbed for floors and similar horizontal surfaces shall
consist of a mix of 1 part cement, 2 parts coarse sand and 4
parts of 10 mm downgraded stone chips by volume. For
vertical and similar surfaces the mix shall consist of 1 part
cement to 3 parts coarse sand by volume.
b) Topping:
The topping, cement screened through a fine mesh and red
oxide of iron pigment powder similarly screened shall be dry
mixed thoroughly in right proportions to produce the desired
colour when laid. The mix shall then be prepared with 1 part
cement (mixed with pigment) and 3 parts coarse sand by
volume. The whole quantity required for each visible area shall
be prepared in one batch to ensure uniform colour.
iii) Laying
The underbed shall be laid in panels of maximum area 5 m2 each
no side shall be more than 2.5 m long. For outdoor locations the
maximum area shall be 2 m2. The forms for the panels shall have
perfectly aligned edges to the full depth of the total thickness of
finish. If specified aluminium or glass dividing strips shall be used.
The panels shall be laid in alternate bays or in chequered board

pattern. No panel shall be cast in contact with another already laid
until the contraction of the latter has taken place.
The underbed shall be laid, compacted, levelled and brought to
proper grade with a screed or float. The topping shall be placed
after about 24 hours while the under bed is still somewhat 'green'
but firm enough to receive the topping. The surface of the
underbed shall be roughened for better bonding. The topping shall
be rolled for horizontal areas and thrown and pressed for vertical
areas to extract all superfluous cement and water to achieve a
compact dense mass fully bonded with the underbed. The topping
shall be levelled up by trowelling and finished smooth with slurry
made with already prepared cement and pigment mixture. About
2.0 kg of the mixture shall be consumed per m2 for horizontal
surface, and 1.0 kg for vertical surface. The surface shall be cured
for seven days by keeping it moist.
iv) Polishing
About 36 hours after laying when the surface has hardened
sufficiently it shall be polished with polishing stone till a smooth thin
surface to the satisfaction of the Engineer-in-charge is achieved.
The finish shall be washed and cleaned just before handing over.
2.5.13.3.3 Terrazzo Finish - In Situ

It shall consist of an underbed and a topping laid over an already
laid and matured concrete base.
i) Thickness
Unless otherwise specified the total thickness of the finish shall be
minimum 40 mm for horizontal and 25 mm for vertical surface of
which the topping shall be not less than 10 mm. While the topping
shall be of uniform thickness the underbed may vary in thickness to
provide necessary slopes. The vertical surface shall project out
6mm from the adjacent plaster or other finishes. Necessary cutting
into the surface receiving the finish shall be done to accommodate
the specified thickness.
All junctions of vertical with horizontal shall be rounded neatly to
uniform radius of 25 mm.
ii) Mix
a) Underbed:
The underbed for floors and similar horizontal surfaces shall
consist of a mix of 1 part cement, 1 1/2 parts sand and 3 part
stone chips by volume, for vertical surfaces the mix shall
consist of 1 part cement to 3 parts sand by volume. The sand
shall be coarse. The stone chips shall be 10 mm downgraded.
Only sufficient water is to be added to give a workably
consistency.
b) Topping:
The mix for the topping shall be composed of cement, colour
pigment; marble dust and marble chips, proportions of the
ingredients shall be such as to produce the terrazzo of colour
texture and pattern approved by the Engineer-in-charge. The
cement shall be white or grey or a mixture of the two to which
pigment shall be added to achieve the desired colour. To 3
parts of this mixture, 1 part marble powder by volume shall be
added and thoroughly mixed dry. To 1 part of this mix, 1 to 1
1/2 parts of marble chips by volume shall be added and
thoroughly mixed dry again.
The pigment must be stable without any fading. It must be very
finely ground. The marble powder shall be from white marble
and shall be finer than IS Sieve No.30. The size of marble
chips may be between 1 mm to 20 mm.
Sufficient quantity to cover each visible area shall be prepared
in one lot to ensure uniform colour. Water to make it just
workable shall be added to a quantity that can be used up
immediately before it starts to set.
iii) Laying
The underbed shall be laid in panels. The panels shall not be more
than 5 m2 in area of which no side shall be more than 2.5 m long.
For exposed locations the maximum area of panel shall be 2.0 m2.
The panels shall be laid in alternate bays or chequered board
pattern. No panel shall be cast in contact with another already laid
until the latter has contracted to the full extent.
Dividing strips made of aluminium or glass shall be used for forming
the panels. The strips shall exactly match the total depth of under
bed plus topping.
After laying, the underbed shall be levelled compacted and brought
to proper grade with a screed or float. The topping shall be laid
after about 24 hours while the underbed is still somewhat 'green'
but firm enough to receive the topping. Slurry of the mixture of
cement and pigment already made shall be spread evenly and
brushed in just before laying the topping. The topping shall be
rolled for horizontal areas and thrown and pressed for vertical
areas to extract all superfluous cement and water and to achieve a
compact dense mass fully bonded with the underbed. The surface
of the topping shall be trowelled over, pressed and brought to a
smooth dense surface showing a minimum 75% area covered by
marble chips in an even pattern of distribution.
iv) Curing
The surface shall be left for curing for about 12 to 18 hours and
then cured by allowing water to stand on the surface or by covering
with wet sack for four days.
v) Grinding and Polishing

When the surface has sufficiently hardened it shall be watered and
ground evenly with rapid cutting coarse grade (No.60) grit blocks,
till the marble chips are exposed and the surface is smooth. Then
the surface shall be thoroughly washed and cleaned. A grout with
already prepared mixture of cement and pigment shall be applied to
fill up all pin holes. This surface shall be cured for 7 days by
keeping it moist and then ground with fine grit blocks (No.120). It
shall again be cleaned with water, the slurry applied again to fill up
pin holes that might have appeared and allowed to be cured again
for 5 days. Finally the surface is ground a third time with very fine
grit blocks (No.320) to get smooth surface without any pin hole.
The grinding shall be done by a suitable machine. Where grinding
machine cannot be used hand grinding may be allowed when the
first rubbing shall be with carborundum stone of coarse grade
(No.60). Second rubbing with medium grade (No.80) and final
rubbing and polishing with fine grade (No.120). The surface shall
be cleaned with water, dried and covered with oil free clean
sawdust if directed by the Engineer-in-charge. The polishing shall
be postponed till handing over if desired by the Engineer-in-charge.
Just before handing over, the surface shall be dusted with oxalic
acid at the rate of 0.33 g/m2 water sprinkled on to it and finished by
buffing with felt or Hessian bobs. The floor shall be cleaned with
soft moist rag and dried. If desired by the Engineer-in-charge, wax
polish to be applied. However, all excess wax polish to be wiped
off and the surface to be left glossy but not slippery.
2.5.13.3.4 Granolithic Finish

Granolithic finish shall either be laid monolithically over base
concrete or separately over hardened base concrete.
i) Thickness
The finish shall be average 20 mm and minimum 12 mm thick,
unless specified otherwise.
ii) Mix
The mix shall consist of 1 part cement, 1 part coarse sand and 2
parts coarse aggregate by volume. The coarse aggregate shall be
very hard like granite and well graded between 6 mm and 12 mm
minimum quantity of water to get workability shall be added.
iii) Laying of monolithic topping
The concrete base shall be laid as per specification 'Cement
concrete' and levelled up to the required grade. The forms shall
remain sufficiently protruding to take the finish.
Within about 3 hours, of laying the base while it is still fully 'green'
the topping shall be laid evenly to proper thickness and grade. If
considered necessary the surface of the base shall be roughened
by wire brushing. Unless manual operation is permitted by the

Engineer-in-charge, mechanical vibrators, of suitable design shall
be used to press the topping firmly and work vigorously and quickly
to secure full bond with concrete base.
The laitance brought to the surface during compression shall be
removed carefully without disturbing the stone chips. The surface
shall then be lightly trowelled to remove all marks, when sufficiently
set, hard trowelling shall be done to secure a smooth surface
without disturbing the stone chips.
For large areas the laying shall be in panels of maximum 25 m2
area. The panels shall be laid in chequered board pattern.
iv) Laying of topping separately on hardened base
The base concrete shall be prepared as stated in clause and slurry
of neat cement applied just prior to laying the granolithic concrete
mix (1:1:2). The method of compaction, etc. shall be same as for
monolithic topping.
v) Curing
Immediately after laying, the finish shall be protected against rapid
drying. As soon as the surface had hardened sufficiently, it shall be
kept continuously moist for at least 10 days by means of wet gunny
bags or ponding of water on the surface. The floor shall not be
exposed to heavy traffic during this period.
vi) Grinding
If grinding is specified, it shall start only after the finish has fully set.
Clause (c) shall be followed. However, the ultimate polish required
shall be decided upon by the Engineer-in-charge.
vii) Finishing
Where specified, sodium silicate or magnesium or zinc silica-
fluoride treatment shall be done. The number of coats to be
applied shall be as required. The concentration and method of
application of the solution shall be as specified in IS 5491 (latest
edition).
2.5.13.3.5 Patent Stone
It shall consist of an underbed and a topping laid on an already laid
and matured concrete base.
i) Thickness
The patent stone finish shall have thickness as stipulated under
clause 3.9.3.4.1 except that the topping shall be 6 mm thick.
ii) Mix
a) Underbed
The mix shall be as stipulated under clause 2.5.13.3.4(item ii)
b) Topping
The mix for the topping shall consist of 1 part cement and 1
part fine sand by volume.
c) Laying
The patent stone finish, including the under bed shall be laid in
alternate bays or in chequered board pattern. No panel shall
be cast in contact with another already laid till the contraction of
the latter has already taken place.
The maximum area of each panel shall be 3.5 m2 of which no
side shall be more than 2 m long.
A cement grout shall be applied and worked into the surface to
receive the finish, the underbed then laid, compacted and
levelled to proper grade with a screed or float. The topping
shall be applied evenly on the underbed while it is not fully set
but firm enough and rolled and pressed to get full bond. The
topping shall be trowelled to a dense finish to the satisfaction of
the Engineer-in-charge. All trowel marks shall be mopped out
with a soft cloth to give a clean smooth surface.
After the surface is sufficiently set, the finished floor shall be
kept moist for 7 days for curing. If desired the finish shall be
polished as directed by the Engineer-in-charge.
2.5.13.3.6 Metallic Hardener like Ironite finish
This will consist of a topping (incorporating iron particles) to bond

with concrete base while the latter is 'green'.
i) Thickness
Unless otherwise specified the metallic hardener finish shall be of
12 mm depth.
ii) Material
The hardening compound shall be uniformly graded iron particles,
free from non-ferrous metal impurities, oil, grease, sand, soluble
alkaline compounds or other injurious materials. When desired by
the Engineer-in-charge, actual samples shall be tested.
iii) Mix
Proportion of the metallic hardener shall be specified or as
indicated by the manufacturer. However, in absence of any such
direction 1 part metallic hardener shall be mixed dry with 4 parts
cement, by weight. To this mixture 6mm nominal size stone chips
shall be added in proportion of 1 part cement (mixed with hardener)
to 2 parts of stone chips by volume and uniformly mixed. Minimum
quantity of water shall be added to make it workable.
iv) Laying
The concrete floor shall be laid as per specification 'Cement
concrete' and levelled up to the required grade. The forms, if any,
shall remain sufficiently projecting to take the finish. The surface
shall be roughened by wire brush as soon as possible. The finish
shall be laid while the concrete underbed is still very 'green' within
about 4 hours of laying of the latter. The finish shall be of uniform
thickness and even dense surface without trowel marks, pin holes,
etc. This topping layer shall be pressed firmly and worked
vigorously and quickly to secure full bond with the concrete base.
Just when the initial set starts the surfaces shall be finished smooth
with steel trowel.
The finished floor shall be cured for 7 days by keeping it wet.
2.5.13.3.7 Mastic Asphalt finish

This is a one layer treatment on concrete or brick base.
i) Thickness
The thickness shall be as specified in the drawing.
ii) Materials
Bitumen shall be industrial bitumen of the grades 90/15 and 75/15
conforming to IS 702 (latest edition).
Mineral filler shall be dry limestone dust passing through 75-micron
IS Sieve.
Fine aggregate shall be crushed and graded natural limestone or
other hard rock.
Coarse aggregates shall be crushed siliceous stone or other
approved aggregate 6mm stone chips shall be used for finish up to
20 mm thick and 10 mm chips for thicker finish.
iii) Composition
Bitumen mastic shall conform to IS 1195 (latest edition) and shall
be either brought to site in blocks weighing about 25 kg or prepared
at site. If brought in blocks, these shall be re-melted in
mechanically agitated mastic cookers and coarse aggregate,
preferably preheated, fed in successive portions until the complete
change is thoroughly incorporated. At no stage during the re-
melting and mixing process, shall the temperature exceed 2050 C.
iv) Laying
The hot mastic shall be laid on dry base surface cleaned thoroughly
by wire brushing and sweeping. The mastic shall be levelled and
when cold to some extent shall be finished with a wooden float with
addition of small quantity of fine sand if required. No load shall be
allowed till the finish has cooled to normal temperature.
The mastic shall be laid in suitable panels of about 15 m2 in area

formed by formers. Succeeding panels shall be laid overlapping
the finished panel so as to melt its edges and form a continuous
finish without joint.
v) Chemical Resistant In-Situ Finish
Chemical resistant in-situ finish shall be as per approved drawings.
About its performance the Engineer-in-charge shall have to be fully
satisfied by test results and examination of similar treatment
already in existence. The Contractor shall get it done by a
specialised manufacturer, with a guarantee of performance from
the organisation and pass it on to the Owner in addition to his own
guarantee.
2.5.13.4. Tiled Finish:
These shall include finish tiles, stone slabs and similar
manufactured or natural items over already laid and matured base
as concrete or masonry by means of an underbed or an adhesive
layer.
2.5.13.4.1 Terrazzo Tile finish
The finish will consist of manufactured terrazzo tile and an
underbed.
i) Thickness
The total thickness including the underbed shall be minimum 40
mm for floors and 30 mm for walls unless otherwise specified.
The skirting, dado and similar vertical surfaces shall project out
6mm uniformly from the adjacent plaster or other wall finishes. The
necessary cutting in to the surface receiving the tiled finish, to
accommodate the specified thickness shall be done.
ii) Tiles: Terrazzo

The tiles shall, unless specifically permitted in special cases be
machine made under quality control in a shop. The tiles shall be
pressed hydraulically to a minimum of 140 kg/m2.
Each tile shall bear on its back permanent and legible trademark of
the manufacturer. All angles of the tiles shall be right angles, all
arises sharp and true, colour and texture of the wearing face
uniform throughout. Maximum tolerance allowed in length and
breadth and the thickness +3 mm. Face of the tile shall be plain,
free from -pin holes and other blemishes. The topping shall be of
uniform thickness not less than 10 mm. The total thickness
including the topping shall be as specified but not less than 20 mm
in any case.
The backing shall be composed of 1 part ordinary grey cement and
3 parts of stone chips by weight mixed with water.
The topping shall be as specified under clause 3.9.3.5.2. The tile

shall be cured at the shop for at least 14 days before delivery to the
site. First grinding shall be given to the tiles at the shop before
delivery. Tiles shall be packed properly to prevent damage during
transit and storage. The tiles must be stored carefully to prevent
staining by damp, rust, oil and grease, or other chemicals.
Tiles made in each batch shall be kept and used separately so that
colour of each areas of the floor may remain uniform. The
manufacturer shall supply along with the tiles the grout mix
containing cement and pigment in exact proportions as used in
topping of the tiles. The containers for the grout mix shall be
suitably marked to relate it to the particular type and batch of tiles.
iii) Mix-Underbed
The underbed for floor and similar horizontal surfaces shall be 1
part lime putty, 1 part surkhi and 2 parts coarse sand by weight
mixed with sufficient water to form a stiff workable mass. For
skirting and dado and all vertical surfaces it shall be about 10 mm
thick and composed of 1 part cement and 3 parts coarse sand by
weight.
iv) Laying
The underbed mortar shall be evenly spread and brought to proper
level and consolidated to a smooth surface. The surface shall be
roughened for better bond. Before the underbed has had time to
set and while it is still fairly moist but firm, cement shall be hand
dusted over it or a cement slurry applied and the tiles shall
immediately be placed upon and firmly pressed by wooden mallet
on to the underbed until it achieves the desired level. The tiles shall
be kept soaked for about 10 minutes just before laying. The joints
between tiles shall be as close as possible and not more than 1.5
mm wide.
Special care shall be taken to check the level of the surface and the
lines of the joints frequently so that they are perfect.
When tiles are required to be cut to match the dimensions these
shall be sawn and edges rubbed smooth. The location of cut tiles
shall be planned in advance and approval of the Engineer-in-
charge taken.
At the junction of horizontal surface with vertical surface, the tiles
on the former shall enter at least 12 mm under the latter.
After fixing, the floor shall be kept moist and allowed to mature
undisturbed for 7 days. Heavy traffic shall not be allowed.
If desired dividing strips as specified under clause 2.5.13.3.5 (item
iii) may be used for dividing the work into suitable panels.
Procedure shall be same as above, except that grinding shall not
commence earlier than 14 days after laying of tiles.
2.5.13.4.2 Chequered Tile Finish

The finish shall consist of manufactured grey or coloured cement
tiles or terrazzo tiles with chequered face and an underbed laid
over concrete or brick surface.
i) Thickness
Thickness shall be same as in clause 2.5.13.4.1(item i).
ii) Tiles: Chequered
The tiles shall have chequers not less than 2.5 cm centre to centre
and not more than 5 cm centre to centre. Depth of grooves shall be
not less than 3 mm. The grooves shall be uniform and straight.
The tiles shall conform to clause 2.5.13.4.1 (item ii) except that
these may have the topping in terrazzo or plain grey cement or
colour pigment added to cement as specified.
iii) Underbed As per clause 2.5.13.4.1(item iii).
iv) Laying As per clause 2.5.13.4.1(item iv)
As per clause 2.5.13.4.1.(item v) except that the tiles shall be
ground and polished by hand after laying taking special care in
polishing the grooves uniformly.
2.5.13.4.3 Glazed Tile Finish
This finish shall be composed of glazed earthen coarse tiles with an

underbed laid over a concrete or masonry base.
i) Thickness
The total thickness shall be between 20 mm and 25 mm including
the underbed.
The tile finish on vertical surface shall project out 6 mm uniformly
from the adjacent plaster or other wall finishes. The necessary
cutting into the surface receiving the finish, to accommodate the
specified thickness shall be done.
ii) Tiles: Glazed
The tiles shall be of earthenware, covered with glaze, white or
coloured, plain or with designs, of 150 mm x 150 mm nominal sizes
and 10 mm thick unless otherwise specified. The tolerance shall
be + 1.5 mm for length and breadth and 0.5 mm for thickness.
Special like internal and external angles, beds, covers, cornices,
corner pieces etc. shall match. The top surface of the tiles shall be
glazed with a glass or matt unfading stable finish as desired by the
Engineer-in-charge. The tiles shall be flat and true to shape. The
colour shall be uniform and fractured section shall be fine grained
in textures dense and homogeneous. The tiles shall be strong and
free from flaws like cracks, chips, craze, specks, crawling, etc. and
other imperfections. The edges and the underside of the tiles shall
be completely free from glaze and the underside shall have ribs or
indentations for better anchorage with the fixing mortar.
The coloured tiles, when supplied, shall preferably come from one
batch to avoid difference in colour.
iii) Mix: Underbed
The mix for the underbed shall consist of 1 part cement and 3 parts
coarse sand by weight mixed with sufficient water or admix if
specified.
iv) Laying
Same as per clause 2.5.13.4.1(item iv)
v) Finishing
The joints shall be cleaned and flush pointed with white cement and
cured for 7 days by keeping it wet. The surface shall be cleaned
with soap or suitable detergent, washed fully and wipe with soft
cloth to prevent scratching before handing over.
2.5.13.4.4 Terrazzo Finish (Mosaic, etc.)
This finish consists of manufactured vitreous, glass, ceramic or
similar hard small pieces set in an underbed over a concrete or
masonry surface, already laid.
i) Thickness
The total thickness including the underbed shall be between 16 mm
and 25 mm.
ii) Terrazzo Finish
These shall usually be 6mm thick pieces of ceramic vitreous china,
tinted glass or similar hard wearing, strong and durable material in
desired shapes and sizes and patterns.
The supply shall come in the desired pattern in full or in sections
convenient for handling, stuck to pieces of strong thick paper on the
surface to be exposed. The gum used for this purpose must be
water soluble and non-staining. The sections shall be properly
marked to avoid mistakes and master drawing shall be available at
the site for guidance.
iii) Mix: Underbed
Same as clause 2.5.13.4.1(item iii) 3
iv) Laying
The specifications for laying if given by the manufacturer of the item
shall be followed provided it is approved by the Engineer-in-charge.
Otherwise clause 2.5.13.4.1(item iv) shall generally be followed.
However, instead of grey cement the slurry shall be made with
white cement to fix the panels.
The paper mounted patterns in sections shall be carefully placed
and pressed in position true to lines and levels. Earliest possible,
the paper shall be peeled off and surface examined and cleaned,
joints flush pointed with white cement and cured for 7 days keeping
it wet.
2.5.13.4.5 Chemical Resistant Tiles Finish
This shall include all varieties of special tiles used for specific
chemical resistance function and an underbed over already laid
concrete or masonry.
i) The chemical resistant tiles, as per drawings shall be of the best
indigenous manufacture unless otherwise specified and shall be
resistant to the chemicals described in the drawings. The tiles shall
have straight edges, uniform thickness plain surface, uniform non-
fading colour and texture.
Glazed tiles if permitted to act as chemical resistant finish shall be
considered under clause.
Usually the chemical resistant tiles shall not absorb water more
than 2% by weight. The tiles shall have at least compression
strength of 700 kg/m2. The surface shall be abrasion resistant and
durable.
ii) Laying
The mortar used for getting or for underbed shall be durable and
strong. The grout which shall be to the full depth of tile, shall have
equal chemical resistant properties. Joints shall be pointed if so
desired. The setting and fixing shall be according to the
manufacturer's specification approved by the Engineer-in-charge.
2.5.13.4.6 Rubber, Vinyl or Asbestos Tile Finish
This shall include various types of tiles manufactured from rubber,
vinyl, etc. set with a sticker on concrete or masonry base. An
underbed may be required to secure desirable surface and grade.
i) Thickness
The thickness of the tiles shall be mentioned in drawings.
ii) Tiles
Unless otherwise desired the tiles shall be square of approved
dimensions. The tolerance in dimensions shall be 1.5 mm.
The face of the tiles shall be free from porosity blisters, cracks,
embedded foreign matters or other physical defects which effect
appearance or serviceability. All edges shall be cut true and
square. The colour shall be non-fading and uniform in appearance,
insoluble in water and resistant to each tile shall be marked on the
back legibly and indelibly with manufacturer's trade mark, the
thickness, sizes, batch number and date of manufacture.
Tiles shall be delivered securely packed and stored in clean, dry,
well ventilated place at a temperature near about to that the tiles
shall be called upon to stand ultimately.
Adhesive to be used for sticking the tiles shall be approved by the

tile manufacturer. The adhesive shall have a short drying time and
long life in addition to toughness.
iii) Mix: Underbed
The underbed where required to make up the specified thickness or
to give the required grade or to get the right type of surface shall be
composed of 1 part lime putty, 1 part cement and 4 parts coarse
sand mixed with just sufficient water to make it workable.
iv) Laying
The tiles shall be kept in the room to be tiled for at least 24 hours to
bring them to the same temperature as the room. For air
conditioned space, the air conditioning shall be completed before
tiling is taken up.
The surface to receive this finish shall be firm even textured but not
too smooth, without undulations and other deficiencies. If an
underbed is laid the same is cured for at least 7 days by keeping it
moist and then fully dried.
The surface shall be thoroughly cleaned. All loose dust particles
shall be removed. Oil and grease if any shall be completely
cleared by use of detergent.
The adhesive shall be applied to fully dry surface in desired
thickness uniformly. The adhesive shall also be applied to the
backs and edges of the tiles and allowed to surface dry. The tiles
shall be placed neatly on the surface exactly to the approved
pattern and set with a suitable tool. If the edges tend to curl up,
weights to be used to keep the edges down. Special care shall be
taken to avoid formation of air pockets under the tiles. The joints
shall be very fine. Any adhesive squeezed out through the joints
shall be removed immediately.
v) Finishing
If any adhesive mark is there on the surface a soft cloth soaked
insolvent shall be used to wipe it off. The surface shall be cleaned
with soft soap, dried and polished with an approved type of polish
just before handing over.
2.5.13.4.7 Stone Slab Finish: Marble Stone and similar Fine Grained Stone
This shall include natural stone slabs of regular shape and

dimensions and capable of taking good polish and an underbed
over concrete or masonry surface.
i) Thickness
The underbed shall be minimum 12 mm and average 20 mm thick.
The slabs may be 25 mm, 30 mm or 40 mm thick as specified.
ii) Stone Slab

The stone slabs shall be made from selected rock, which are hard,
sound, homogeneous and dense in texture and free from flaws.
Angles and edges shall be true, square, and free from chipping and
surface shall be plane. The slabs shall preferably be machine cut
to the required dimensions. Tolerance of + 5 mm in dimensions
and + 2 mm in thickness will be allowed and unless specified the
slabs shall be minimum 300 mm x 300 mm.
The stone slab shall come from specific regions and in specific
quality with top surface fine chisel dressed. All sides shall also be
fine chisel dressed to the full depth to allow finest possible joints.
The slabs shall be delivered to the site well protected against
damages and stored in dry place under cover.
iii) Mix: Underbed
Same as clause 2.5.13.4.6(item iii).
iv) Laying
The sides and top surface of the slabs shall be machine rubbed or
table rubbed with coarse sand and washed clean before laying.
The underbed mortar shall be evenly spread and brought to proper
level on the area under each slab. The slab shall be laid over the
underbed, pressed and tapped down with wooden mallet to the
proper level. The slab shall then be lifted and the underbed
corrected as necessary and allowed to stiffen a little. Next, quick
cement slurry shall be spread over the surface. The edges of the
slab shall be buttered with slurry of cement, grey/white/mixed with
pigment matching the colour of the stone slabs. The slab shall be
gently laid and tapped with wooden mallet to bed properly to a very
fine joint and to the required level. All surplus cement slurry shall
be removed and the surface mopped clean with wet soft cloth. The
laid finish shall be cured for 7 days by keeping it wet.
v) Polishing, Finishing
Fine chiselling shall be done to remove the slight undulations that
usually exist at the joints. The polishing and finishing shall be done
as specified under clause 2.5.13.4.3(v). However, the joints shall
be so fine in the case of stone slabs that grouting shall not be
called for.
2.5.13.4.8 Stone Slab Finish: Sand Stone and Coarse Grained Stone Finish
Generally clause shall be followed except that the workmanship

and finish shall not be fine as explained hereunder.
The slabs shall be rough chiselled or fine chiselled as specified.
Tolerance may be allowed up to + 6 mm for rough finish, but no
sharp unevenness shall be allowed. For fine chiselling the
unevenness shall be limited to + 2 mm. The sides shall be chisel

dressed at least to half slab depth so that the maximum deviation
from straight line shall be within 25 mm. Beyond this depth the
edge may be slightly splayed.
The joint thickness shall be kept limited to 5 mm in case of rough
finish and 3 mm in case of fine finish unless wider joints are
specified. The joints shall be grouted with white of coloured
cement.

The finish shall be checked specially for:
a) Level, slope, plumb as the case may be
b) Pattern and symmetry
c) Alignment of joints, dividing strips, etc.
d) Colour, texture
e) Surface finish
f) Thickness of joints
g) Details of edges, junction etc.
h) Performance
i) Precautions specified for durability
2.5.13.6 IS Codes (All referred codes should be latest edition):

Important relevant codes for this section:
IS 13753 Dust pressed ceramic tiles with water absorption of
E>10%.
IS 13754 - Dust pressed ceramic tiles with water absorption of 6
%< E>=10%.
IS 13755 - Dust pressed ceramic tiles with water absorption of 3
%< E>=6%.
IS 13756 - Dust pressed ceramic tiles with water absorption of
E<=3%.
I.S 1196 - Code of practice for laying bitumen mastic flooring.
I.S 1197 - Code of practice for laying of rubber floors.
I.S 1237 - Cement concrete flooring tiles.
I.S 1443 - Code of practice for laying and finishing of cement and
concrete flooring tiles.
I.S 2114 - Code of practice for laying in situ Terrazo tiles.
I.S 2571 - Code of practice for laying in situ terrazzo floor finish.
I.S 3461 - PVC asbestos floor tiles.

I.S 4860 - Specification for acid resistant bricks.
I.S 5318 - Code of practice for laying of flexible PVC sheet and tile
flooring.
I.S 5491 - Code of practice for laying in situ granolithic concrete
floor topping.
2.5.14.0 TECHNICAL SPECIFICATION FOR METAL DOORS, WINDOWS,

VENTILATORS, LOUVERS ETC:
2.5.14.1 Scope:
The work in general shall consist of supplying and erecting and
installation of all metal doors, windows, ventilators, louvers, glazes
partitions, etc. as shown on drawings with all materials complete
excluding supply of glass and glazing.
2.5.14.2 Materials:
Steel sections used for fabrication of doors, windows, etc. shall be
standard steel sections as specified in I .S 1038 (latest edition) and
I.S 1361(latest edition) as specified in drawing.
Steel sheets for frames, shutters, louver blades, etc. shall be of
gauge mentioned in this specification.
Hardware and fixtures of the best quality from approved
manufacturers shall only be used. The Bidder shall specifically
state the particular manufacturer's materials be proposes to use. All
hardware and fixtures shall be able to withstand repeated use.
Door closers shall conform to I.S 3564 (latest edition) and shall be
suitable for doors weighing 61-80 kg unless otherwise stated. Each
closer shall be guaranteed against manufacturing defect for one
year and any defect found within this period shall be rectified or the
closer replaced free of charge. Concealed door closers shall be
either floor mounted or transom mounted, suitable for installation
with metal doors. It shall conform to the performance requirements
and endurance test stated in I.S 3564(latest edition).
The Contractor shall submit samples of each type of hardware to
the Engineer-in-charge. The approved samples shall be retained by
the Engineer-in-charge for comparison with bulk supply. The mastic
for caulking shall be of best quality from a manufacturer approved
by the Engineer-in-charge. In general, fixing of mastic on metal
frames shall be as per I.S 1081(latest edition) and/or as approved
2.5.14.3 Fabrication:
2.5.14.3.1 Steel Doors, Windows, Ventilators, Louvers, etc.
i) Door Frames
Frames shall be fabricated from 0.8mm. Sheet. They shall be
mortised, reinforced, drilled and tapped for hinges and lock and bolt
striker. Wherever necessary, frames shall be reinforced for door-
closer. Welded construction with mitred corners shall be used.
Rubber door silencers shall be furnished for the striking jamb.
Loose 'T' masonry anchors shall be provided. Frames shall finish
flush with floor and adjustable floor anchors shall be supplied.
Frames shall be brought to site with floor ties/weather bars installed

in place.
ii) Double Plate Flush Door shutters

Door shutters shall be 45 mm thick, completely flush design and
shall comprise of two outer sheets of 0.63mm steel sheet rigidly
connected and reinforced inside with continuous vertical 20G
stiffeners, spot welded in position at not more than 150 mm on
centres. Both edges of doors shall be joined and reinforced full
height by steel channels placed immediately inside and welded to
the door faces. Top and bottom of doors shall be reinforced
horizontally be steel channels running full width of door. Doors shall
not have more than 2.5 mm clearance at jambs and head, shall
have proper bevel of lock stiles and rails to operate without binding,
and shall be reinforced at corners to prevent sagging or twisting.
Pairs or double doors shall have meeting stile edges bevelled or
rebated. Where shown on drawing, the doors shall be sound-
deadened by filling the inside voids with mineral wool or other
suitable approved materials.
Door shall be mortised, reinforced, drilled and tapped in shop for
hinges, locks and bolts. They shall also be reinforced for closers,
push plates and other surface hardware where necessary. Any
drilling and tapping required for surface hardware shall be done at
site. Where shown in drawing, provision shall be made for fixing,
glazing, vision panels, louvers, etc. Glazing mouldings shall be of
18G steel of extruded aluminium section with profiles shown in
drawing and suitable for fixing 6 mm glass. Louver blades shall be
V or Z shaped and made out of 16G sheets.
iii) Single Sheet Door Shutters
Single sheet doors shall be made from best quality 18G mild steel
sheets, and shall present a flush surface on the outsider. The
inside shall be stiffened with semi-tubular edge and central
stiffening rail which shall convey the lock and other furniture. The
frames shall be made from best quality 0.8mm mild steel sheets.
Wherever required as shown on drawings, provisions for fixing
glass panes, louvers, etc. shall be made.
The manufacturing shall be done as specified in 2.5.14.3.1(item ii)
'Double Plate flush Door shutters'.
iv) Sliding Doors
Sliding doors shall be either double plate or single plate
construction as required and made out of 0.63mm steel sheets with
adequate stiffeners. The Contractor shall specify the weight of the
door in his shop drawing and submit the manufacturer's catalogue
of the sliding gear he proposes to use. Where shown on drawings,
the Contractor shall make provisions for openings in the door for
monorail beams. Doors shall close positively to exclude rainwater
from seeping in. Sliding doors shall withstand specified wind loads
without buckling or jamming. The door shall slide freely under all
ambient conditions.
v) Steel Windows, Sashes, Ventilators, etc.
These shall conform in all respects to I.S 1038 (latest edition) and
I.S 1361 (latest editions) and as shown on drawings. The details
as called for in the above codes shall be applicable for coupling
mullions.
All welds shall be dressed flush on all exposed and contact
surfaces.
Where composite unit openings are shown on drawings, the
individual window units shall be joined together with requisite
transoms and mullions. All windows shall be outside glazed, fixed
with putty or metal glazing beads.
2.5.14.3.2 Shop Coat of Paint
The shop paint for steel doors, windows etc. shall be best lead or
zinc chromate primer paint from approved manufacturers. All
surfaces shall be thoroughly cleaned of rust, grease, loose mill
scales, etc. and given one coat of shop paint. Portions like
mullions, transoms, etc. which will be inaccessible after assembly
of units shall be given an extra coat of paint before assembly.
Where called for in the drawings, all steel doors, windows etc. shall
be not dip galvanised to give a coating weight of 1 - 2 oz. per
sq.ft. One coat zinc chromate primer coat shall then be applied as
shop paint.
2.5.14.4 Transport and Installation:

2.5.14.4.1 Handling and Storage of Fabricated Material
All metal doors, windows, etc. shall be packed and crated properly
before despatch, to ensure that there will be no damage to the
fabricated materials. Loading into wagons and trucks shall be done
with all care to ensure safe arrival of materials at site in undamaged
condition.
All metal doors, windows, etc. shall be stored under cover in a way
to prevent damage or distortion.
2.5.14.4.2 Assembly and Erection at Site
In general, the fixing of steel doors, windows, ventilators, louvers,
etc. shall conform to IS 1081(latest edition). The Contractor shall
assemble and install all steel doors, windows, sashes, fixed metal
louvers, etc. including transoms and mullions for complete units in
respective places keeping proper lines and levels, and in approved
workmanlike manner, to give trouble free and leak proof
installation. If required by the Engineer-in-charge, the installation
shall have to be carried out under the supervision of the

manufacturer's staff.
After installation of steel doors, windows, etc. all abrasions to shop
coat of paint shall be retouched and made good with the same
quality of paint used in shop coat.
All coupling mullions, transoms, frame, etc. in contact with adjacent
steel and other members, shall be well bedded in mastic. The
Contractor shall bring to the site the mastic cement in original
sealed containers of manufacturer and shall apply it as per the
instructions.
Door shutters, partitions, hardware fixtures, etc. shall be fixed only
after major equipment has been installed in rooms.
Wherever required, nylon cords of approved quality shall be
supplied along with pivoted sashes and shall be of adequate length
to terminate one metre from the floor. Loose ends of cords shall
and in metal or plastic pull as approved by the Engineer-in-charge.

2.5.14.5.1 For Fabricated Items
a) Overall dimensions shall be within + 1.5 mm of the size.
b) Mullions, transoms, etc. shall be in one length and
permissible deviations from straightness shall be limited to
1.5 mm from the axis of the member.
c) Door and window shutters shall operate without jamming.
The clearance at head and jamb for door shutters shall not
be more than 1.5 mm.
d) Door leaves shall be undercut where shown on drawings.
e) Doors, windows, frames, etc. shall be on a true plan, free
from warp or buckle.
f) All welds shall be dressed flush on exposed and contact
surfaces.
g) Correctness of location and smoothness of operations of all
shop installed hardware and fixtures.
h) Provision for hardware and fixtures to be installed at site.
i) Glazing beads shall be cut with mitred corners.
j) Glazing clips, fixing devices, etc. shall be supplied in
adequate numbers.
k) Shop coats shall be properly applied.
2.7.11.5.2 For Installed Items
Installations shall be at correct location, elevation and in general,
on a true vertical plane.
a) Fixing details shall be strictly as shown on drawings.
b) Assembly of composite units shall be strictly as per drawings

with mastic caulking at transoms and mullions, gaskets,
weather strips, etc. complete.
c) All frames on external walls shall be mastic caulked to
prevent leakage through joint between frames and masonry.
d) All open-able sections shall operate smoothly without
jamming.
e) Locks, fasteners etc. shall engage positively. Keys shall be
non-interchangeable.
f) Cutting to concrete or masonry shall be made good and all
abrasions to shop paint shall be touched up with paint of
same quality as shop paint.
2.5.14.5.3 Information to be submitted
a) Before starting fabrication of all metal doors, windows,
etc. the Contractor shall submit detailed fabrication
drawings to the Engineer-in-charge for approval. The
fabrication shall be started only after approval of
drawings.
b) The Contractor shall submit a programme of work to be
done for the approval of the Engineer-in-charge.
c) Before bulk supply, the Contractor shall submit for the
approval of the Engineer-in-charge samples of all bought
out items and samples of each type of fabricated item.
The samples shall be retained by the Engineer-in-charge
for comparison with bulk supply.

Following are some of the important I.S codes relevant to this
section.
I.S 1038 - Steel doors, windows and ventilators.
I.S 1081 - Code of practice for fixing and glazing of metal (Steel
and aluminium) doors, windows and ventilators.
I.S 1361 - Steel windows for industrial buildings.
I.S 4351 - Steel door frames.
IS 1948 (1961) Specification for aluminium doors, windows and
ventilator.
2.5.15.0 TECHNICAL SPECIFICATION FOR GLASS AND GLAZING:
2.5.15.1 Scope:
The work in general shall consist of supplying and fixing all glass
and glazing including all clips putty, mastic cement etc. wherever
required as shown on drawings and specification.
2.5.15.2 General:
The Contractor shall supply and install all glass and glazing as
required for various doors, windows, sashes, ventilators and fixed
louvers, miscellaneous glazing and partitions, unless otherwise
stated in the drawings or schedule. All glass shall be of superior
quality from approved manufacturer, having uniform refractive
index and free from flaws, specks and bubbles. The glass shall be
brought to site in the original packing from the manufacturer and
cut to size at site. The cut edges shall be straight and free from
chips, spalls or any other damages.
2.5.15.3 Materials:
a) Glare reducing or heat absorbing glass shall be approved
quality and special care shall be taken to grind smooth and
round off the edges before fixing.
b) Clear glass shall be flat drawn sheet glass and shall be at
least 4 mm thick. Sheet glass for doors shall be minimum
5.5 mm thick.
c) Wired glass shall be thick rolled glass with centrally
embedded 24G wire mesh or Georgian type. This may be or
clear or coloured glass, as shown in drawings or schedules.
d) Obscure glass shall have a cast surface on one side.
e) Coloured and figured glass shall be as per approved
sample.
f) The general, the putty shall conform to I.S 419 and be of
best quality from approved manufacturer. It shall be brought
to site in the manufacturer's original packing. Quick setting
putty shall be used for windows and sashes except when
glare-reducing glass is used where it shall be of non-setting
type.
g) Neoprene gaskets with snap fit glazing beds shall be fixed
as per manufacturer's instructions and shall sit snugly
against glass to give a leak proof installation.
2.5.15.4 Glazing, Setting and Finish:
All glazing clips, bolts, nuts, putty, mastic cement, etc. as required
shall be supplied by the Contractor.
All glass shall be thoroughly cleaned before putting in position.
Each glass panel shall be held in place by special glazing clips of
approved type. As specified in relevant IS Codes, four glazing clips
shall be provided per glass panel, except for large panels where six
or more clips shall be used as per Engineer-in-charges instructions.
All holes that may be necessary for holding the clips, glazing beads
and all other attachments shall be drilled by the Contractor.
Glass panes shall be set without springing, and shall be bedded in
putty and back puttied, except where mouldings or gaskets are
specified. Putty, mastic cement etc. shall be smoothly finished to a
true even line. Obscure and figured glass shall be set with smooth
side out.
After completion of glazing work, the Contractor shall remove all dirt
stains, excess putty etc, clean the glass panes and leave the work
in perfectly acceptable condition. All broken cracked or damaged
glass shall be replaced by new ones at the Contractor's own cost.

a) All installations shall be free from cracked, broken or
damaged glass, edges, of large panes of thicker glass and
heat absorbing glass shall be inspected carefully for
chipped, cracked or un-ground edges.
b) Glazing shall be carefully done to avoid direct contact with
metal frames.
c) All glass shall be embedded in mastic or fixed by neoprene
gaskets to give a leak proof installation.
d) At completion, the panes shall be free from dirt, stains,
excess putty etc, to the complete satisfaction of the
Engineer-in-charge.

Following are some of the important I.S Codes relevant to this
section:
I.S 1081 Code of practice for fixing and glazing metal doors,
windows and ventilators.
I.S 3548 - Code of practice for glazing in building.
2.5.16.0 TECHNICAL SPECIFICATION FOR ROLLING STEEL SHUTTERS/

GRILLS:
2.5.16.1 Scope:
This specification covers the design, supply of materials,
fabrications, delivery and erection of rolling shutter/grills with mortar
drives and/or manual operation including all accessories as herein.
All electrical works will be as per Indian Electricity Rules.
2.5.16.2 Components:
a) Slats for rolling shutters shall be made from tested bright cold
rolled, annealed MS strips, not less than 0.9 mm thick for
shutters up to 3.5 m wide and not less than 1.25 mm thick for
shutters 3.5 m wide and above, machine rolled at 755 mm
rolling centres, interlocking with each other. The profile will be
such as to prevent excessive deflection under specified wind
load.
b) Rolling grills shall be constructed out of 6 mm diameter rods at
35 mm on centres running horizontally flexibly connected with
vertical links spaced not more than 200 mm centres.
Alternatively, rolling grills shall be made from perforated slats of
approved design reinforced with 6mm diameter rods.
c) End looks shall be heavy type MCI/CI and shall be provided at
each end of alternate slate unless specified otherwise in the
schedule.
d) Bottom bars shall be finished with two angles not less than 6
mm thick for external shutters. A flexible contact leather strip
shall be applied to make tight contact with the floor.
e) Guides shall be of such depth as to retain the shutter under a
wind pressure of 150/sq.m or as specified in schedules.
f) Shaft shall be of steel pipe of sufficient size to carry the torsion
load with a maximum deflection of 1/360th of span. Grease
packed ball bearings or bushings shall be provided for smooth
trouble free operation.
g) Hoods shall be formed of not less than 20 gauge steel, suitably
reinforced to prevent sag.
h) Locks shall be slide bolt and hasp, or cylinder lock operable
from one or both sides. Provision to securing hand chain with
pad lock. Provision for removable handle for hand cranks, etc.
shall be made as described in schedule or as desired by the
Engineer-in-charge.
i) Power unit shall be suitable for 3 phases, 50 Hz, 415 volt AC
power supply and shall be either floor or wall mounted unit. The
motor shall be of sufficient capacity to move the shutters in
either direction at a speed of 0.3 m/s. In addition to the drive
unit (motor, Gear box, coupling) each standard power unit shall
include an electro-magnetic brake, a reversing starter with built

in overload protection, a limit switch and one push button
station located inside the building unless otherwise stated in
schedule or drawing.
The bottom bar of motor operated doors shall be provided with
a sensitive edge, electrically connected to stop the travel of the
door on meeting an obstruction.
j) Operating chains shall be of tested quality, heavily galvanised
and with all ends rounded to assure smooth operation and hand
protection.
k) Reduction gears shall be high strength grey cast-iron, machine
moulded from machine cut patterns.
2.5.16.3 Manually Operated Shutters/Grills:

Manually operated shutters shall be easily operable by one person.
The speed of operation shall be about 0.3 m/s. In general,
manually operated shutters shall be push pull type for openings up
to 9 m2 in area. Larger shutters shall be either chain/gear operated
or crank and gear operated. The crank handles shall be
removable. All shutters shall be lockable from one or both sides as
described in schedule or as desired by the Engineer-in-charge.
2.5.16.4 Power Operated Shutters/Grills:
These shall be operable from a push button conveniently located
beside the door or as shown on drawings. One emergency hand
chain/crank operation shall also be provided for use in case of
failure of the electrical system. Where called for in schedule,
externally mounted shutters shall be operated by control
mechanism located inside the building.
2.5.16.5 Shop Paint:
Shutters shall be painted with one coat of red lead or zinc chromate
primer. Where specified, doors shall be galvanised and
subsequently painted one coat of zinc chromate for adhesion of
field coat.
2.5.16.6.1 Shop Inspection
After completing the manufacture of the different components of the
rolling shutter, an arrangement for shop inspection by the Engineer-
in-charge shall be made to check the conformity with approved
shop drawings.
2.5.16.6.2 Field Inspection
After installing the shutters, the Contractor shall test the
performance of the shutter in the presence of the Engineer-in-
charge. The doors shall be smoothly operable under all ambient
conditions. All control and locking devices shall give fault free
performance.
2.5.16.6.3 Guarantee
The Contractor shall give one year's guarantee for the successful
operation of the shutters. This shall be supported by a separate
and unilateral guarantee from the manufacturer of the shutters.

I.S 6248 - Metal rolling shutters and rolling grills.
2.5.17.0 TECHNICAL SPECIFICATION FOR SUSPENDED CEILING:
2.5.17.1 Scope:
The work under this section shall include the supply and installation
of suspended ceiling using insulation/acoustic boards, plaster of
Paris boards, 'Perspex' etc. together with the suspension system as
shown on drawing or specified in Schedule with all materials labour
and equipment. The work shall also include providing of openings
in the ceiling for lighting, air conditioning diffusers etc, as shown on
drawings or instructed by the Engineer-in-charge.
Proprietary systems shall be installed in accordance with the
manufacturers instructions
2.5.17.2 Suspension System:
2.5.17.2.1 General
Suspension system shall consist of the grid supporting the ceiling
panels, intermediate runner supports for the grid if any and
hangers, wall angles etc. required to suspend the grid or the
runners from structural walls, slabs and beams or trusses.
All members of the suspension system shall be of sufficient
strength and rigidly to carry the ceiling boards or sheet in a true and
level plane without exceeding a deflection of 1/360th of their span.
All joints in ceiling panels shall run straight and cross joint shall be
at perfect right angles. Angle moulds where shown on drawings
shall be securely fixed to walls. All drillings of structural concrete or
welding to steel for installation of the suspension system shall be
included in the scope. All M.S sections used for supports, etc. shall
be given one coat of synthetic enamel paint over a coat of red lead
primer. All wood supports shall be painted with two coats of
'Solignum' or other approved wood preservatives before erection.
2.5.17.2.2 Metal Grid Suspension System
Aluminium grid ceiling system shall be of approved manufacturer.
Steel ceiling system shall also be jolly snap grid of approved
quality.
Angle cleats or other suitable fixing device shall be fixed to the
structural beam or slab above for fixing of hangers. Main runners
shall be hung by MS flats, angles or 12G or heavier galvanised tie
wire hangers at maximum 1.2 m centres. Extra hangers shall be
provided at light fixtures that are supported from the ceiling system.
The spacing of main and cross runners shall be shown on
drawings.
The cross tees shall intersect main runners in pattern shown on
drawing and positively locked together with intersection clips. All
perimeter areas shall have angle mouldings fixed to vertical wall
surfaces and end tees shall rest on the moulding, unless otherwise
shown on drawing.
2.5.17.2.3 Timber Grid Suspension System

Unless otherwise shown in drawings, the suspension system shall
consist of 50 mm x 50 mm pre-treated teakwood batten grid
suspended in the same manner described for metal grid system.
The spacing of timber battens shall be as shown on drawing. Extra
battens shall be provided where necessary for openings for light
fixtures, AC grills, etc.
2.5.17.3 Ceiling Panels:
Ceiling panels shall be best quality material in thickness and
properties as called for in the "Schedule of Items". The Contractor
shall submit test certificates to the Engineer-in-charge for approval
before bulk supply. The ceiling panels may be of the following
types:
a) Plaster of Paris boards
b) Expanded polystyrene insulation boards
c) Fibre insulation boards
d) Wood particle boards
e) Glass fibre reinforced polystyrene sheets
f) Flat asbestos sheets.
Acrylic plastic sheets, translucent or figured glass sheets, moulded
plastic louvers, etc. shall be from approved manufactures and in
thickness specified in schedule.
2.5.17.3.2 Installation of Ceiling Panels
Installation of ceiling panels shall be strictly as per manufacturer's
instruction.
For exposed grid ceiling system, tile hold down clips shall be used
at the rate of minimum one per 1.2 metre length of perimeter.
These shall however be omitted in access panels which shall be
located as per the instruction of the Engineer-in-charge.
For concealed grid ceiling system, tiles shall be fixed to the
supporting grid in manner shown on drawing or as specified by the
manufacturer. Where V joints in tiles are called for in drawings,
these shall be in true lines, where flush surface is required, and
joints shall be filled with approved filler material and finished to give
a neat uniform surface. Where shown on drawings and schedule of
items, 6 mm thick cement: lime: Sand (Prop 1:1/2:3) or cement:
Sand (1:3) plaster shall be applied on the under surface or ceiling
boards and finished in a true and even surface without undulations
suitable for subsequent painting. Special care shall be taken to
neatly finish the ceiling at junctions with walls, light fixtures diffusers
etc.

Finished ceiling shall be at the correct place and present a pleasing
and uniform appearance, free from sags, warps, disfigured or
damaged boards. Joints, exposed grids, etc. shall be in true lines
and symmetrically placed in manner shown on drawings. Cut-outs
for light fixtures, diffusers etc. shall be of exact dimensions and in
exact locations.
I.S 2441 - Code of practice for fixing ceiling coverings.
2.5.18.0 TECHNICAL SPECIFICATION FOR ROOF WATER PROOFING,

INSULATION AND ALLIED WORKS:
2.5.18.1 Scope:
This specification covers providing, laying, repairing, finishing,
curing, testing, protection, maintenance till handling over of roof
water proofing, insulation and allied works for buildings and at
locations covered under the scope of the Contractor.
2.5.18.2 Preparation:
2.5.18.2.1 Grading Underbed
The surface to receive the underbed shall be roughened and
thoroughly cleaned with wire brush and water. The joints in case of
pre-cast planks used for roofing shall be thoroughly filled in with 1:2
cement mortar using 'Impermo' or approved water proofing
compound. Oil patches if any shall be removed with detergent. The
surface shall be soaked with water and all excess water removed
just before laying of the underbed.
The underbed shall not be laid under direct hot sun and shall be
kept in shade immediately after laying so as to avoid quick loss
surface water. The underbed shall be cured under water for at least
7 days.
The underbed shall be laid to provide an ultimate run off gradient
not less than 1 in 120 and as directed by the Engineer-in-charge.
Up to an average thickness of 25 mm the underbed shall usually be
composed of cement and sand plaster. For higher thickness the
underbed shall be made with cement concrete.
The underbed shall be finished to receive the waterproofing
treatment direct or insulation as the case may be.
The grading plaster shall be average 25 mm thick maximum. It
shall consist of cement and coarse sand in the ratio 1:4 nominal by
volume. The sand and cement shall be thoroughly mixed dry and
then water added. Each batch of mix shall be consumed before the
initial set starts.
The plaster shall be fully compacted to the desired grade in
continuous operation. The surface shall be even and reasonably
smooth.
Concrete shall be used where the sub grade is more than average
25 mm thick. It shall consist of cement concrete 1:2:4 nominal mix
by volume with 12 mm down stone chips and coarse sand. The
aggregate shall be mixed dry and minimum quantity of water shall
be added to make the mix workable.
The mix shall be laid to proper grade, fully consolidated and
surface shall be smooth and even.
2.5.18.2.2 Insulation
Where roof insulation is required, detailed proposals for its type,
supply and installation shall be submitted to the Engineer-in-charge
for approval.
2.5.18.2.3 Fillets
Fillets at junction of roofs and vertical walls shall be provided with
the same insulating material as provided for the main roof
insulation. The fillets shall be 150 mm x 150 mm in size unless
otherwise shown on drawings or instructed by the Engineer-in-
charge.
Where there is no insulation over roof slab, fillets shall be cast in
situ cement concrete (1:2:4) nominal mix by volume.
2.5.18.3.1 Chemical Impregnation Water proofing External
i) Treatment
The treatment of water proofing basements and underground
structures comprises of forming a base around the structure by
creating an impermeable layer of chemical grout between the RCC
structure and adjoining strata resisting water infiltration.
The process comprises of laying an impermeable layer of chemical
grout horizontally between the base concrete bedding and the RCC
structure and is continued and carried along the outer surface of
the vertical walls up to a height of 300 mm above the adjoining
ground level. This water proofing shall be carried out in operations
as below.
1st course of cement mixed with chemical CH-9 shall be applied.
2nd course of 25 mm thick cement mortar 1:3 (1 cement: 3 coarse
sand) mixed with chemical CH-9.
3rd course of 25 mm to 35 mm thick red sandstone with joints
sealed with neat cement mixed with chemical CH-9.
4th and final course shall be of cement plaster 1:4 (1 cement: 4
coarse sand) on top of red sand stone mixed with chemical CH-9
with 12 cm gauge stone grit embedded in plaster. Similar process
shall be adopted for vertical faces.
ii) Measurement
Measurement shall be in square metre of the net actual surface
area grouted. The length and breadth shall be measured correct at
a cm.
iii) Guarantee
The Contractor through the specialised agency of sub-Contractor
shall give a guarantee against any leakage for a period of 10 years.
Any leakage or defect during this period shall be made good by the
Contractor at his own cost in a manner to be decided by the

Engineer-in-charge.
2.5.18.3.2 Water proofing with felt lining
i) Bitumen felt type 3 grade I waterproofing (4 layers finished with
asphalt/crushed stone chips and/or gravel.
a) A layer of special roofing asphalt at 1.45 kg/m2.
b) A layer of bitumen felt Hessian based self-finished felt
type 3 Grade-I, of approved make.
c) A layer of special roofing asphalt at 1.45 kg/m2.
d) A layer of crushed pea size stone chips and/or gravel.
ii) Bitumen felt type-3, grade-I, waterproofing (3 layers) with surface
painted with asphalt and finished with brick tiles.
a) A layer of special roofing asphalt at 1.45 kg/m2.
b) A layer of bitumen felt Hessian based self-finished felt
type 3 grade-I, of approved make.
c) A layer of special roofing asphalt base at 1.45 kg.
2.5.18.3.3 Damp Course Lining for Basements, Water Tanks and Foundations
i) A layer of BRC Primer @ 0.2 litres per m2.

a) A layer of hot air blown asphalt @ 1.6 kg/m2.
b) A layer of bitumen-felt fibre based self-finished felt
type-2 grade-2 weighing 82 1bs. per 108 sq.ft. of
approved make.
c) A layer of hot air blown asphalt @ 1.6 kg/m2.
ii) Damp coursing specifications (8 layer) consisting:
a) A layer of BRC Primer 0.25 litres per m2.
b) A layer of hot air blown asphalt @ 1.6 kg/m2.
c) A layer of bitumen felt Hessian based self-finished felt
type-2 grade-2 of approved make.
d) A layer of hot air blown asphalt @ 1.6 kg/m2.
e) A layer of bitumen felt Hessian based self-finished felt
type-2 grade-2 of approved make.
f) A layer of hot air blown asphalt at 1.6 kg/m2.
g) A layer of bitumen felt Hessian based self-finished felt
type-2, grade-2, of approved make.
h) A layer of hot air blown asphalt @ 1.6 kg/m2.
iii) NOTES:
a) Roofs
After specifications at 2.5.18.3.3 (item ii) has been laid, it will
be protected with tiles and every care is to be taken while
laying the brick or stone tiles so that the waterproofing is not
damaged or punctured by the sharp edged implements or
bricks, stone or walking over it with some shoes having nails
etc.
b) Basements
This waterproofing is laid on the floors and taken up on the
vertical walls 30 cm. above the ground level where a chase
50 mm wide and 50 mm deep is cut and the fabric tucked in.
After the water proofing is laid on the floors it will be
necessary to protect the same with RCC or cement concrete
thickness of which will depend on the hydrostatic pressure of
sub soil water and on the verticals by cladding wall with brick
or stone masonry. Prior to the laying of RCC or cement
concrete on floors a layer of bricks or stone is to be laid on
waterproofing (so that the fabric is not damaged by the sharp
edges of the ballast etc.) comprising:
- A layer of Bitumen felt fibre based self-finished felt type-2
grade of approved make.
- A layer of hot air blown asphalt @ 1.6 kg/m2.
c) General Conditions
The rates quoted shall include the cost of materials, labour
and all charges complete at the site of work, and for any
preparation civil work found necessary prior, during or after
the execution of the work which will have to be carried out,
and for making the surface reasonably smooth and dry by the
application of cement plaster before applying water proofing
felt as per specifications.
d) Guarantee
The Contractor through the specialised agency of sub-
Contractor shall give a guarantee against any leakage for 10
years. Any leakage or defects during this period shall be
made good by the Contractor through the sub-Contractor at
his own cost in a manner to be decided by the Engineer-in-
charge, to their entire satisfaction.
e) Measurement
As actually laid at site in m2.
2.7.18.3.4 Waterproofing by Guniting Basements, Raft Tanks, Walls, etc.
i) Concrete surface to be gunited shall be cleaned of all loose and

foreign materials. When required the surface shall be hacked
chiselled or sand blasted to make it rough to receive gunite.
ii) Equipment
Only standard guniting equipment shall be used. Compressed air
for the cement gun and the water tank shall be supplied by a
compressor of minimum capacity of 210 ft3/min at 100 lb/in2.
iii) Mix
The mix for guniting shall consist of 1 part cement: 3 parts coarse
sand. The mix shall be a little damp to prevent segregation of sand
and cement during the passage through hosepipe. The water shall
be sufficient for the hydration of cement.
iv) Reinforcement
Reinforcement shall consist of BS, WG, IRC (or equivalent) wire at
100 mm centres both ways. The mesh shall be anchored through
suitable dowels in the case of vertical surface. For 50 mm thick
gunite shall have one mardh as above. For 75 mm thick gunite
where required shall be done in two operations. Both the base and
top coats shall be provided with welded wire mesh as above.
v) Guniting
Shall be got done through a firm of repute as sub-Contractor to be
approved by the Engineer-in-charge with skilled workers well
trained in the operation of the equipment.
The nozzle shall be held at right angles to the surface. The gunite
surface should neither show dry spots nor bleeds, and shall be
cured properly for a minimum period of 14 days by spreading wet
Hessian cloth over the gunited surface. The curing shall be
commenced after 4 to 5 hours of the guniting operation.
vi) Measurement
The length and breadth of the net area gunited shall be measured
and paid for per square metre.
vii) Guarantee
The Contractor through the specialised agency of sub-Contractor
shall give a guarantee against any leakage for 2 years. Any
leakages or defects during this period shall be made good by the
Contractor through the sub-Contractor at his own cost in a manner
to be decided by the Engineer-in-charge to their entire satisfaction.
2.5.18.3.5 Water proofing Basements, Tanks, Walls, etc. by Using Cement
Water Proofing Compound.
The cement waterproofing compound shall conform to IS

2645(latest edition) and shall be approved by the Engineer-in-
charge. It shall be added to the cement and content of concrete or

mortar @ 3% by weight or as per manufacturers specifications.
The waterproofing treatment with the use of cement water proofing
compound shall be done as follows:
i) By adding water proofing compounds to concrete mix while
concreting pile caps, rafts, walls and retaining walls.
a) During concreting adequate dewatering measures shall be
adopted by the Contractor to keep the excavations and/or
basements dry so that normal setting variety of cement
water proofing compound can be used.
b) If for any reason concreting is to be carried out in or under
water, the quick setting variety of the waterproofing
compound shall be used.
c) Only sufficient quantity of waterproofing compound shall be
mixed as can be used within one hour for normal setting
variety of waterproofing compound.
ii) Plastering the outside of the retaining walls with 12 mm thick

cement plaster 1:3 (1 cement: 3 coarse sand) with an admixture of
waterproofing compound at 3% by weight of cement or as per
manufacturer's specifications.
iii) Plastering the inside of the retaining walls, columns walls etc. 25
mm thick overall in three layers of 12 mm, 6 mm and 6 mm thick
each in cement mortar 1:2 (1 cement: 2 coarse sand) in the 1st two
layers of 12 mm and 6 mm thick. The last 6 mm thick layer shall be
in cement mortar 1:2 (1cement: 2 fine sand). The 1st two layers
shall be left rough in order to receive the subsequent layer to give
adequate key. In all the 3 layers waterproofing compound shall be
added @ 3% by weight of cement or as per manufacturer's
specifications.
iv) Laying 36 to 50 mm thick cement concrete floor over rafts with an
admixture of cement water proofing compound as per
manufacturer's specifications.
v) Guarantee - The Contractor through the specialised agency and
sub-Contractor shall give a guarantee against any leakage for ten
(10) years. Any leakage or defects during this period shall be made
good by the Contractor at his own cost in a manner to be decided
by the Engineer-in-charge to their entire satisfaction.
2.5.18.3.6 Waterproofing Roofs with Expanded Polyethylene KINIFOAM

i) A layer of bituminous primer @ 0.4 kg per m2.
ii) A layer of semi hot asphalt blown grade 85/25 or 90/15 @
1.8 kg per m2.
iii) A layer of 2mm thick expanded Polyethylene, KINIFOAM.
iv) A layer of Neoprene adhesive @ 300 to 350 ml. per m2.

v) A layer of 2 mm thick expanded polyethylene KINIFOAM.
2.5.18.3.7 Insulating and Water Proofing Roof Terraces of Air Conditioned
Areas with Expanded Polyethylene KINIFOAM
i) A layer of bituminous primer @ 0.4 kg/m2.
ii) A layer of semi hot asphalt blown grade 85/25 or 90/15 @
1.8 kg/m2.
iii) A layer of 6mm thick expanded polyethylene KINIFOAM.
iv) A layer of Neoprene adhesive @ 300 to 350 ml/m2.
v) A layer of 6mm thick expanded Polyethylene KINIFOAM.
vi) A layer of Neoprene adhesive @ 300 to 350 ml/m2.
vii) A layer of 6mm thick expanded Polyethylene KINIFOAM.
i) Roof grading concrete laid to slope as specified.
ii) Brick tile/or pre-cast cement tile/or pre-cast Terrazo tile or
china mosaic treatment.
2.5.18.3.8 Protection Treatment in Terraces Solar Heat and Moisture.
China Mosaic 3 layer treatment

Preparation of surface - The final roof terrace after water proofing
shall be smooth finished with cement plaster 1:4 (1 cement: 4 fine
sand) to receive the following treatment.
i) A layer of BRC primer @ 0.2 litre/m2.
ii) A layer of roofing asphalt @ 1.45 kg/m2.
iii) A layer of broken glazed tiles of odd sizes and shape with as
close joints as possible grouted with white cement.
Measurements shall be in square metre correct to two decimal
places. Length and Breadth of actual work done shall be
measured correct to one cm.

The surface level shall be such as to allow quick draining of water
without leaving any pool anywhere. The finishing course shall be
fully secured and shall have an even density. There shall not be
any bubble formation or crushed or squeezed insulation on
underbed.
The Contractor shall give a guarantee in writing for all works
executed under this specification supplemented by a separate and
unilateral guarantee from the specialised agency for the roof water
proofing treatment work. The guarantee shall be for material and
workmanship for five (5) years in case of normal treatment, ten (10)
years for heavy treatment and twenty (20) years for extra heavy
treatment. The mode of execution of the guarantee shall be

acceptable to the Owner.

Important relevant codes applicable to this specification:
I.S 73 - Paving Bitumen.
I.S 702 - Industrial Bitumen.
I.S 1201 to 1220 Method for Testing Tar and Bituminous
Materials.
I.S 1322 - Bitumen felts for water proofing and damp proofing.
I.S 1346 - Code of practice for water proofing of roofs with Bitumen
felts.
2.5.19.0 TECHNICAL SPECIFICATION FOR WATER SUPPLY:
2.5.19.1 Scope:
This section includes supply of all materials, labour and incidentals
for water supply system.
2.5.19.2 Materials:
All materials, fittings, fixtures and appliances shall be of the best
quality conforming to relevant Indian standards and shall be
procured from approved manufacturers. Unless specifically allowed
by the Engineer-in-charge, the Contractor shall submit samples of
fittings and fixtures which will be retained by him for comparison
when bulk supplies are received at the site. Ultimate choice of type,
model and manufacture lies completely with the Engineer-in-
charge.
It shall be the responsibility of the Contractor to procure the
materials selected by the Engineer-in-charge. Hence orders are to
be placed with the manufacturers in time, so that the materials are
available at the site well ahead of their requirement.
The materials brought to the site shall be stored in a separate
secured enclosure away from the building materials. Pipe threaded
sockets, brass and other expensive items shall be kept under lock
and key. Fragile items shall be checked thoroughly when received
at the site and items found damaged shall not be retained at the
site.
2.5.19.2.1 Pipes and Pipe Fittings
Under scope of this specification, pipes and pipe fittings may be of
any or a combination of the following type:
a) Cast iron
b) Steel lined, coated with bituminous composition out
coated with cement concrete or mortar or galvanised.
c) Reinforced concrete
d) Pre-stressed concrete
e) Asbestos cement
f) Lead (Not to be used for potable water)
g) PVC
h) Copper
i) Brass
j) Wrought iron
2.5.19.2.2 Water Reservoirs

Water reservoirs like pressed steel tanks and GI tanks shall come
under scope of this specification. Reservoirs made of concrete
masonry or fabricated steel shall be covered by respective work
specifications.
2.5.19.2.3 Related works
All works, like earth work, masonry, concrete, steel work, cutting
holes, chases, repairs and rectifications associated directly with
installation of water supply systems shall come under scope of the
Contractor unless specifically excluded. These works are not
detailed out in this specification.
2.5.19.2.4 Regulations
The work which is required to be carried out under the scope of this
section shall only be executed by a licensed plumber engaged by
the Contractor and he shall obtain all necessary sanctions,
permission, certificates etc. from Municipal and or other local
authorities and shall abide by all the rules of such authorities.
While basic layouts may be available in the drawings provided by
the Owner, the details might have to be supplemented by the
Contractor for approval of the Engineer-in-charge.
Special attention shall be given by the Contractor to economy.
Symmetry layout is very important. Fittings meant for operation
shall be located and oriented to allow easy reach and operation.
Maintenance, repairs and replacements of pipes, fittings and
fixtures must be conveniently possible.
2.5.19.3.1 Pipe Lines
i) Laying
In addition to fulfilling the functional requirements all pipelines shall
be laid true to line, plumb and level. Any deviation shall need
approval of the Engineer-in-charge. Meticulous care shall be taken
to avoid chances of airlock and water hammer.
Pipes shall be laid on continuous unyielding surface or on reliable
supports at least one near each joint and spacing as directed by
the Engineer-in-charge. The support must be strong, neat and shall
have provisions for securing the pipes in every direction and easy
maintenance. Pipes shall be encased or concealed in masonry or
concrete if shown on drawing or directed by the Engineer-in-
charge.
ii) Back Flow
The layout of pipe work shall be such that there is no possibility of
backflow towards the source of supply from any cistern of
appliances, whether by siphonage or otherwise. All pipe works shall
be so laid or fixed and maintained as to be and to remain
completely watertight, thereby avoiding waste of water, damage to

property and the risk of contamination of the water conveyed.
iii) Contamination
There shall be no cross connection whatsoever between a pipe or
fitting for conveying or containing wholesome water and a pipe or
fitting for containing impure water or water liable to contamination
or of uncertain quality or water which has been used for any
purpose.
No piping shall be laid or fixed so as to pass into or through any
sewer, scour outlet or drain or any manhole connected therewith.
iv) Underground Piping
Underground piping shall be laid at such a depth that it is not likely
to be damaged by traffic and other loads and frost, where
applicable.
The size and depth of the trench shall be as approved by the
Engineer-in-charge. Backfilling be done with selected fine earth,
unless otherwise permitted, in 150 mm layers and carefully
consolidated. Special care shall be taken while filling in the vicinity
of the pipe to avoid damages. Before backfilling the laid pipe shall
be fully tested and approved.
Where the pipe rests on rock it may be bedded on a layer of fine
selected material or concrete to avoid local point support.
If the pipeline (except GI pipelines) is required to be laid in black
cotton soil it shall be ensured that the pipe is encased 200 mm in
sides and 300 mm minimum on top and bottom with sand before
the rest of the trench is backfilled with selected earth.
The trench shall be so treated by gradient and filling in the area that
it does not act as a drainage channel.
v) Concealed Piping
Where desired by the Engineer-in-charge or shown on the
drawings the pipes shall be concealed in masonry or concrete of
the structure. The Contractor may coordinate with the building
Contractor for leaving the chases, openings, conduits as
necessary. However, the Contractor will rectify if required the
chases, openings and conduits, supplement and make good after
laying and testing if the concealed pipelines.
2.5.19.3.2 Jointing of pipes
Jointing of pipes shall be completely leak proof and durable.
Instruction of the manufacturer shall be followed unless desired
otherwise by the Engineer-in-charge. However, usually
recommended practices are stated below for guidance:
i) Cast Iron
a) Spigot and Socket Joints
Lead Joint: The joint is made by first caulking in clean spun
yarn up to half depth and filling the remainder by running in
molten lead taking care that no drops enters the joint and
then thoroughly caulking the lead. The lead need not extend
into the joint further than the back of the groove formed in the
socket. After completing the joint it shall not be allowed to
move. For rectification the joint shall be completely redone.
b) Flanged Joints
Flanged joints shall be made by jointing rings of good quality,
smooth and hard compressed fibre board of thickness not
less 1.5 mm and of such width as to fit inside the circle of
bolt. Diagonally opposite bolts shall be tightened in pairs and
in stages so that degree of all bolts in a joint is similar.
Damaged gaskets shall be replaced.
ii) Steel
Plain-ended steel pipes may be jointed by welding. Screwed and
socket joints shall be carefully tightened. Care shall be taken to
remove any burr from the ends of the pipes. Jointing compound, if
used, shall be lead free and approved by the Engineer-in-charge.
iii) GI Pipes
Threads shall be cut with sharp tools, and before jointing all scales
shall be removed from pipes by suitable means. The screw
threads of the pipe shall be cleaned out and the joint made by
screwing the fittings after treating the threads with approved pipe
jointing compound. Once a joint has been screwed up it shall not
be backed off unless the threads are re-cleaned and new
compound applied.
iv) Asbestos Cement Pipes
Socket and spigot ended pipes shall be jointed by caulking with
tarred gasket and grouted with 1:3 cement sand mortar.
v) Lead
Lead and lead alloy pipes shall be jointed with wiped solder joints.
vi) Concrete
Concrete pipes may be socket and spigot ended, collar or band
jointed. Jointing shall be effected by caulking with 1:3 cement sand
mortar.
vii) PVC
Manufacturer's instruction shall be followed. For beating approved
equipment with adequate control shall be used.
viii) Tyten joints

Manufacturer's instruction shall be strictly followed in marking such
joints. Tyten joints shall be made by push on type 'Tyten' rubber
gasket and such rubber gasket shall conform to the specification
stipulated by the pipe manufacturer. The tools specified by the pipe
manufacturer shall be used to secure the joint fully.
2.5.19.3.3 Painting
Where mentioned in the Schedule, underground steel and cast iron
pipes shall be given 2 coats of bituminous paint on the outside after
laying, when painting is to be done above ground GI pipes shall be
given a coat of zinc chromate primer. GI and MS pipes shall be
given one coat of best quality paint.
2.5.19.3.4 Storage Tanks and Fittings
i) Polyethylene Water Storage Tanks

a) Material
Polyethylene used for manufacture of tanks and manhole lids may
be high density (HDPE), low density (LDPE) or linear low density
(LLDPE) and shall conform to IS: 10146 (latest edition).
Polyethylene shall be compounded with carbon black so as to
make the tank resistant to ultra violet rays from the sun. The
percentage of carbon black content in Polyethylene shall be 2.5+
0.5% and shall be uniformly distributed. The materials used for the
manufacture of tank, manhole lid and fittings shall be such that they
neither contaminate the water nor impart any test, colour, odour or
toxity to water.
b) Manufacture and finish
The tanks shall be manufactured by rotational moulding process.
Each tank and the manhole lid shall be single piece having
arrangement for fixing and locking the manhole lid with the tanks.
Excess material at the mould parting line and near the top rim shall
be neatly cut and finished. The internal and external surface of the
tanks shall be smooth, clean and free from hidden internal defects
like air bubbles pit and metallic or other foreign material inclusion.
Capacity of tank, minimum weight of the empty tank (without
manhole lid) and the manufacture brand name shall be embossed
on the top surface of the tank near manhole.
c) Shape, Size and Capacity
The tank shall be cylindrical vertical with closed top having a
manhole. Diameter and height of the tank of various capacities
shall be as per manufacturers specification and a clearance of +
3% shall be permitted on these dimensions. Capacity of the tank or
up to the bottom of the inlet location whichever is less. Capacity of
the tank shall be specified. Extra capacity if any shall be ignored.
d) Weight and Wall Thickness

Minimum weight of the empty tank (exclusive of manhole lid fittings)
and the minimum wall thickness of top, bottom and sides shall be
as specified under. Wall thickness shall be checked beyond 150
mm of the edge where the direction of the plane of tank surface
changes.
Dimensions shall be measured to the nearest cm and weight of the
empty tank shall be recorded to the nearest 100g. Capacity of the
tank as defined earlier shall be calculated to the nearest litre.
Sl.No Capacity litres Minimum wall Minimum
weight
Thickness (mm) of empty
tank (Kg)
1 2000 8.2 64.0
2 2500 8.2 81.0
3 3000 8.8 96.0
4 4000 10.4 138.0
5 5000 10.7 191.0
6 6000 10.7 209.0
7 7500 10.7 250.0
8 10000 11.5 363.0
9 15000 11.5 550.0
10 20000 13.2 814.0
e) Installation and Fitting
The flat base of the tank shall be fully supported over its whole
bottom area on a durable rigid flat and level platform sufficiently
strong to stand without deflection the weight of the tank when fully
filled with water. Depending upon the capacity and location tanks
may be suitably anchored as per the directions of the Engineer-in-
charge. For inlet, outlet and other connections fully threaded GL,
HDPE or PVC connections with hexagonal check nuts and
washers on either side of the tank wall shall be provided. Holes for
threaded connections shall be drilled and not punched. Pipes
entering or leaving the tank shall be provided with unions and
suitably supported on a firm base to avoid damage to the tank
walls.
e) Manhole lid
The lid shall rest evenly and fit over the rim of the manhole so as to
prevent the ingression of any foreign matter into the tank. The lid
shall be provided with suitable arrangement for locking it with the
tank. The tank and its components shall conform to the local bye-
laws for prevention of mosquito menace.
ii) Valve, Cocks, Bib Taps

All valves, stop cocks, taps etc, shall conform to relevant Indian
standard specifications and shall be of best quality from approved
manufacturers. These shall be suitable for working pressures
mentioned in approved schedule. Nominal size and material shall
be as per approved schedule.
iii) Protection
Open end of each pipe shall be protected during installation by
suitable covers or plugs so that the ends, threads, socket or spigot
are not damaged and no foreign material can find its way into the
pipeline.
Fittings and fixtures liable to be misused or stolen during the
construction phase shall be fitted only before testing and handing
over.
2.5.19.4 Testing and Acceptance:
2.5.19.4.1 Inspection before Installation
All pipes, fittings and appliances shall be inspected, before delivery
at the site to see whether they conform to accepted standards. The
pipes and fittings shall be inspected on site before laying and shall
be sounded to disclose cracks. Any defective items shall be clearly
marked as rejected and forthwith removed from the site.
2.5.19.4.2 Testing of Mains after Laying
After laying and jointing, the main shall be slowly and carefully
charged with water, so that all air is expelled from the main by
providing a 25 mm inlet with a stop cock, allowed to stand full of
water for a few days if time permits, and then tested under
pressure. The test pressure shall be 5 kg/cm or double the
maximum working pressure, whichever is greater. The pressure
shall be applied by means of a manually operated test pump, or in
the case of long mains or mains of a large diameter, by a power
driven test pump, provided that the pump is not left unattended. In
either case due precaution shall be taken to ensure that the
required test pressure is not exceeded. Pressure gauges shall be
accurate and shall preferably have been recalibrated before the
test. The pump having been stopped, the test pressure shall
maintain itself without measurable loss for at least five minutes. The
end of the main shall be closed by fitting a water tight expanding
plug and the plug shall be secured by struts to resist the end thrust
of the water pressure in the mains.
2.5.19.4.3 Testing of service pipes and fittings

The service pipes shall be slowly and carefully charged with water
allowing all air to escape avoiding all shock or water hammer. The
service pipe shall then be inspected under working conditions of
pressure and flow. When all draw off taps are closed the service
pipes shall be absolutely watertight. All piping, fittings and
appliances shall be checked for satisfactory support and protection

from damage, corrosion and frost.
Important relevant I.S Codes for this specification are listed below.
Latest editions shall always be consulted.
I.S 2065 - Code of practice for water supply in buildings.
I.S 1172 - Code of basic requirements for water supply, drainage
and sanitation.
I.S 1200 (Pt. XVI) Method of measurement for Laying of water
and sewer lines including appurtenant items.
I.S 1239 - Specification for Mild steel tubes and steel tubes and
tubular and other Wrought steel pipe fittings (10 mm to 15 mm
nominal diameter).
I.S 1536 - Specification for centrifugally cast (spun) iron pressure
pipes for water gas and sewage.
I.S 1537 - Specification for vertically cast iron pressure pipe for
water, gas and sewage.
I.S 3486 - Specification for cast iron spigot and socket drainpipes
(80 mm to 250 mm nominal diameter).
I.S 458 Pre-cast Concrete pipes (with and without reinforcement).
I.S 783 - Code of practice for laying of concrete pipes.
I.S 1592 - Asbestos cement pressure pipes and joints.
I.S 1626 - Asbestos cement pipes, gutters and fittings (Spigot and
socket types).
I.S 404 - Lead pipes.
I.S 3076 - Low density polyethylene pipes for potable water
supplies.
I.S 4984 - High density polyethylene pipes for potable water
supplies.
I.S 2501 Solid drawn Copper tubes for general Engineering
purposes.
I.S 407 Brass tubes for general Engineering purposes.
I.S 1230 - Cast iron rain water pipes and fittings.
I.S 804 - Rectangular pressed steel tanks.
I.S 3589 - Specification for electrically welded steel pipe for water,
gas and sewage (200 mm to 2000 mm nominal diameter).
I.S 784 Pre-stressed concrete pipes.
2.5.20.0 TECHNICAL SPECIFICATION FOR CARPENTRY & JOINERY:

2.5.20.1 Scope:
This shall include supply, fittings and fixing of timber frames to
doors and windows with MS holdfasts, panelled or flush doors,
windows, shutters, partitions wall panelling, shelves, furniture, etc.
as shown in drawings, including a prime coat of approved paint,
varnish, or fixing of plastic laminate where called for in the
schedule. This shall also include the supply and fixing of all
hardware and fixtures shown in approved drawings.
2.5.20.2 Installations:
i) Timber
Unless otherwise specified, all timber shall be best quality well-
seasoned CP teakwood free from large or loose knots cracks or
other defects. Where specified, timber shall be treated with
approved wood preservative before use. Before starting the
carpenters work, the Contractor shall have the rough timber
approved by the Engineer-in-charge.
ii) Plywood
Plywood shall be commercial quality or with decorative surface
veneer. Unless specifically permitted otherwise the adhesive used
in plywood shall be phenol formaldehyde resin of BWR grade
conforming to I.S 848(latest edition).
iii) Laminated Plastic Sheets
The colour, pattern, finish and textures shall be approved by the
Engineer-in-charge and the bulk supply procured in sheet sizes
which will ensure the least number of joints in one surface.
iv) Flush Doors
Flush doors shall be solid core doors with commercial or decorative
faces and hardwood edges.
The core for solid core doors shall be of black board or wood
particle board. Manufacturer's literature and test certificates shall
be submitted for the approval of the Engineer-in-charge. The
contractor shall give a guarantee that the adhesive used is phenol
formaldehyde of BWR grade, conforming to I.S 848(latest edition).
The thickness shall be as per approved drawings.
v) Fixtures:
Fixtures for doors, windows, furniture, etc. shall be as given below:
Schedule of hardware fittings unless otherwise specified shall be as
given below:
a) Single leaf door shutters
i) 100mm long butt hinges 3 Nos.
ii) Approved mortice lock (6 lever) or sliding door bolt 1 No
300 x 16 mm
iii) 300 mm long tower bolt with 12 mm shoot 1 No
iv) 150 mm long tower bolt with 12 mm shoot 1 No

v) 125 mm handles 2 Nos.
vi) Floor stopper 1 No
vii) Rubber buffer 1 No
b) Double leaf door shutters

i) 100 mm long butt hinges per leaf 3 Nos.
ii) Approved mortice lock (6 lever) or sliding door bolt 2 Nos.
300 x 16 mm
iii) 300 mm long tower bolt with 12 mm shoot 2 Nos.
iv) 150 mm long tower bolt with 12 mm shoot 1 No
v) 125 mm handles 4 Nos.
vi) Floor stopper 2 Nos.
vii) Rubber buffer 2 Nos.
c) Bathroom door
i) 100 mm long butt hinges 3 Nos.
ii) 200 mm long tower bolt with 12 mm shoot 1 No
iii) Approved latch with a pair of handles 1 No
d) Single leaf window shutter
i) 100 mm long butt hinges 2 Nos.

ii) 150 mm long tower bolt with 12 mm shoot 1
No
iii) 100 mm long tower bolt with 12 mm shoot 1
No
iv) 100 mm handle 1
No
v) Hook & eye 200 mm long 1
No
e) Double leaf window shutter
i) 100 mm long butt hinges for one leaf 2 Nos.
ii) 150 mm long tower bolts with 12 mm shoot 2 Nos.
iii) 100 mm long tower bolts with 12 mm shoot 1 No
iv) 100 mm handle 2 Nos.
v) Hook and eye 200 mm long 2 Nos.
f) Holdfasts
i) Door 6 Nos.
ii) Window 4 Nos.
iii) Ventilator 2 Nos.
vi) Schedule of hardware fittings:

a) General:
The fittings shall be of iron, brass, and aluminium or as specified.
These shall be well made, smooth and free from sharp edges, flaws
and other defects, screw holes shall be counter sunk to suit the head
of the wood screws. All hinge pins shall be of steel with riveted heads.
- From fittings shall be bright finished or black enamelled or copper
oxidised.
- Brass fittings shall be bright finished brass, oxidised, or chromium
plated.
- Aluminium fittings shall be bright, finished anodised in choice shade or
as specified.
The screw used shall be of the same metal and finished as the fittings
and shall be of the required size. For aluminium fittings anodised steel
screws shall be used. The screw shall be driven with a screwdriver
and not hammered.
b) Butt Hinges:
Hinges shall be heavy quality of mild steel, brass, brass oxidised
aluminium or as specified. Butt hinges shall be cranked.
Brass and steel butt hinges shall conform to I.S 205(latest edition).
MS butt hinges shall be made from sheet; aluminium and brass
hinges shall be extruded type and made from extruded sections
c) Tower Bolts:
Shall be of mild steel, brass oxidised or aluminium as specified:
- Plate and straps shall be riveted the barrel bolt shall be cast including
the knob.
- Brass Tower Bolts: The bolt with knob shall be cast and rolled and
shall be made in one piece.
- Aluminium Tower Bolts: Shall be made out of extruded sections. Knob
shall be screwed to the bolt and riveted at the back.
d) Sliding Door Bolts (Aldrop):
These shall be of metal as specified, and shall have smooth sliding
action. MS and brass sliding bolts shall conform to I.S 281(latest
edition).
Brass sliding bolts shall be made from rolled brass. The hasp and
the bolt shall be in one piece. The fixing and staple bolts shall be
cast 6mm studs and shall be threaded, provided with round
washers and nuts of square of hexagonal shape
e) Handles:
- Iron handles - Shall be of the size specified and shall be made out of
sheet steel pressed into oval section. They shall conform to I.S 208(latest
edition) and shall be fixed with 2.5 cm long screws.
- Brass Handles - Shall of the specified size, shape and pattern made out of
cast brass. They shall conform to I.S 208(latest edition) and shall be fixed
with 2.5 cm long screws.
- Aluminium Handles - Shall be of size specified finished bright or anodised

made out of cast aluminium to shape and pattern required. These shall
be fixed with 2.5cm long screws.
f) Mortice lock:
Mortice lock with latch and a pair of lever handles shall have steel casing
and brass bolts and shall be right or left handles as required. It shall be of
approved make and quality. The lock for single leaf door shall have plain
face and for double leaf a rebated face. The lever handles with spring
shall be mounted on plates and shall be bright brass finished or chromium
plated of oxidised as approved
g) Mortice Latch:
Mortice latch with one dead bolt and a pair of lever handles shall have
steel casing and brass bolt, right or left handed as required. It shall be of
approved make and quality. The latch for single leaf door shall be
mounted on plates and finished brass bright chromium plated or oxidised
as approved
h) Floor Door Stopper:
Shall be of shape, pattern and size specified of cast brass with a rubber
cushion. It shall be brass finished right, chromium plated or oxidised as
approved. The length of the plate shall determine the size of floor
doorstopper
i) Hooks and eyes:
Shall be of mild steel or hard drawn brass and shall conform to IS
207(latest edition). The size of hooks and eyes shall be determined by the
length of hook from out to out
j) Fan light catch:
Shall be of MS or cast brass and shall be brass finished bright, chromium
plated or oxidised approved. Steel spring of the catch shall be capable of
taking a minimum load of 1 kg before it is fully pressed
k) Safety hasp and staple:
Shall be of mild steel or cast brass and shall conform to IS 363(latest
edition). MS hasp and staple shall be finished black, stove enamelled.
Brass hasp and staple shall be right finished or chromium plated or
oxidised as approved. The kingpin in both cases shall be of mild steel
with riveted heads. The chest shall fit the staple correctly. The staple
shall be determined by the length of the bigger leaf of the hasp.
2.5.20.2.2 Workmanship
i) General
The work shall be done by skilled carpenters as per details shown
on drawing or instructed by the Engineer-in-charge.
Framing timber and other work shall be close fitting with proper
wood joinery, accurately set to required lines or levels and rigidly
secured in place. The surface of frame etc. which will come in
contact with masonry after fixing shall be given two coats of

approved paint before fixing. Mastic caulking shall be done after
fixing external door and window frames.
Special care shall be taken to match the grain of timber of plywood
which will be subsequently polished. Screwing or nailing will not be
permitted to the edge of plywood or chipboard sheets. All exposed
plywood edges shall be finished with teakwood lipping unless
otherwise shown on drawings.
Fixing of frames and partitions shall generally be with 40 mm x 6
mm x 300 mm long MS holdfasts bifurcated at end and grouted
with 1:2:4 cement concrete. The gap between masonry and
external door and window frame shall be caulked with mastic. MS
grills or guard bars shall be provided to windows where called for in
the drawings or schedule of items.
ii) Finish
All carpentry work after finishing shall be sand papered smooth. A
prime coat of paint shall be given after inspection of the Engineer-
in-charge to all surfaces other than those which shall be
subsequently polished or covered with laminated plastic sheet.
iii) Surface Treatment
When shown on drawings or called for in Schedule, decorate ply or
laminated plastic sheets shall be bonded under pressure to the
surface to be finished. The adhesive used shall be of approved
brand and brought to site in sealed containers. The rate of
application and the length of time for which the pressure is to be
applied shall be as per the manufacturer's instructions. The edge
of sheets shall be protected by teak lipping or bevelled as shown
on drawings.
2.5.20.3.1 Door and Window frames
All frames shall be square and flat at the time of delivery and shall
be checked for dimensions and corner angles. After fixing they
shall be on a fine vertical plane. All external door and window
frames shall be caulked with mastic.
2.5.20.3.2 Door and Window Shutters
Shall be of proper size, shape and design and free of warp. When
fixed to frames, these shall operate smoothly without jamming and
all latching of locking devices shall engage properly without
pressure.
2.5.20.3.3 Partitions, Paneling, Pelmets, Furniture, etc.
i) General
These shall conform to drawings in all details. No nail marks, etc.
shall be permitted. Plywood grains shall be matched to give a
uniform and pleasing appearance.
ii) Partitions
Partitions shall be checked for rigidly of fixing and plumb.
iii) Pelmets
Pelmets shall be checked for rigidly of fixing and adequate
clearance of fixtures.
iv) Cupboard Shutters
Shutters shall operate smoothly without jamming and locks and
bolts shall engage securely.
v) Drawers
Drawers shall operate smoothly and have back stops to prevent
them from being pushed too far. Locks engage securely.
v) Loose Furniture
Furniture when placed on a level surface tables tops etc. shall be
horizontal and the pieces stand stable on legs or supports.

Some of the important relevant codes for the sections are:
I.S 1003 - Timber panelled and glazed shutter.
I.S 2191 - Wooden flush door shutters (cellular and hollow core
type).
I.S 2202 - Wooden flush door shutters (Solid core type).
I.S 4021 - Timber door, window and ventilator frames.
2.5.21.0 TECHNICAL SPECIFICATION FOR MISCELLANEOUS METALS:
2.5.21.1 Scope:
This shall include supply, fabrication and erection of miscellaneous
metal items of light nature in gates, grills, balcony and stair
handrails, partitions, structural mullions and transoms, ladders,
hangers, monorails, MS inserts, masonry anchors, shelf angles,
anchor bolts, fasteners, etc. as shown on drawing or as instructed
by the Engineer-in-charge. The above items shall be of fabricated
or cast MS section/aluminium/brass, cast iron, MS and galvanised
MS sheets, aluminium sheet, expanded metal, wire mesh etc. as
shown on drawings.
2.5.21.2 Fabrication or Casting:
2.5.21.2.1 General
All work shall be done according to approved shop drawings. All
workmanship shall be equal to the best practice in modern
structural or foundry shop.
2.5.21.2.2 Shop Connections
i) All shop connections shall be riveted or welded except when noted
otherwise on drawings.
ii) Welding of steel shall be done in accordance with the I.S 816
(latest edition) - Use of metal arc welding for general construction in
Mild steel. Welding of aluminium shall be done in accordance with
IS 2812 (latest edition) - Arc welding of Aluminium and Alloys.
Special care shall be taken to grind smooth all welded surfaces that
shall remain exposed to view. Welds shall be electrically
continuous if so required by the Engineer-in-charge.
iii) Shop Coat
Before leaving the shop, all metal work shall be thoroughly cleaned
by effective means of all loose mill scale rust and foreign matter.
Except where encased in concrete, all steel work shall be given
one coat of approved metal protective paint, applied by brush
thoroughly and evenly, applied to dry surface. When specified on
Schedule, steelwork shall be galvanised and painted with a coat of
zinc chromate primer. Aluminium surfaces which shall come in
contact with masonry shall be given one coat of bituminous paint.
2.5.21.3 Erection:
2.5.21.3.1 Bracing
The Contractor shall provide all necessary temporary guys and
braces to ensure alignments and stability of the members and to
take care of all loads to which the structure may be subjected,
including erection equipment and operation of the same.
2.5.21.3.2 Temporary Bolting up

As erection proceeds the Contractor shall plumb up and level all
members and shall securely bolt up to take care of all dead load,
wind load and erection stresses. Wherever piles of materials,
erecting equipment of other loads are carried during erection,
proper provision shall be made to take care of the stresses
resulting from the same.
2.5.21.3.3 Turned Bolt
For field connections where bolting is specified, holes for the turned
bolts may be reamed in the field, if required. All drilling or reaming
for turned bolts shall be done after the parts to be connected are
assembled.
2.5.21.3.4 Welding
Where specified on drawings, welding shall be done in accordance
with I.S 816(latest edition) for steel and I.S 2812 (latest edition) for
Aluminium and Alloys.
2.5.21.3.5 Cutting and Fittings
No cutting of sections, flanges, web of angles shall be done without
the approval of the Engineer-in-charge. Where indicated on the
drawings holes, cuttings etc. shall be provided as required for
installation to the work by other Contractors. No additional holes or
cuttings other than those shown on drawings shall be made without
the approval of the Engineer-in-charge.
2.5.21.3.6 Drifting
Correction of minor misfits and a reasonable amount of reaming
and cutting of excess stock from rivets may be permitted. For this,
light drifting may be allowed to draw holes together. Twist drills
shall be used to enlarge holes as necessary to make connection.
Reaming that weakens the members or makes it impossible to fill
the holes properly or to adjust accurately after reaming shall not be
allowed.
Any error in shop work which prevents the proper assembling and
fitting of parts by moderate use of drift pins or a moderate amount
of reaming and slight chipping and cutting shall immediately be
called to the attention of the Engineer-in-charge and approval of the
method of correction obtained. The use of cutting torches to
enlarge or alter rivet holes shall not be permitted.
2.5.21.3.7 Grouting
All bearing plates, loose lintels and beams, etc. shall be set to
proper grade and level by the Contractor and the Engineer-in-
charge's approval obtained before proceeding with the grouting.
Grouting shall be done in 1: 1 1/2:3 concrete with 6 mm down stone
chips.
2.5.21.3.8 Anchor Bolting

Where shown on drawings, the miscellaneous metal items shall be
fixed to concrete by case hardened and drawn carburizing steel
expander nut and bolt. The Contractor shall submit the
manufacturer's literature showing the average pull out and average
shear values for bolts of various sizes. The bolts shall be fixed
strictly as per the manufacturer's instructions.
2.5.21.3.9 Pipe joints
MS pipes shall be joined by threaded sockets or by welding cast
iron pipes shall be socket and spigot jointed and caulked with hemp
and molten lead.
2.5.21.3.10 Spot painting
All field rivets and bolts and also any serious abrasion to shop paint
shall be spot painted with the same materials as used for the shop
paint or equivalent.
2.5.21.3.11 Making Good
All cutting to concrete or masonry shall be made good to the
2.5.21 4 Acceptance Criteria:
a) All items shall be of correct shape, size, weight etc. shown on
drawings and schedule of items.
b) For installed items, the tolerances shall be as follows:
c) Permissible deviation from straightness - 1 in 1000
d) Seats, stiffener connections etc. shall be as per approved
drawings and shall not interfere with architectural clearance.
e) All castings shall be free from blow holes, cracks and other
blemishes.

I.S 2062 Steel for General structural purpose.
I.S 800 - Code of practice for use of structural steel in general
building construction.
I.S 816 - Use of metal arc welding for general construction in mild
steel.
I.S 2812 - Recommendation for manual tungsten inert gas arc
welding of aluminium and aluminium alloys.
I.S 3150 - Hexagonal wire Netting.
I.S 4948 - Welded steel wire fabric for general use.
List of Vendors NIT of 132/33kV Sub-station at Kusmunda OCP
2.6.0.0 APPROVED VENDORS LIST OF DIFFERENT EQUIPMENT
Sl. ITEM DESCRIPTION NAME OF APPROVED MANUFACTURERS

No.
1 MOTOR (L.T.) : KIRLOSKAR/ BHEL/ SIEMENS/ MARATHON
ELECTRIC MOTORS/ JYOTI/ NGEF/ ABB/
CROMPTON GREAVES/ BHARAT BIJLEE/
INTEGRATED ELECTRIC COMPANY LTD/ LAXMI
HYDRAULICS PVT. LTD./ BALDOR ELECTRIC/
LENZE MECHATRONICS PVT. LTD.
2 MOTOR (H.T.) : KIRLOSKAR/ BHEL/ SIEMENS/ MARATHON

ELECTRIC MOTORS/ JYOTI/ NGEF/ ABB/
CROMPTON GREAVES/ BHARAT BIJLEE/
INTEGRATED ELECTRIC COMPANY LTD. / LAXMI
HYDRAULICS PVT LTD/ BALDOR ELECTRIC
3 FLP MOTORS : KIRLOSKAR/ BHEL/ BHARAT BIJLEE/ CROMPTON

GREAVES/ MATHER & GREAVES/ LAXMI
HYDRAULICS PVT LTD
4 POWER : KIRLOSKAR/ BHEL/ BHARAT BIJLEE/ GE

TRANSFORMER INDUSTRIAL/ CROMPTON GREAVES/ ANDREW
YULE/ SIEMENS/VOLTAS/ ABB/ NGEF/ Transformers
& Electricals/ Tesla Transformers Ltd./Pan-electro
Technic/ TRANSGIETZ/Voltech Transformers PVT Ltd
/ Raychem RPG(up to 5 MVA)/Supreme Power
Equipment Pvt Ltd/ Voltamp Transformers(upto
40MVA, 220kV) / Technical Associates Ltd.,
5 LIGHTING : KIRLOSKAR/ BHEL/ BHARAT BIJLEE/ GE

TRANSFORMER INDUSTRIAL/ CROMPTON GREAVES/ ANDREW
YULE/ SIEMENS/VOLTAS/ ABB/ NGEF/ L &T /
POWER MASTER ELECTRICAL PVT. LTD/
Transformers & Electricals/ Tesla Transformers Ltd./
ELECTRO TEKNICA
6 CONTROL : L&T/ SIEMENS/ JYOTI/ GE INDUSTRIAL/ NGEF/

TRANSFORMER KIRLOSKAR/ BHARAT CUTLER HAMMER
7 VACCUM CURCUIT : KIRLOSKAR SYSTEMS/ BHEL/ JYOTI/ MEI/ SIEMENS/

BREAKER/ 6.6/ 11 kV ABB/ GE INDUSTRIAL/ ALIND /NGEF/ ANDREW

No.
SWITCHGEAR YULE/ ASEA / SOUTHERN SWITCHGEAR (SSG)/
ELECTRO TEKNICA/ MEDITRON/ SAIT Mine
Line/BIECCO LAWRIE/ APE POWER PVT. LTD./
MEGAWIN SWITCHGEAR/ MEDITRON/ Amiya
Industries/OPG Power Systems/ Pascal Switchcare
India Pvt. Ltd.
8 VACCUM : GE INDUSTRIAL / JYOTI/ UNIVERSAL ELECTRICAL/

CONTACTOR BHEL/ ANDREW YULE/ SIEMENS/ CROMPTON
GREAVES/ MEGAWIN SWITCHGEAR/ Amiya
Industries/ Electroteknica Switchgears .
9 LT SWITCH BOARD : NGEF/ L&T/ ANDREW YULE/ GE INDUSTRIAL /

PANEL/ MOTOR JYOTI/ SIEMENS/ BHARATIA INDUSTRIES LTD./
CONTROL CENTRE/ ABB/ EASUN ENGG/ CROMPTON GREAVES/
AIR CIRCUIT KIRLOSKAR/ SYSTEMS / SCHNEIDER/ CONTROL &
BREAKER / MCCB / SWITCHGEAR COMPANY/ MINILEC(INDIA) PVT LTD/
MCB / RCCB STANDARD/ ELECTRICALS LTD/ JOLLY ENGG./
TRANSGIETZ ENTERPRIZES Ltd. / MEGAWIN
SWITCHGEAR/ MEDITRON/ Amiya Industries/
ZENITH CONTROLS/ HPL India./PRAYAS
AUTOMATION/ AC Power System/ ELECTRO
TEKNICA/Voltech Controls and Automation Pvt Ltd./
OPG Power Systems/ Aadroit Enginers/ Pascal
Switchcare/ Prayas Automation Pvt.Ltd.
10 P.F.CORRECTION : ABB/ MADHAV CAPACITOR/ GE INDUSTRIAL /

EQIPMENT VOLTAS/ YESHA/ KHATAU JUNKER/ BHEL/
UNISTAR/ NGEF/ BHARATIA INDUSTRIES LTD./
EPCOS/ Prayas Automation Pvt.Ltd.
11 POWER CABLES & : CABLE CORPORATION/ FORT GLOSTER/

CONDUCTORS UNIVERSAL CABLES/ NICCO/ PREMIER CABLES/
HINDUSTAN CABLES/ INCAB/ ASEAN / HAVELLS/
RADIANT/ LASER CABLES/ SKYTONE/ LUMINO/
SIECHEM / Ravin Cables Ltd./ KEI INDUSTRIES/ HPL
India( upto 1.1kV)/ Crystal Cable Industries/ Polycab
wires pvt. ltd./ Thermo Cables.
12 CONTROL CABLES : CABLE CORPORATION/ FORT GLOSTER/ NICCO/

ASEAN/ UNISTAR/ HINDUSTAN CABLES/ K.D.K./
RAJNIGANDHA CABLES/ HAVELLS/ RADIANT/
LASER CABLES/ SKYTONE/ SIECHEM/ Ravin Cables
Ltd./ KEI INDUSTRIES/ Crystal Cable Industries/
Thermo Cables.

No.
13 COMMUNICATION : HINDUSTAN CABLES/ DELTRON/ TOSHNIWAL/
CABLES INCAB / VINDHYA TELELINK LTD/ SIECHEM.
HT/LT TRAILING : UNISTAR/ INCAB/ SKYTONE

CABLES/ELASTOME
14
RIC TRAILING
15 COMMUNICATION : ITI/ PHILIPS / MOTWANE/ TATA TELECOM /

SYSTEM/ UPTRON/ GE INDUSTRIAL / ECIL/ CROMPTON
EQUIPMENT GREAVES
16 LIGHT FITTINGS : PHILIPS/ CROMPTONS/ GE INDUSTRIAL / BAJAJ/

ECE / GLOLITE /ANCHOR/HPL India Ltd.
17 RELAYS / Control : GEC ALSTOM/ L&T/ UNIVERSAL ELECTRIC/

and relay panel SIEMENS/ KIRLOSKAR SYSTEMS/ A.V.K.-S.E.G.
CONTROLS LTD./ BCH / EASUN REYROLL / ABB
/ANDREW YULE/ TELEMECANIQUE/ / BHARATIA
INDUSTRIES LTD. / CONTROL & SWITCHGEAR
COMPANY LTD/ MINILEC(INDIA) PVT LTD / SAIT
Mine Line. / MEGAWIN SWITCHGEAR/ Amiya
Industries / Voltech Control and Automation/ JOLLY
ENGINEERING
18 PLC : L&T/ SIEMENS/ ALLEN BRADLEY/ KELTRON/

UPTRON/ TTS SYSTEMATIC PVT. LTD./ ABB/
MITSUBISI/ SCHNEIDER/ GE FANUC/ BHARATIA
INDUSTRIES LTD/ MINILEC(INDIA) PVT LTD/
HONEYWELL/PRAYAS AUTOMATION/ Prayas
Automation Pvt.Ltd.
19 CT'S & PT'S : ELECTRIC POWER EQPT./ EASTERN SWITCHGEAR/

AUTOMATIC ELECTRIC/ POLYCRETE LTD. / KAPPA/
ABB /CONTROL & SWITCHGEAR COMPANY LTD. ./
MAX ENERGY PVT. LTD./ APE POWER PVT. LTD./
MEGAWIN SWITCHGEAR/ Electroteknica
switchgears.
20 L.T. CONTACTOR : SIEMENS/ L & T/ BHARATIA INDUSTRIES LTD./ GE

INDUSTRIAL / ANDREW YULE/ JYOTI / HAVELL'S/
KIRLOSKAR SYSTEMS / ABB / TELEMECANIQUE
21 PUSH BUTTON; : L&T/ SIEMENS/ ESSEN/ BCH/ BHARATIA

INDICATING LAMP INDUSTRIES LTD/ RASS CONTROLS/ Hotline
Switchgears & Control.
22 CONTROL : L&T/ KAYCEE/ JYOTI/ ESSEN/ SIEMENS /HAVELL'S

No.
SWITCHES
23 ISOLATING : SIEMENS/ L&T/ BHARATIA INDUSTRIES LTD./

SWITCHES ANDREW YULE/ GE INDUSTRIAL/ JYOTI/
CROMPTON GREAVES/ HAVELL'S/
TELEMECHANIQUE / ABB/ CONTROL &
SWITCHGEAR COMPANY / MINILEC (INDIA) PVT LTD
/STANDARD ELECTRICALS LTD
24 H.T. LOAD BREAK : JYOTI/ NGEF/ SIEMENS/ KIRLOSKAR SYSTEMS/

SWITCH BHEL/ ABB/ EASUN/ MEI / CONTROL &
SWITCHGEAR COMPANY/STANDARD ELECTRICALS
LTD.
25 CONTROL CONSOLE : L&T/ SIEMENS/ JYOTI/ NGEF/ GE INDUSTRIAL/

WITH COMPONENT KIRLOSKAR SYSTEM/ ANDREW YULE/ APLAB/ ABB/
ALLEN BRADELY/ BHARTIA INDUSTRIES LTD/
MINILEC (INDIA) PVT LTD/ SKYTONE/ ZENITH
CONTROLS
26 BATTERY & : CHLORIDE/ STANDARD/ AMCO / INSTANT

BATTERY CHARGER, SOLUTIONS
LOAD BANK,
ANNUNCIATOR
27 (a) LIGHTNING : ICE/ OBLUM/ IGE (I) LTD./ WS

ARRESTER INSULATORS/CROMPTON GREAVES/ SATCOM
ELECTRONICS
(b) EARTHING SATCOM ELECTRONICS / M/s Jef Techno Solutions

SYSTEM/ SURGE Pvt Ltd.
PROTECTION
SYSTEM
28 WELDING : ADVANI OERLICON/ INDIAN OXYGEN/ PHILIPS/

TRANSFORMER/ MG ESAB
WELDING SET
29 ALTERNATOR : JYOTI/ BHEL/ KIRLOSKAR ELECTRIC/ CROMPTON

GREAVES/ AVK-SEG CONTROLS LTD.
30 DG SET : KIRLOSKAR ELECTRIC/ CUMMINS/ LEYLAND /

JYOTI/ SRI RAM HONDA/ YAMAHA
31 LIMIT SWITCH, PULL : R.K.ELECTRICALS/ ESSEN/ SIEMENS/

CORD SWITCH, BELT TECHNOCRAT/ PHOTO CONTROL/ JAYSHREE
SWAY SWITCH, ELECTRONICS/ BHARTIA INDUSTRIES LTD/ SAIT
CENTRIFUGAL Mine Line/ Protocontrol Instruments./Hotline

No.
SWITCH etc. Switchgears & Control / Hotline Switchgears &
Control
32 TIMER : BCH/ TELEMECANIQUE/ L&T/ SIEMENS/ GE
INDUSTRIAL / ABB/ MINILEC(INDIA) PVT LTD.
33 ELECTRO MAGNETIC : ELECTROMAG/ PBL/ Industries syndicate / BCH
BRAKE
34 METERS : AEP/ IMP/ HPL INDIA/ Hotline Switchgears & Control
35 SELECTOR SWITCH : L&T/ SIEMENS/CROMPTON/ BHARTIA INDUSTRIES

LTD/ RASS CONTROLS.
36 HRC FUSE : GE INDUSTRIAL / L&T/ SIEMENS/ STANDARD/ ABB/
CONTROL & SWITCHGEAR COMPANY LTD/
STANDARD ELECTRICALS LTD./ MEGAWIN
SWITCHGEAR.
37 HOOTERS : TULLU/ NATIONAL/ Hotline Switchgears & Control
38 AIR CONDITIONER : ACCAIRE/ BLUE STAR/ VOLTAS/ GODREJ/ CARRIER
39 TRANSWITCH UNIT : TRANSGIETZ or Equivalent
40 UNITIZED : TRANSGIETZ/ MEGAWIN SWITCHGEAR.

SUBSTATION
41 HV FIELD SWITCH : TRANSGIETZ / ELECTRO TEKNICA

(3.3 & 6.6 kV)
42 DCS, SCADA, CCTV : HONEYWELL or Equivalent

and RTU for Sub-
station automation
and Electrical SCADA
43 TRANSFORMERS, : MEGAWIN SWITCHGEAR / Raychem RPG

DRY TYPE- UPTO 36
kV and 2500 kVA
44 Tubes & Sleeves-Heat : Siechem or Equivalent

shrinkable
45 Building wires : Siechem, KEI Industries
46 Automatic Voltage : Transformers & Electricals or Equivalent

Regulator
47 Level Switches, : Protocontrol Instruments or Equivalent

Chute Block Detector,
Level Detector, Level

No.
Transmitter
48 Proximity Switches : Protocontrol Instruments or Equivalent.

(Inductive,
Capacitative, Optical,
Magnetic, Ultrasonic)
49 C.I. Earthing Pipes- : Kapilansh Dhatu Udyog or Equivalent

ELECTRODE
50 Terminal Blocks / : Elmex Controls Pvt Ltd or Equivalent

Interface Modules
51 SOFT STARTERS/ : Danfoss Industries Pvt Ltd./PRAYAS AUTOMATION/

VARIABLE Parker Hannifin India Pvt Ltd/ Prayas Automation
FREQUENCY DRIVE Pvt.Ltd.
PANEL
52 On line UPS System : Novateur Electrical and Digital System Pvt. Ltd
53 Bus Duct : Aadroit Enginers
54 JUNCTION BOX Prayas Automation Pvt.Ltd.
Note : In case the bidder intends to supply the P&M from vendors not listed in the
Approved Vendor List , written approval of the Employer shall be taken, who after evaluating
the eligibility and qualification of such Vendors, may choose to include them in Approved
Vendor List.
Bidder in his bid shall furnish information for evaluation and qualification of such
vendors. The criterion and format for evaluation of vendor is given below.
In addition, the approved vendors of other Coal India Subsidiaries will also be
considered.
No further request for inclusion of vendors after finalization of tenders shall be

entertained.
Format for Additional Vendor Evaluation:
PART I GENERAL
1.0 Name of the company
2.0 Nature of the company Proprietary/ partnership/
Private/ Public Limited)
(Attach photocopy of articles of association/
Registration/Partnership/Deeds etc.)
3.0 Registered office
4.0 Works address
5.0 Name of chief executive
6.0 Name of the person to be contacted for this bid
(Furnish photocopy of attorney)
7.0 OFFICE :
Telephone no :
Fax No:
E-mail :
Web site, if any
8.0 WORKS :
Telephone no :
Fax No:
9.0 Total area of the factory
Covered
Uncovered
Factory layout
10.0 Total number of employees
Managerial
Technical
Administrative
Support services
11.0 Organisation chart
12.0 Range of products manufactured
(Enclosed all relevant technical catalogue and
literature)
13.0. Year of commencement of manufacturing
PART II TECHNICAL
1.0 Details of major products manufactured
Type
Size
Description
Annual production for preceding three years
2.0 Has your product been tested by any agency? If yes,
indicate details, copies of qualification approval,
test certificates), test reports etc.
3.0 Foreign Collaboration ( if any)
Products covered
Name and address of collaborator
Status of collaboration
Scope of involvement and responsibility with
respect to this bid, if any.

Proof in support thereof
4.0 Details of plant and machinery
Include list of major items of plant and equipment
relevant to the products under considerations.
5.0 Have you supplied the product similar to product
under consideration to other firm? If yes, furnish
name of such firm(s) & details of such product.
6.0 Quality Assurance
How is the quality assurance function carried out
? Give its organization and linkage with the Chief
Executive.
Are there written procedures for all quality
related activities?
If the firm is ISO 9000 certified company, then
please attach a copy of the certificate showing
range of product covered & its validity.
7.0 Do you have an R & D Department?
If so, furnish details of its infrastructure and
laboratory test facilities.
8.0 How is quality control of raw materials, purchased
items exercised ? If goods coming in are inspected,
provide following details :
Test equipment and facilities available in factory
Assistance from external agencies
Description of test (s)
Name of the agency carrying out the tests (s)
9.0 Inspection and quality control of finished products
Test equipment and facilities available in factory
Assistance from external agencies.
10.0 Principal customers
Name and address
Product indication there operating parameters
Sales for last two years
Users performance certificates
11.0 Future Expansion
Programme
Installation of new machinery
Any other information you would like to provide
11.0 Process plan / flow chart of product under
consideration
12.0 Product brochures
13.0 Details of BIS licence, if any
14.0 Outsourcing activities for product under
consideration (if any)
Activities to be outsourced
List of out source agencies for each activity and
their official address
List of P&M & testing facilities available with

outsourced agencies
List of product manufactured by outsourced
agencies
List of client of outsourced agencies
Attach copy of order received from client for

outsourcing agency and performance certificate ,
if any
Any other information about outsourced agencies
(whether ISO certified, BIS licence holder etc.)
PART III COMMERCIAL
Name and address of your banker(s)
1.0
2.0 Value of current assets as on date

3.0 Value of current liabilities as on date
(Attach balance sheets for last three years)
4.0 Net fixed assets
5.0 Value of total sales during the previous years
6.0 Value of orders in hand, enclose copy of supply

order
7.0 Value of total capital employed
8.0 Balance sheet of last year
9.0 Source of finance
10.0 Borrowing limit as sanctioned by bank, if any
11.0 Are your products covered by warranty, if so, state
Period
Scope of warranty
FORMAT FOR VENDOR EVALUATION
1. PART I GENERAL
1.0 Name of the company
2.0 Nature of the company(Proprietory/partnership/

Private/Public Limited) (Attach photocopy of
articles of association/Registration/Partnership/
Deeds etc.)
3.0 Registered office
4.0 Works address
5.0 Name of chief executive
6.0 Name of the person to be contacted for this bid
(Furnish photocopy of attorney)
7.0 OFFICE :
7.1 Telephone no :
7.2 Fax No:
7.3 E-mail :
7.4 Web site, if any
8.0 WORKS :
8.1 Telephone no :
8.2 Fax No:
9.0 Total area of the factory
9.1 Covered
9.2 Uncovered
9.3 Factory layout
10.0 Total number of employees
10.1 Managerial
10.2 Technical
10.3 Administrative
10.4 Support services
11.0 Organisation chart
12.0 Range of products manufactured
(Enclosed all relevant technical catalogue and
literature)
13.0 Year of commencement of manufacturing
PART II TECHNICAL
1.0 Details of major products manufactured
1.1 Type
1.2 Size
1.3 Description
1.4 Annual production for preceding three years
1.5 Specify the product for which Vendor approval
is being sought
2.0 Has your product been tested by any agency? If
yes, indicate details, copies of qualification
approval, test certificates), test reports etc.
3.0 Foreign Collaboration ( if any)

3.1 Products covered
3.2 Name and address of collaborator
3.3 Status of collaboration
3.4 Scope of involvement and responsibility with
respect to this bid, if any.
3.5 Proof in support thereof
4.0 Details of plant and machinery
4.1 Include list of major items of plant and equipment
relevant to the products under considerations.
5.0 Have you supplied the product similar to product
under consideration to other firm? If yes, furnish
name of such firm(s) & details of such product.
6.0 Quality Assurance
6.1 How is the quality assurance function carried
out ? Give its organization and linkage with the
Chief Executive.
6.2 Are there written procedures for all quality
related activities?
6.3 If the firm is ISO 9000 certified company, then
please attach a copy of the certificate showing
range of product covered & its validity.
7.0 Do you have an R & D Department?
7.1 If so, furnish details of its infrastructure and
laboratory test facilities.
8.0 How is quality control of raw materials,
purchased items exercised ? If goods coming in
are inspected, provide following details :
8.1 Test equipment and facilities available in
factory
8.2 Assistance from external agencies
8.3 Description of test (s)
8.4 Name of the agency carrying out the tests (s)

9.0 Inspection and quality control of finished
products
9.1 Test equipment and facilities available in
factory
9.2 Assistance from external agencies.
10.0 Principal customers
10.1 Name and address
10.2 Product indication there operating parameters
10.3 Sales for last two years
10.4 Users performance certificates
11.0 Future Expansion
11.1 Programme
11.2 Installation of new machinery
11.3 Any other information you would like to provide

12.0 Process plan / flow chart of product under
consideration
13.0 Product brochures
14.0 Details of BIS licence, if any
15.0 Outsourcing activities for product under
consideration (if any)
15.1 Activities to be outsourced
15.2 List of out source agencies for each activity

and their official address
15.3 List of P&M & testing facilities available with
outsourced agencies
15.4 List of product manufactured by outsourced
agencies
15.5 List of client of outsourced agencies
15.6 Attach copy of order received from client for

outsourcing agency and performance
certificate , if any
15.7 Any other information about outsourced agencies
(whether ISO certified, BIS licence holder etc.)
PART III COMMERCIAL
1.0 Name and address of your banker(s)
2.0 Value of current assets as on date

3.0 Value of current liabilities as on date
(Attach balance sheets for last three years)
4.0 Net fixed assets
5.0 Value of total sales during the previous years
6.0 Value of orders in hand, enclose copy of supply

order
7.0 Value of total capital employed
8.0 Balance sheet of last year
9.0 Source of finance
10.0 Borrowing limit as sanctioned by bank, if any
11.0 Are your products covered by warranty, if so,
state
11.1 Period
11.2 Scope of warranty
Schedules, Data and Price Bid NIT for 132/33 kV Substation at Kusmunda OCP
2.7.0.0 CHECKLIST OF SCHEDULES (To be submitted in part I of the offer)
Bidder's Name & Address:
To,
The General Manager (CMC),
S E C L,
Seepat Road,
Bilaspur(C.G.)
Dear Sir,
Sub: List of Schedules furnished in the offer.
Ref: Turnkey Owner Document for Design, Supply, Erection &

Commissioning of 132/33 kV substation at Kusmunda OCP.
We are submitting herewith information in respect of our offer in

relevant parts as mentioned below:
----------------------------------------------------------------------------------------------------------------
Sl.No. Description Schedule No Bid
Part
----------------------------------------------------------------------------------------------------------------
01 Qualification information I Part- I
02. Work completion schedule II Part-II
03. Acceptance of Terms and conditions III Part-II
04. Performance Guarantee IV Part-II
05. System, Scope of supply and standards V Part-II
06. Technical deviations VI Part-II
07. Additional provisions included in the offer
over and above the Owner specifications VII Part II
08. Instruments for conducting performance and
efficiency tests VIII Part-II
09. List of spares, Tools & tackles IX Part-II
10. Technical information and data of major
equipment X Part-II
11. Detailed break up of bid price XI Part-III
Yours faithfully,
Date:
(Signature)
(Printed Name)
Place: (Designation)
(Firms Seal)
2.7.1.0 SCHEDULE I : QULIFICATION INFORMATION (To be submitted in part I

of the offer)
To,
S E C L, Seepat Road,
Bilaspur(C.G.)
Dear Sir,
Sub: Qualification Information

We are submitting the required qualification in respect of our offer as given

below:
(As per clause 1.2.0.0 of Volume-I)
Dated: Yours faithfully,
Place:
(Signature)
Printed Name
Designation
Firm's Seal
2.7.2.0 SCHEDULE II :- WORK COMPLETION SCHEDULE (to be submitted in

Part II of the offer)
To,
S E C L, Seepat Road,
Bilaspur(C.G.)
Dear Sir,
Sub: Work completion schedule

We hereby declare that the following completion schedule shall be followed by

us for design, supply, erection and commissioning of 132 kV /33 kV sub station at
Kusmunda OCP stipulated in this NIT. The period will commence from the date as
stipulated in this NIT. However detailed CPM/PERT will be submitted filling with the
following:
Sl No. Particulars Period in week
1. Completion of Engineering including soil survey,

design, preparation, approval of drawings etc.
2. Establishment of site office
3. Commencement of Civil & Structural works
4. Completion of Civil & structural works.
5. Commencement of manufacturing equipment
6. Commencement of dispatch of equipment
7. Completion of dispatches
8. Commencement of erection
9. Completion of erection
10. Completion of pre-commissioning and Testing
11. Commencement of trial operation
12. Successful completion of trial operation
13. Final acceptance of the plant by company
----------------------------------------------------------------------------------------------------
Dated: Yours faithfully,
Place: (Signature)
Printed Name
Designation
Firm's Seal
2.7.3.0 SCHEDULE III : Acceptance of terms and conditions (to be submitted in

To,

S.E.C.L., Seepat Road,
Bilaspur(C.G.)
Dear Sir,
Sub: Acceptance of Terms and Conditions.

We hereby confirm total and unconditional acceptance of the General Terms and
Conditions of Contract, Additional Terms and Conditions of Contract, General
Technical Conditions, Erection Conditions of Contract, Special Terms and Conditions
given in Volume-I of the Bid document.
Yours faithfully,
Date:
Place:
(Signature)
(Printed Name)
Designation
Firm's Seal
2.7.4.0 SCHEDULE IV: Performance guarantee (to be submitted in Part II of the

offer)
Bidders Name & Address:
To,

SECL, Seepat Road,
Bilaspur (C.G.)
Dear Sir,
Sub: Performance Guarantee

We declare that the we warrant that the equipment will be new and in
accordance with the Owner document and free from defects in material
and workmanship for a period of twelve (12) calendar months
commencing immediately on the satisfactory completion of the trial
operations. Guarantee/Warrantee received from the manufacturer will
be also extended to the Employer. The liability will be limited to the
replacement of any defective parts in the equipment under normal use
and arising solely from faulty design, materials and /or workmanship
and such defective parts are replaced free of cost at site.
We declare that the ratings and performance of the equipment and

system as a whole supplied by us are guaranteed for a period of twelve
(12) calendar months.
Yours faithfully,
Dated:
(Signature)
Place: (Printed Name)
Designation
Firm's Seal
2.7.5.0 SCHEDULE V: System description (to be submitted in Part II of the offer)
Bidder's name & Address:
To,

SECL, Seepat Road,
Bilaspur (C.G.)
Dear Sir,
Sub: System description, Scope of supply, Standards

Commissioning of 132/33 kV sub station at Kusmunda OCP. We
are submitting herewith the System description, entire scope of
supply covered by our offer and Standards followed.
Yours faithfully,
Dated:
Place: (Signature)
(Printed Name)
(Designation)
Firm's Seal
2.7.6.0 SCHEDULE VI: Technical deviations (to be submitted in Part II of the offer)
To,

SECL, Seepat Road,
Bilaspur (C.G.)
Dear Sir,
Sub: Technical deviations

The following are the clause-wise technical deviations with reference to

the Owner Document. These deviation/variations/exceptions are
exhaustive and except for these deviations/variations/the entire work
shall be performed as per the Owner specifications as given in the
Owner Document. We agree that any conditions/variations/deviations
etc if found elsewhere in our proposal shall not be given effect to:
Clause No. Statement of Deviation / variations Reasons
Yours faithfully,
Dated:
(Signature)
Place: (Printed Name)
Designation
Firm's Seal
2.7.7.0 SCHEDULE VII : Additional provisions included in the offer over and above
the specifications given in the Tender document (to be submitted in Part II of
the offer)
To,

SECL, Seepat Road,
Bilaspur( CG)
Dear Sir,
Sub: Additional provisions included in the offer over and above the
specifications given in the Tender document

Commissioning of 132/33/kV substation at Kusmunda OCP.
Following are the additional information in respect of our offer:
S.No. Description of information Reasons
Yours faithfully,
Dated:
Place:
(Signature)
Printed Name
Designation
Firm's Seal
2.7.8.0 SCHEDULE VIII: Instruments for conducting performance and efficiency

tests (to be submitted in Part II of the offer)
To,

SECL, Seepat Road,
Bilaspur (GG.)
Dear Sir,
Sub: Instruments for conducting performance and efficiency tests.

The following are the instruments which will be leased out by us free of
charge to SECL for conducting performance and efficiency tests on
equipment supplied and installed. Apart from these instruments, any
other instruments that will be essential for the purpose will also be
supplied by us free of charge. All instruments will carry calibration
certificates.
Instrument Purpose/Type of Qty. required Duration of leasing

test period
Yours faithfully,
Dated:
Place:
(Signature)
Printed Name
Designation
Firm's Seal
2.7.9.0 SCHEDULE IX : List spares, tools and tackles (to be submitted in

To,

SECL, Seepat Road,
Bilaspur (CG.)
Dear Sir,
Sub: List of spares and tools & tackles

1.0 Tools and tackles
The tools and tackles shall be as specified at clause no 2.3.11.2 of this

document.
2.0 Mandatory Spare Parts
The Contractor shall furnish the list of mandatory spares along with the
specifications, quantity and price. The Employer will scrutinise the list and
order will be placed separately.
Yours faithfully,
Dated:
Place: (Signature)
Printed Name
Designation
Firm's Seal
2.7.10.0 SCHEDULE X: Technical information and data of major equipment (to be

submitted in Part II of the offer)
To,

SECL, Seepat Road,
Bilaspur (CG.)
Dear Sir,
Sub: Technical information and data of major equipment.

We are submitting the Technical information and data of major equipment /

items included in our offer as per the format enclosed. We are also submitting the
drawings, design calculation sheets, technical pamphlets etc considered for selection
of various components/assemblies, sub assemblies etc. in the separate enclosed
sheets.
Yours faithfully,
Dated:
(Signature)
Printed Name
Designation
Place: Firm's Seal
2.7.10.1 Technical specifications of 132/33 kV Isolators
132 kV 33kV
1) Manufacturers Name & Place of manufacture
2) Type
3) Maximum continuous rating (Amps)
4) No. of units:
a) Without earthing blade
b) With earthing blade
5) Three second short time rating (kA)
6) Temperature rise corresponding to:
a) Item 3 above (deg. C)
b) Item 5 above (deg. C)
7) Current density at the minimum cross section

of switch blade
8) Contacts: (main, earth)
a) Material
b) Type
c) Area
d) Pressure
e) Whether Silver plated or not
9) Clearance:
a) Between live parts & ground (mm)
b) Between phases (mm)
c) Between fixed contact and blade in open

position (mm)
10) Location, type and number of bearing
11) Maximum capacitive current that can safely be

interrupted .
12) Auxiliary Contacts:
a) No. of NO contacts
b) No. of NC contacts
c) Rating of auxiliary contact
13) Type of operating mechanism
14) Type and make of insulator
15) Size and weight of insulator
16) No. of insulator per stack
17) 1 minute dry and wet withstand voltage

per stack
18) Impulse withstand voltage of insulator

stack at 1.2 x 50 microseconds full wave
19) Weight of complete switch per phase
20) Type of interlock
21) Dimensions
22) GA drawing of 132 kV and 33 kV isolators
23) Type test certificates for temperature rise,

short circuit capacity, dry, wet and impulse tests,
furnished Yes/No
24) Technical Literature
The complete set of Technical literature catalogues

And pamphlets shall be furnished with the offer.
25) Standards followed (Details shall be given)
2.7.10.2 Technical Parameters of 132 kV & 33 kV Lightning Arresters
132kV 33kV
1) Manufacturers name and place of manufacture
2) Type
3) Model
4) Number of units
5) Rated voltage of Arrester (kV)
6) Nominal discharge current (Amps.)
7) Power frequency spark over voltage

(minimum) (kV - rms)
8) Impulse spark over voltage 1.2 x 50

microsecond wave (kV)
9) Maximum front of wave impulse spark over

voltage (kV peak)
10) Virtual steepness for front of wave for above

(kV / microsecond)
11) Maximum residual voltage for discharge current

of: (10/20 microsecond wave ) (kV peak)
a) 1500 Amps.
b) 2500Amps.
c) 5000 Amps.
d) 10000 Amps
e) 20000 Amps.
12) High current 4/10 microsecond test value (kV)
13) Long duration current tests:
a) Current peak (Amps.)

b) Virtual duration (Microsecond)
14) Weigh of complete unit (Kg)
15) Height of complete unit from base to the

line side (mm)
16) Minimum recommended spacing between

Arresters (centre-to-centre in mm)
17) Minimum clearance:

- Phase to ground
- Phase to Phase
18) Earthing arrangement provided for earthing

side of arresters
19) Insulation withstand strength of casing

insulator. One minute, 50 Hz dry and wet
full wave impulse
1.2 x 50 microsecond (kV peak)
20) Porcelain creepage distance (mm)
21) GA drawing of 120 kV and 30 kV Lightning Arrestors
22) Type test certificates furnished Yes/No
23) The complete set of Technical literature catalogues

And pamphlets shall be furnished with the offer.
24) Standards followed:- (Details shall be arranged)
2.7.10.3. Technical Parameters of 132/33kV Current Transformers
132 kV 33 kV
1) Manufacturers name & place of manufacture
2) Type
3) Rated Voltage
4) No. of units/sets of 3 units
5) Rated primary current
6) Rated secondary current
7) Secondary terminal voltage:

a) Normal current
b) 10 times normal current
c) 20 times normal current
8) Number of cores
9) Core details:
Rated Class of Accuracy limit
Output Accuracy Factor
Core I
Core II
Core III
Core IV
Core V
10) Secondary knee point voltage:
Core I
Core II
Core III
Core IV
Core V
11) Short time current rating:
1 sec. rms (kA)

3 sec. rms (kA)
12) Dynamic current (kA (peak)
13) Rated continuous current (A)
14) Temperature rise over ambient (deg C)
15) Current density (Amps/sq mm)
16) Current and phase errors at rated burden

and rated frequency
17) One minute power frequency dry withstand

test voltage (kV rms)
18) One minute power frequency wet withstand

test voltage (kV-rms)
19) 1.2 x 50 microsecond impulse withstand

test voltage (kV peak)
20) One minute power frequency withstand test

voltage on secondary (kV rms)
21) Weight of oil (kg)
22) Total weight (kg)
23) Magnetisation curve of CT cores
24) Mounting details
25) Overall dimensions
26) Dimensional drawing with mounting details
27) Type test certificates furnished yes/no

and pamphlets shall be furnished with the offer.
29) Standards followed: (Details shall be arranged).
2.7.10.4 Technical Parameters of 132/33 kV Potential Transformers
132 kV 33 kV
1) Manufacturers name & place of manufacture
2) Type
3) Rated primary Voltage (V)
4) Number of units/sets of 3 units
5) Number of secondary windings
6) Rated secondary voltage(V)
7) Rated burden (VA)
8) Accuracy class
9) Maximum voltage error
10) Maximum phase angle error
11) Temperature rise at 1.1 times rated voltage

with rated burden (deg. C)
12) Rated voltage factor and time
13) Temperature rise for item no. 11 above (deg. C)
14) One minute power frequency withstand

test (dry) voltage (kV-rms)
15) One minute power frequency withstand test

(wet) voltage (kv rms)
16) 1.2 x 50 microsecond impulse wave

withstand test voltage (kV peak)
17) One minute power frequency withstand voltage

on secondary (kV-rms)
18) Grade of oil
19) Weight of oil (kg)
20) Total weight (kg)
21) Mounting details
22) Overall dimensional drawing with mounting details
24) The complete set of Technical literature

catalogues and pamphlets shall be furnished with the offer.
25) Standards followed: (Details shall be arranged).
2.7.10.5. Technical Parameters of 132 kV SF6 Circuit Breakers
132 kV
2) Type
3) Rated voltage:
4) Number of units
5) Class: Indoor & outdoor
6) Maximum (continuous) service rated voltage
7) No. of poles of circuit breaker
8) Type of mounting:
9) Type of operation
10) Normal current rating
a) Under normal conditions
b) Under site conditions
11) Short time current rating
a) One second r.m.s. (kA)
b) Three seconds r.m.s. (kA)
12) Rated operating sequence
13) Maximum temperature rise over ambient temperature

(degree C)
14) Breaking capacity:
a) symmetrical (kA)
b) symmetrical rupturing capacity at

rated service voltage (kVA)
c) asymmetrical (kA)
15) Making capacity (kA peak)
16) First pole to clear factor
17) Maximum interrupting capacity under phase opposition

condition (MVA)
18) Maximum line charging current breaking capacity without

the over voltage exceeding 2.5 times the rated phase to
neutral voltage (Amps.)
19) Maximum line charging current breaking capacity and

corresponding over voltage recorded in test:
a) Supply side (Amps)
b) Line side (Amps)
20) Total break time in milliseconds
a) At 10% rated interrupting capacity
b) At rated interrupting capacity
21) Arcing time (m.sec.)
22) Making time (m.sec.)
23) Data on restriking voltage 100% rated 50% rated

capacity capacity
a)Amplitude Factor
b) Phase Factor
c) Natural frequency
d) Rate of Rise of Restriking

voltage (volts/microsecond)
24) Maximum over voltage to switching transformer

on no-load and the charging current
25) Dry 1 minute power frequency withstand test

voltage for complete circuit breaker (kv rms)
a)Between line terminal and grounded objects
b) Between terminals with breaker contacts open
26) 1.2 x 50 microseconds full wave impulse with stand

voltage for complete circuit breaker
a) Between line terminal and ground (kV peak)
b) Between line terminal with circuit
breaker contacts open (kV rms)
27) Dry 1 minute power frequency withstand voltage for

for insulator (kv-rms)

voltage for insulator (kv peak)
29) Creepage distance to ground (mm)
a) Between Phases (mm)
b) Live parts to Earth (mm)
c) Live parts to Ground level(mm)
30) Number of breaks per phase
31) Total length of breaks per phase (mm)
32) Rate of contact travel - Opening mm/ms

- Closing mm//ms
33) Type of main contacts
34) Type of auxiliary contacts
35) Material of auxiliary contacts
36) Contacts silver plated or not
37) Thickness of silver plating
38) Contact pressure:
39) Number of auxiliary contacts provided:
a) Those closed when breaker is closed
b) Those open when breaker is closed
c) Those adjustable with respect to

position of main contact
a) Opening
b) Closing
41) Whether circuit breaker is trip-free
42) Whether circuit breaker is anti-pumping
43) Lock out pressure - at closing
- at tripping
44) Tripping and closing control circuit voltage (V)
45) Power required for trip coil at 110 V DC (W)
46) Power required for closing coil at 110V DC (W)
47) Type of pneumatic equipment for 132 kV C.B.
48) Normal air pressure for pneumatic operation (kg/sq m)
49) Total weight (kg) :
50) Overall dimension (mm)
51) General outline drawings of the breaker indicating

foundation details, overall dimensions etc.

and pamphlets shall be furnished with the offer
53) Standards followed (list shall be arranged)
2.7.10.5. Technical Parameters of 33 kV Vacuum Circuit Breakers
2) Type
3) Rated voltage:
4) Number of units
5) Class: Indoor & outdoor
6) Maximum (continuous) service rated voltage
7) No. of poles of circuit breaker
8) Type of mounting:
9) Type of operation
10) Normal current rating
a) Under normal conditions
b) Under site conditions
11) Short time current rating
a) One second r.m.s. (kA)
b) Three seconds r.m.s. (kA)
12) Rated operating sequence
13) Maximum temperature rise over ambient temperature

(degree C)
14) Breaking capacity:
a) symmetrical (kA)
b )symmetrical rupturing capacity at

rated service voltage (kVA)
c) asymmetrical (kA)
15) Making capacity (kA peak)
16) First pole to clear factor
17) Maximum interrupting capacity under phase opposition

condition (MVA)
18) Maximum line charging current breaking capacity without

the over voltage exceeding 2.5 times the rated phase to
neutral voltage (Amps.)
19) Maximum line charging current breaking capacity and

corresponding over voltage recorded in test:
a) Supply side (Amps)
b) Line side (Amps)
20) Total break time in milliseconds
a) At 10% rated interrupting capacity
b) At rated interrupting capacity
21) Arcing time (m.sec.)
22) Making time (m.sec.)
23) Data on restriking voltage 100% rated 50% rated

capacity capacity
a)Amplitude Factor
b) Phase Factor
c) Natural frequency
d) Rate of Rise of Restriking

voltage (volts/microsecond)
24) Maximum over voltage to switching transformer

on no-load and the charging current
25) Dry 1 minute power frequency withstand test

voltage for complete circuit breaker (kv rms)
a)Between line terminal and grounded objects
b) Between terminals with breaker contacts open

voltage for complete circuit breaker
a) Between line terminal and ground (kV peak)

b) Between line terminal with circuit breaker contacts open (kV rms)
27) Dry 1 minute power frequency withstand voltage for

for insulator (kv-rms)

voltage for insulator (kv peak)
29) Creepage distance to ground (mm)
a) Between Phases (mm)
b) Live parts to Earth (mm)
c) Live parts to Ground level(mm)
30) Number of breaks per phase
31) Total length of breaks per phase (mm)
32) Rate of contact travel - Opening mm/ms

- Closing mm//ms
33) Type of main contacts
34) Type of auxiliary contacts
35) Material of auxiliary contacts
36) Contacts silver plated or not
37) Thickness of silver plating
38) Contact pressure:
39) Number of auxiliary contacts provided:
a) Those closed when breaker is closed
b) Those open when breaker is closed
c) Those adjustable with respect to

position of main contact
a) Opening
b) Closing
41) Whether circuit breaker is trip-free
42) Whether circuit breaker is anti-pumping
43) Lock out pressure - at closing
-at tripping
44) Tripping and closing control circuit voltage (V)
45) Power required for trip coil at 110 V DC (W)
46) Power required for closing coil at 110V DC (W)
47) Type of pneumatic equipment for 132 kV C.B.
48) Normal air pressure for pneumatic operation (kg/sq m)
49) Total weight (kg) :
50) Overall dimension (mm)
51) General outline drawings of the breaker indicating

foundation details, overall dimensions etc.

and pamphlets shall be furnished with the offer
54) Standards followed (list shall be arranged)
2.7.10.6. Technical Parameters of 132 /33 kV, 40 (ONAN)/50 (ONAF) MVA

Transformer
1) Manufacturers name & place of manufacture.
2) Coil winding type HV & LV
3) Number of phases
4) Number of units
5) Frequency
6) Dry or oil immersed
7) Core or shell type
8) Direction of power flow
9) Type of cooling
10) Rated Power (MVA)
a) With ONAN cooling
a) With ONAF cooling
11) Rated system nominal voltage (kV) :
a) HV Winding
b) LV winding
12) Short circuit level which the transformer

will be able to withstand for nominal
system voltage (MVA)
13) Type of tap changer
14) Control/operation of tap changer
15) Range of tapings
16) Details of on load tap changer (OLTC)
a) Number of steps of OLTC
b) Rated voltage (kV)
c) Rated current (A)
d) Step voltage (kV)
e) Approx. overall dimension in mm
f) Approx. overall weight in kg
g) Approx. overall quantity of oil in Lts
h) Time to complete one step change in seconds
17) Insulation level for:
a) HV winding
b) LV winding
18) Clearances in mm.
a) HV terminals
i) In oil
- Between phases
- Phase to earth
ii) In air
- Between phases
- Phase to earth
b) LV terminals
i) In oil
- Between phases
- Phase to earth
ii) In air
- Between phases
- Phase to earth
19) Connections symbol & vector group reference.
20) Whether neutral terminals provided for :
a) HV Winding
b) LV Winding
21) Insulation level of neutral terminals :
a) Rated short duration power

frequency withstand voltage (kV)
b) Lightning impulse withstand

voltage (kV)
22) Total weight /quantity of oil in transformer

including bushings, conservator at ambient
temperature including 5% extra (kg/lit.)
23) Thickness of transformer tank plates (mm)
a) Sides
b) Bottom
c) Radiators
d) Cover
24) Net weight of core (kg)
25) Net weight of copper (kg):
a) HV winding
b) LV winding
26) Weight of complete transformer with all

fittings & oil at ambient temperature (kg)
27) Weight of complete transformer with all

fittings but without oil (kg)
28) Weight of the heaviest shipment package (kg)

and its overall dimension (mm)
29) Dimensions of the transformer:

a) Maximum height to the top of the bushings (m)
b) Overall width (m)
c) Overall length (m)
30) Minimum clear height for lifting the core and the
windings from the tank (m)
31) Width of track gauge (mm)
32) Type of core- Base mounted or Cover mounted.
33) Insulation of winding:
a) HV
b) LV
34) Insulation of core bolts
35) Insulation of core end plates.
36) Insulation core laminations
37) Cooling plant details
a) Radiator
i) Make & type
ii) No. of radiator banks
iii) Total radiating surface
iv) Thickness of radiator fins
v) Clear distance between radiator fins
vi) Width of radiator fins
b) Fans
i) No. of fans per 50% banks
ii) No. of standby fans per 50% banks
iii) Rating of fan.
38) Approximate capacity of conservator tank (lit)
39) Limit of hottest spot temperature for which

the transformer is designed (deg. C)
40) Maximum limit of winding temperature rise

measured by resistance method when the oil
is in circulation (deg. C)
41) Maximum limit of top oil temperature rise

measured by thermometer (deg. C)
42) Maximum ambient temperature considered for
above limits of temperature rise (deg C)
43) Time for which the transformer is

designed without any adverse effects for
any external short circuit either at the HV
terminals or at the LV terminals with the
short circuit MVA as specified (seconds)
44) Guaranteed maximum iron loss in kW at

75 degree C of average winding temperature
and at rated voltage
45) Guaranteed maximum load loss (i.e. Copper

loss + Stray loss) at average winding temperature
of 75 deg. C and at rated current (kW)
46) Guaranteed maximum auxiliary loss in kW

because of consumption by the cooling fans
at average winding temperature of 75 deg. C
47) Load loss including cooler loss at rated current

and at 75 degree C :
a) For ONAN rating (kW)
b) For ONAF rating (kW)
48) Impedance at rated current and frequency at

75 deg. C and rated MVA (%)
49) Reactance at rated current and frequency

and MVA base : HV LV (%)
50) Resistance at 75 deg. C of:
a) HV winding (Ohms)
b) LV winding (Ohms)
51) Resistance drop on full load (%)
52) Percentage reactance at rated current and

frequency
53) Impedance voltage drop at 75 deg. C.

HV - LV
54) Exciting current in % of and power factor:
a) At normal voltage & normal frequency
b) At maximum voltage & normal frequency
55) Efficiency at 75 deg. C without cooling plant on:
a) At unity power factor.

i) On 125% load
ii) On 100% load
iii) On 75% load
iv) On 50% load
v) On 25% load.
b) At 0.8 power factor.

i) On 125% load
ii) On 100% load
iii) On 75% load
iv) On 50% load
v) On 25% load.
56) Load at which maximum efficiency occurs (as percent

of full load) and power factor at which it occurs
57) Maximum efficiency (%)
58) Regulation at full load at unity P.F. and at 75 deg. C

expressed as a percentage of normal voltage
59) Regulation at full load at 0.8 PF and at 75 deg C

expressed as a percentage of normal voltage
60) Test voltages:

a) Power frequency high voltage test:
i) Test voltage for one minute withstand test of

line end of winding (kV- rms)
ii) Test voltage for one minute withstand test of

both line and the neutral ends of LV winding
winding (kV- rms)
b) Power frequency high voltage test:
i) Test voltage for 1.2x50 microsecond full wave

withstand test of HV winding line end (kV peak)
ii) Test voltage for 1.2x50 microsecond full wave

withstand test of LV winding line end (kV peak)
61) Type and routing test certificates as per IS furnished
62) Details of Bushings
i) Type
ii) Momentary power frequency dry withstand voltage
iii) Visible power frequency discharge voltage
iv) One minute dry withstand power frequency voltage
v) One minute wet withstand power frequency voltage
vi) Under oil flash cover or puncture withstand

power frequency voltage
vii) Full wave withstand impulse voltage
viii) Under oil flush over or puncture/withstand

impulse voltage
ix) Creep distance in air.
x) Recommended gas filling
xi) Wt of assembled bushing
The complete set of Technical literature catalogues

and pamphlets for transformer, Nitogen Injection System and accessories
shall be furnished with the offer.
64) Standards followed List shall be furnished
65) Accessories provided list shall be furnished
66) GA Drawing showing the dimensions shall be arranged.
67) The construction of the Transformer should be as such that Nitrogen

Injection system for Fire fighting can be installed Details of such system to
be indicated in the GA drawing.
2.7.10.7. Technical Parameters of Control and Relay Panels
1) Name of the manufacturer
2) Nos. of control and relay panel provided for 132 kV control
3) Nos. of control and relay panel provided for 33 kV control
4) Nos. of control and relay panels for 132 kV/33 kV transformer
5) Nos. of control panel for On load tap changer (OLTC)
6) Physical dimensional details of various control and relay

panels as provided
7) Degree of protections provided for various C and R panels
8) Details of various relays provided (132 kV side and 33 kV side)
a) Name(s) of manufacturer
b) Model nos. and quantity
c) Type of protections provided
9) Details of various meters provided (132 kV side and 33 kV side)
a) Name(s) of manufacturer
b) Model nos. and quantity
c) Type of protections provided
10) Details of various indicative devices provided for 132 kV
and 33 kV control panels and OLTC control panels
11) Sizes and types of wires used for internal wiring of various
control panels
12) Sets of various control switches and push buttons with related
functions provided
13) GA drawing of various control and relays panels
14) Test certificates furnished Yes/No
15) Standards followed - Details shall be furnished
2.7.10.8. Technical Parameters of 200 kVA, 33 kV/415 V-230 V (L-L) Station

Transformer
1) Name of manufacturer and place of manufacture
2) kVA Rating
3) Rated voltage
HV nominal : kV
HV highest system : kV
LV nominal : V V
LV highest system : V V
4) Rated Frequency
5) No. of phases
6) Rated full current

a) HV winding : Amps
b) LV winding ( 415 V) : Amps
c) LV winding (230 V) : Amps
7) Vector group
8) Tapings
a) Range
b) No. of steps
c) Type of tapping
9) Maximum ambient temperature
10) Type of cooling
11) Temperature rise
a) On oil : deg. C
b Windings : deg. C
12) Total loss at rated voltage at principal

taping and rated frequency
13) Component losses
a) No load loss at rated voltage on principal : kW

tapping and at rated frequency
b) Full load loss at rated current at principal

tapping at 75 deg. C : kW
14) Impedance voltage at rated current for the

principal tapping : %
15) Reactance at rated current and rated frequency : %
16) No load current at rated voltage and rated frequency Amps.
17) Insulation level
a) Separate source power frequency withstand voltage
i) HV. winding : kV (RMS)

ii) LV. winding : kV (RMS)
b) Full wave lightning impulse withstand voltage

c) Inducted over voltage withstand

d) Switching impulse withstand voltage

18) Efficiencies at 75 deg. C at unity power factor:
a) At full load : Percent

b) At full load : Percent
c) At full load : Percent
19) Regulations at full load at 75 deg. C :
a) At unity power factor : Percent

b) At 0.8 power factor lagging Percent
20) Terminal arrangement:
a) HV side
b) LV side
c) Neutral
21) Approximate masses
a) Core and windings : kg
b) Tank, fittings and accessories : kg
c) Oil : kg
d) Total mass : kg
22) Approximate quantity of oil required for first filling : liters
23) Approximate overall dimensions
a) Length : mm
b) Breadth : mm
c) Height : mm
24) GA drawing showing dimensions
25) Type and routine test certificate as per IS : Yes/No
26) List of accessories being supplied
27) The complete set of technical literature catalogues

and pamphlets for transformer and accessories shall be
furnished along with the offer.
26) Standard followed List shall be arranged
2.7.10.9 Technical Parameters for 415V Power Distribution Board
a) Manufacturers name
b) 415V Switch Board type with description of

Incoming & outgoing switch gears
c) Applicable standards
d) Rated Voltage & frequency with permissible variations
e) Symmetrical short circuit withstand current at rated voltage

of switch gear cubicle.
f) Peak short circuit with stand current
g) Degree of protection as per IS: 2147
i) Breaker cubicles
ii) Busbar chamber
h) Cubicle sheet metal details
i) Cold rolled / hot rolled

ii) Size of structural frames and load bearing members
iii) Thickness, front end / rear end
iii) Thickness, sides and top
i) Clearance in air
i) Between phases
ii) Between phase and earth
j) Standard height, width and depth typical panel
i) MCCB panel
ii) MCB panel
k) MCCB
i) Makers name
ii) Type and designation
iii) Applicable standard
iv) Voltage and frequency with permissible variations
v) Rated operation duty
vi) Rated current at 50 degree centigrade ambient temperature
vii) Rated symmetrical breaking current
viii) Rated peak making current
ix) Rated short time rating (for 1 sec)
x) Setting range
xi) Details of protection provided
xii) No of phases
l) MCB
i) Make
ii) Voltage and frequency with permissible variation
iii) Rated current at 50 degree centigrade ambient temperature
iv) Rated breaking current
v) No. of poles
vi) Details of protection provided
m) Power Busbars and Insulators
i) Bus bar sizes and material
ii) Minimum clearance
Phase to Phase (mm)

Phase to earth (mm)
iii) Continuous current rating at 50 degrees centigrade
iv) Temperature rise over ambient Temperature of 50

degrees in centigrade for continuous current rating
v) One second current rating (kA)
vi) Short circuit current rating and duration
n) Fuses
i) Make
ii) Type
iii) Applicable standard
iv) Rated voltage
v) Rupturing capacity (kA)
vi) Peak Cut-off Current (kA)
vii) Whether mounted on an insulated

carrier (Yes/No)
o) Voltmeter
i) Make
ii) Type
p) Ammeter
i) Make
ii) Type
iii) Scale Range
q) Indicating Lamps
i) Make
ii) Type
iii) Voltage
r) Push Buttons
i) Make
ii) Type designation
s) G.A. Drawings of the Switch Board showing major dimensions
2.7.10.10. Technical Parameters for Lighting Distribution Board
i) Maker's name
ii)Type
iii) Standard to which the various equipment conform
iv)Details of enclosure
v)Rated voltage frequency
vi)Rating , no of poles and make of MCCB
vii)Rating, no of poles and make of miniature circuit breaker
viii)Fault withstand cap. for 1 sec, kA.
ix)Electrical single line diagram with all components along with relevant details
x)Details of construction.
xi)Whether general arrangement drawing furnished.
xii)Whether min. illumination levels as per specification and maintained.
xiii)Bus bar material
xiv)Bus bar size
xv)Details of protections provided
xvi)Details of meters provided
2.7.10.11. Technical Parameters of DC Distribution Board (DCDB)
i) Name of the manufacturer :
ii) Physical dimension of the board
iii) Technical parameters of float/boost

battery changer unit
iv) Type & rating of AC supply control unit
v) Outgoing DC supply control units, type

nos. and respective rating
vi) Meters provided with details
vii) Details of various selections provided
viii) Details of DC Cell such as type,

capacity, voltage, overall dimensions etc
ix) Degree of protection provided (IP no.)
x) Drawings to be furnished:
a) GA drawing of battery changer unit
b) GA drawing of DC distribution board
xi) Test certificates furnished Yes/no
xii) Standard followed- list to be arranged
2.7.10.12. Technical Parameters for Illumination System

i) Lighting Fixtures
a) Maker's name
b) Type of fixture
c) Brief description of the fixture
d) Polar curves
e) Overall dimensions
ii) Lamps
a) Maker's name
b) Type
c) Min. luminous flux
d) Bulb finish/Lamp colour
e) Specified life, in hours
f) Rated voltage, volts
g) Rated power, watts
h) Starting period
iii) Ballast
a) Maker's name
b) Type
c) Standard to which the equipment conforms
d) Rated voltage, volts
e) Energy loss
f) Power factor
g) Voltage range
h) Starting and operating voltage
iv) Capacitor
a) Maker's name
b) Rated voltage, volts
c) Capacitor, mfd.
d) Overall dimension
e) Suitability for use with different type of lamp
v) Starter
a) Maker's name and type
b) Operating voltage
vi) Wiring Cable
a) Maker's name
b) Standard to which the cable conforms
c) Voltage grade, volts
d) Size of conductor, sq. mm
e) Conductor material
f) Insulation
vii) Junction Box
a) Maker's name
b) Make
c) Material and thickness
viii) Switch
a) Maker's name
b) Type
c) Rated voltage, volts
d) Current rating Amps.
ix) Constructional Details of lighting towers
x) Details of emergency lighting and safety lighting
2.7.10.13. Technical Parameters for Power, Lighting, Control and Special

cables
a) Maker's name
b) Standard to which the cable conforms
c) Voltage grade, volts
d) Suitable for restricted earthed system (power cable)
e) Permissible voltage and frequency variation for satisfactory
operation.
f) Continuous current rating with single cable laid in air in an
ambient temperature for a maximum conductor temperature of
70 deg C, Amps.
g) De-rating factors for the following shall be indicated:
i) Variation in ambient air temperature (for cable laid in air)
from 30C to 50C in step of 5C.
ii) Variation in ambient ground temp. (for cables laid direct in
ground) from 15C to 40C in steps of 5C
iii) Grouping
h) De-rating factors for different spacing of cables considering
multi-core cables installed in horizontal formation in single row
as well as in different tiers-
i) Cables laid in concrete cable trenches with removable
covers.
ii) Cables laid in cable trays
iii) Cables laid in ground
iv) Depths of laying for cables laid to be directly in ground.
i) Short circuit current
i) Short circuit current, kA
ii) Duration of short circuit
iii) Conductor temperature allowed for the short circuit duty.
j) Conductor
i) Material
ii) Nominal cross sectional area, sq. mm
iii) Number and diameter of wires.
k) Insulation
i) Material
ii) Thickness
iii) Composition
l) Colour scheme for identification of cables

m) Inner -sheath -material, diameter and thick.
n) Outer serving -material and thickness
o) Armour -material, type and sectional details
p) Insulation resistance at 20 deg c per 1000m.
q) Conductor temperature corresponding to maximum continuous
current, C.
r) Overall diameter, mm
s) Weight per 1000m
t) Conductor resistance at 20 deg c per 1000m
u) Recommended minimum installation radius
v) Safe pulling force when pulled by pulling eye
w) Dimension and weight of cable drum with maximum and min.
length of cable for each eye.
x) High voltage test and water immersion test voltage.
2.7.10.14. Technical Parameters of 132 kV and 33 kV Post and Disc

(Tension) Insulators
POST INSULATOR DISC/STRING INSULATOR
33 kV 132kV 33 kV 132 kV
1) Manufacturers name &

place of manufacturer
2) Place of manufacture
3) Type and designation
4) Outside diameter (mm)
5) Centre to centre distance(mm)
6) Creepatge distance of one

disc/post insulator
7) Total min. creepage distance

for slack/strings
8) Weight per unit (kg)
9) Electromechanical strength of
a) each unit
b) complete stack/string
10) Breaking strength of
a) one unit
b) complete stack/string
11) Impulse flash over voltage (kV)
12) Impulse withstand voltage (kV)
13) Dry one minute power frequency

withstand voltage (kV)
14) Wet one minute power frequency

withstand voltage (kV)
15) Puncture voltage (kV)
16) Drawings GA drawing showing all dimensions
The complete set of technical literature catalogues and pamphlets shall be

furnished along with the offer.
18) Standards followed List shall be furnished.
2.7.10.15. Technical Parameters for Fire Fighting System
i) Schematic layout diagram showing the location of water hydrant, fire

pipes, sumps, pump hose etc.
ii) Schematic layout of pump house showing the layout of pumps,
valves, piping etc.
iii) Fire Hydrant / landing valves:
a) Type/make of water hydrant
b) Water consumption at each hydrant point(m3/hr)
c) Terminal head (m)
d) Material of construction
e) Operating details.
f) Technical pamphlets.
g) Number of hydrant points.
h) Number of hydrant point working simultaneously
iv) Hose cabinet / Hose
a) Material of construction of cabinet and qty. of cabinets.
b) Material of construction of hose.
c) Diameter of hose.
d) Number of rolls at each cabinet.
e) Length of hose in each roll.
f) Make
v) Hose reel
a) Make
b) Location and quantity.
c) Length of hose
d) Material of construction
e) Diameter of hose.
f) Make
vi) Portable extinguishers
a) Make
b) Type of fire extinguishers
c) Capacity and numbers of each type
d) Manufacturer's descriptive pamphlet
vii) Smoke/Fire Detection
a) Make
b) Type and make

c) Specific technical features
d) Operating principles
e) Location
f) Manufacturer's descriptive technical pamphlets.
viii) Sump, Pump house
a) Material of construction
b) Sump capacity in lit.
c) Size of sump
d) Size of pump house
ix Pumps
a) Make
b) Type
c) Quantity
d) Discharge in lps.
e) Head in m
f) Motor power in kW
g) Diesel engine power
x) Piping
a) Make
b) Diameter
xi) Details of control system
xii) Water requirement
2.7.11 SCHEDULE XI: Price Bid (to be submitted in Part III of the offer) Vol-III of
the NIT
To,

SECL, Seepat Road,
Bilaspur(CG.)
Dear Sir,
Sub: Detailed break-up of bid price.

We are submitting herewith detailed break-up of bid price as per scope of

supply given in Volume-II of this Owner document. The price bid is given in the
separate sheets which are being submitted in Part-III of the offer.
Yours faithfully,
Dated:
Place:
(Signature)
(Printed Name)
Designation
Firm's Seal
SUB STATION BUILDING
BARBEDWIRE FENCING

Nit 132 KV

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TURNKEY TENDER DOCUMENT

NIT No. : GM(CMC)/SECL/BSP/132 kV Kusmunda SS/Turnkey/2014/688

Job No.- 502255

PARA PARTICULARS PAGE

Job No.- 502255 Vol-II

PARA PARTICULARS PAGE

Job No.- 502255 Vol-II

SL SUBJECTS DRAWING NO.

Job No.- 502255 Vol-II

2.1.1.1 It is proposed to construct on turnkey basis a 132/33 kV substation of

2.1.1.2 Necessary technical parameters have been given in the subsequent

2.1.1.3 Tenderers/Bidders are requested to get themselves acquainted with the

2.1.1.4 Tenderers/Bidders are required to furnish the information in the schedules/

2.1.2.0 LOCATION AND COMMUNICATION

2.1.2.1Kusmunda opencast expansion project (50 Mty capacity) of Kusmunda Area

2.1.4.0 CLIMATIC CONDITIONS

2.1.4.4 The ambient temperature rises to maximum of 50 degrees centigrade in

2.1.5.0 This substation will feed power initially to 3 nos. of 33 kV substations of

2.2.0.0 SYSTEM DESCRIPTION

2.2.1.0 Incoming Power Supply Arrangement

The proposed 132/33 kV substation at Kusmunda Open Cast project

2.2.2.0 Brief Description of the Proposed Substation

Total of 16 nos. 33kV out going feeders will be provided.

2.2.3.0 Power Transformers ( 2x40/50 MVA,132 /33 kV)

2.2.3.1 Two numbers of Power Transformers will be provided at this

2.2.3.2 The transformer will be mounted on a trolley so that it can be moved on

2.2.4.0 Isolator / Disconnecting Switches

2.2.5.0 Potential Transformer

2.2.5.1 Required number of Potential Transformers (PT) shall be provided in

2.2.6.0 Current Transformer

All 132 kV CTs shall have five cores(1-1-1-1-1 A) with 15 VA burden.

All incoming 33 kV CTs shall have 3 cores (1-1-1 A) with 15 VA

2.2.7.0 132 kV SF6 Circuit Breaker & 33 kV Vacuum Circuit Breakers

The transformer protection shall include following ;

(i) High speed biased numerical differential protection in 132 kV

All the auxiliary circuits of the protective system will be operated by

2.2.9.0 Signaling arrangement:

The following system of signaling (audio and visual) shall be provided

2.2.10.0 Interlocking arrangement:

2.2.10.1 Various interlocking systems will be provided to prevent

- Simultaneous supply to a bus bar from two sources

2.2.11.0 Protection to Main Transformer and SF6 Circuit Breakers

2.2.11.1 The following protections will be provided

i) The Transformers will be provided with protections for Through

2.2.12.0 Metering arrangement / Instrumentation:

Digital microprocessor based power meter shall be provided on

i) Values of current (RMS), Voltage (RMS), frequency.

xiii) Self diagnostic tests

These will be flushed in the front panel of respective control panels.

2.2.13.0 Auxiliary power supply:

2.2.13.1 Two numbers of 200 kVA, 33 kV/0.44 kV - 0.23 kV (L-L)

2.2.14.0 110V DC Supply:

-closing and tripping coils of Circuit Breaker

2.2.15.0 Illumination system:

conductor cables. Required number of out going circuits will be

2.2.16.0 Power, Lighting, Control Cables:

2.2.17.0 Bus system:

2.2.18.0 Earthing System

Clause 17.8 Earthing of lightning arresters

Clause 17.8.1The base of lightning arresters shall be directly

Clause 17.8.2 Individual earth electrodes should be provided for each

Clause 17.8.3 For lightning arrestors mounted near Transformer,

Clause17.9. Earthing of miscellaneous, substation and generating