Technical Specification GRP Pipes

PART- B
MECHANICAL
PART- B
SUB-SECTION – III A-01
GRP PIPES, FITTINGS & SPECIALS

CLAUSE NO.
TECHNICAL REQUIREMENTS
SPECIFICATION FOR GLASS FIBRE REINFORCED PLASTICS (GRP) PIPES,

FITTINGS & SPECIALS
1.00.00 GENERAL
This specification covers the specific requirement of design, material, manufacture /

fabrication, constructional features, inspection & testing; transportation, handling,
lowering, laying, jointing, hydro testing and annual maintenance contract of Glass
Fibre Reinforced Plastics (GRP) Pipes, Joints, fittings and specials.
2.00.00 CODE AND STANDARDS
The design, manufacture, inspection and testing of GRP water pipes shall comply
with the latest Indian Standard, IS: 14402 (GRP Pipes, Joints and Fittings for use for
sewerage, Industrial waste and water (other than potable) or ASTM 3517 (Standard
Specification for Fiberglass (Glass Fiber Reinforced Thermosetting Resin) Pressure
Pipe in the case of pressure pipes) or AWWA C 950 (Standard for fiber glass
pressure pipe) & AWWA M 45 (Fiberglass Pipe design) unless otherwise specified
elsewhere in this Technical Specification.
The various codes used in the design, manufacture and testing of GRP pipes are as
follows:
S.No. Code No. Code Title

1. IS 14402 GRP Pipes, Joints and Fittings for use for sewerage,
Industrial waste and water (other than potable) -
specification
2. IS 12709 GRP Pipes, Joints and Fittings for use for potable
water supply - specification
3. IS 5382 Specification for Rubber sealing rings for gas mains,
water mains and sewers
4. IS 13916 Installation of GRP Piping system - code of practice
5. IS 6746 Unsaturated polyester resin systems - specification
6. IS 11273 Woven roving fabrics of 'E' glass fibre
7. IS 11320 Glass fibre rovings for the reinforcement of polyester
and of epoxide resin systems
8. IS 11551 Glass fibre chopped strand mat for the reinforcement
of epoxy, phenolic and polyester resin systems
9. IS 1367 (Part 1 Technical supply conditions for threaded steel
to 20) fasteners
10. AWWA C950 Standard for fiber glass pressure pipe
11. AWWA M 45 Fiberglass Pipe design
12. ASTM C 33 Standard specification for Concrete aggregates
13. ASTM D 638 Standard Test Method for Tensile Properties of
Plastics
14. ASTM D 695 Standard test method for compressive properties of
rigid plastics
15. ASTM D 1599 Standard Test Method for Resistance to Short-Time
Hydraulic Pressure of Plastic Pipe, Tubing, and
Fittings
DARLIPALI STPP STAGE-I (2X800 MW) Sub-Section – IIIA-01

TECHNICAL SPECIFICATIONS Page
MAKE-UP WATER PIPES PACKAGE GRP PIPES, FITTINGS &
SECTION VI –Part – B 1 of 11
BID DOCUMENT NO: CS- 9549-132D-2 SPECIALS
CLAUSE NO.
16. ASTM D 2105 Standard Test Method for Longitudinal Tensile

Properties of Fiberglass (Glass-Fiber-Reinforced
Thermosetting-Resin) Pipe and Tube
17. ASTM D 2290 Standard Test Method for Apparent Hoop Tensile
Strength of Plastic or Reinforced Plastic Pipe by Split
Disk Method
18. ASTM D 2412 Standard Test Method for Determination of External
Loading Characteristics of Plastic Pipe by Parallel-
Plate Loading
19. ASTM D 2563 Standard practice clarifying visual defects in glass
reinforced plastic laminated parts
20. ASTM D 2583 Standard Test Method for Indentation Hardness of
Rigid Plastics by means of a Barcol Impressor
21. ASTM D 2992 Standard practice for obtaining hydrostatic or pressure
design basis for Fiberglass Pipe and Fittings
22. ASTM D 2996 Standard specification for Filament-Wound Fiberglass
(Glass-Fiber-Reinforced-Thermosetting-Resin) Pipe
23. ASTM D 3262 Standard Specification for Fiberglass (Glass-Fiber
Reinforced Thermosetting Resin) Sewer Pipe, in the
case of gravity sewer pipes.
24. ASTM D 3517 Standard Specification for Fiberglass (Glass Fiber
Reinforced Thermosetting Resin) Pressure Pipe
25. ASTM D 3567 Standard practice for determining dimensions of
Fiberglass (Glass Fiber Reinforced Thermosetting
Resin) Pipe and Fittings
26. ASTM D 3681 Standard Test Method for Chemical Resistance of
Fiberglass (Glass-Fiber-Reinforced Thermosetting -
Resin) Pipe in a Deflected Condition
Reinforced Thermosetting Resin) Sewer and Industrial
Pressure Pipe.
28. ASTM D 3839 Standard guide for underground installation of
Fiberglass Pipes.
Reinforced Thermosetting Resin) Pipe Joints Using
Flexible Elastomeric Seals
30. ASTM D 5365 Standard Test Method for Long-Term Ring-Bending
Strain of Fiberglass (Glass-Fiber-Reinforced
Thermosetting-Resin) Pipe
31. ASTM D 5421 Standard specification for contact molded "Fibre glass"
flanges.
32. ASTM F 477 Standard Specification for Elastomeric Seals
(Gaskets) for Joining Plastic Pipe
33. BS 5480 British Standard Specification for Glass reinforced
plastics (GRP) pipes, joints and fittings for use for
water supply or sewerage
34. ISO 1172 Textile-glass-reinforced plastics -- Prepregs, moulding
compounds and laminates -- Determination of the
textile-glass and mineral-filler content -- Calcination
methods

CLAUSE NO.
3.00.00 DESIGN REQUIREMENTS
3.01.00 Nominal Diameter
The nominal diameter of the pipe shall be as specified in the data sheet. The inside
diameters and tolerances on diameters for the specified nominal diameter shall
conform to the requirements stated in IS: 14402 / AWWA C 950 / ASTM D3517.
3.02.00 Length
Pipes shall be supplied in nominal lengths of 6m/9m/12m as per requirements. The

tolerances on nominal lengths shall be as per relevant IS / AWWA / ASTM standards
to which they are supplied.
3.03.00 Wall Thickness
The average Wall thickness of the pipe shall not be less than the minimum wall
thickness published in latest manufacturer’s catalogue. However, minimum wall
thickness in these published wall thicknesses of manufacturer shall conform to the
tolerance limit as given in relevant IS / AWWA / ASTM standards to which GRP pipes
are supplied.
Contractor shall submit design calculations as per AWWA M 45 & AWWA C 950 to
establish the adequacy of pipe size, pressure class and stiffness class selected for
the GRP pipes.
3.04.00 Pressure Class
GRP pipes shall have the pressure class as per the data sheet attached at the end
of this subsection.
3.05.00 Stiffness Class
The pipe shall be stiff enough to meet the design requirement with particular regard
to installation method, burial depths, deflection limits, buckling and vacuum
requirements.
GRP pipes shall have the stiffness class as per the data sheet attached at the end
of this subsection.
3.06.00 Hoop and Longitudinal tensile strength
GRP pipe system shall meet the minimum hoop tensile strength and minimum
longitudinal tensile strength requirements specified in IS 14402 / AWWA C 950 /
ASTM D3517 for the pressure class specified in the data sheet attached at the end
of this subsection.
4.00.00 MATERIAL REQUIREMENTS
4.01.00 Resin: A thermosetting polyester resin (isopthalic resin) to be used and quality
parameters shall be as per relevant IS / AWWA / ASTM standards.

CLAUSE NO.
4.02.00 Glass Fiber Reinforcement: Glass fiber reinforcement shall be of commercial

grade ‘E’ type and shall conform to IS 11273, IS11320 or IS11551 as appropriate or
relevant ASTM standards.
4.03.00 Other Materials
Other materials used in the manufacturing of pipe like aggregates, fillers and
additives shall be in accordance with the relevant IS / AWWA / ASTM standards.
5.00.00 MANUFACTURING REQUIREMENTS
The pipe shall be manufactured through Filament winding process (Continuous

Filament Winding process using advancing mandrel method or Helical Filament
Winding process) by winding continuous glass fibre filaments saturated with liquid
resin or preimpregnated with partially cured resin (subsequent heating may be
required to polymerize the resin system) onto the outside of a mandrel in a
predetermined pattern under controlled tension as described in ASTM D 2996 to
result in a corrosion resistant, composite structure to meet the operating conditions.
5.01.00 Wall composition
Structure of pipe shall have chemical resistant liner, reinforced structural layer and
outer surface layer.
GRP Pipes (as required) shall have to be provided with UV stabilizers and flame
retardants in the resin coat of outer surface layer.
6.00.00 JOINTS
The pipeline shall have a jointing system that shall provide for fluid tightness for the
intended service condition.
All GRP pipes and fittings shall be joined with unrestrained sleeve couplings (Double
REKA joint) or un-restrained double `O’ ring bell-Spigot joints. Thrust blocks are to be
provided at each bends irrespective of buried as well as over ground GRP piping. For
over ground piping, anchors are to be provided at reducers, branch offs, Tee-offs,
expanders and terminal points of other suppliers apart from at points in straight run
separated by an interval of 90 meters approx as per AWWA- M45 (for pipes upto 400
mm dia.) and as per system requirements for large sizes.
Flanged Joint
Flanged joints shall be used for connecting GRP pipes with valves, pumps and other
material piping etc. Flanged joints shall be used with EPDM gasket and hot dip
galvanized bolts. The flanged joint is made from the same material as the pipe.
Rubber gaskets
Rubber gasket used with push-on flexible joints shall conform to the requirements
of IS: 5382 / ASTM F 477.
Rubber gaskets for use with flanged joints shall conform to IS 5382 or equivalent.

CLAUSE NO.
7.00.00 GRP FITTINGS & SPECIALS
7.01.00 General
All GRP fittings, such as bend / elbows, ends, tees, flanges and reducers etc. shall be
equal to or superior in performance to pipe of the same classifications and shall be
smoothly finished internally.
Generally, all GRP fittings are to be manufactured in factory. Dimensions of the

fittings shall be as per relevant standards and drawings shall be submitted to
Employer for approval.
Only in exceptional circumstances, specific required fittings may be permitted

(Employer’s approval) to be fabricated / laminated at site under the supervision of
manufacturer of pipes. However, such site fabricated / lapped fitting / branch off shall
be hydro tested at pressure no less than 1.5 times the pressure class along-with the
pipes.
7.02.00 Fittings made from straight pipe
Fittings shall be fabricated from complete pipes or portions of straight pipe complying
with IS 14402 / ASTM standards as applicable for the pipe classifications. The fitting
shall comply with the declared design requirement and be suitably mitred. The mitre
shall be over wrapped externally and internally with liner, woven roving and/or
chopped strand mat to ensure the longitudinal and circumferential tensile strength is
at least equal by design to that of the pipe with which the fittings is to be used. All
fittings shall have sufficient end length of pipe to accommodate over wrapped length
of fitting and pipe.
7.03.00 Fittings made by Moulding
Moulded GRP fittings shall be made by hand lay-up, contact moulding, hot or cold
press moulding or tape winding with internal liner.
8.00.00 TYPE TESTS
8.01.00 The contractor shall carry out the type tests as listed in this specification on the pipes
to be supplied under this contract. The bidder shall indicate the charges for each of
these type tests separately in the relevant schedule of Section - VII- (Forms &
Procedures) and the same shall be considered for the evaluation of the bids. The
type tests charges shall be paid only for the test(s) actually conducted successfully
under this contract and upon certification by the Employer.
8.02.00 The type tests shall be carried out in presence of the Employer’s representative, for
which minimum 15 days notice shall be given by the contractor. The contractor shall
obtain the Employer’s approval for the type test procedure before conducting the type
test. The type test procedure shall clearly specify the test set–up, instruments to be
used, procedure, acceptance norms, recording of different parameters, interval of
recording, precautions to be taken etc. for the type test(s) to be carried out.
8.03.00 The Long term type tests stipulated in Cl.8.05.00 below should have been conducted
by the manufacturer or its technology provider on the pipes similar to those proposed

CLAUSE NO.
to be supplied under this contract, at an independent laboratory or duly approved by

accredited third party agency. Bidder shall submit these type test reports to the
Employer along with the bid. The manufacturer shall however carry out the short term
/ reconfirmation/ requalification tests as stipulated in Cl.8.05.00 below.
Further, the Employer reserves the right to waive conducting of any or all type tests
(short term/ reconfirmation tests) under this contract. In case such type tests are
waived for any reason whatsoever, the type test charges shall not be payable to the
contractor.
8.04.00 Not Used.
8.05.00 The following type tests shall be carried out:
a) Long term hydrostatic strength / Long term hydrostatic pressure
Manufacturer or its technology provider should have already carried out the full type
testing as described in method A of IS 12709/ Procedure-B of ASTM 2992, duly
approved by accredited third party agency.
Further, the manufacturer shall carry out the requalification test as described in
method B of IS 12709/ reconfirmation test of ASTM 2992 on the same pressure class
& stiffness class as specified for the pipes under this package.
b) Chemical resistance of pipe in a deflected condition
Manufacturer or its technology provider should have already carried out the full type
testing as described in method A of IS 14402 / Procedure-A or Procedure-B of ASTM
3681, duly approved by accredited third party agency.
Further, the manufacturer shall carry out the requalification test as described in
method B of IS 14402 / reconfirmation test of ASTM 3681 on the same pressure
class & stiffness class as specified for the pipes under this package.
c) Joint testing
All joints shall meet the laboratory performance requirements of section 7 of ASTM
D4161. It shall be conducted on joint prototypes of elastomeric gasket sealed
couplings in accordance with section 7 of ASTM D4161 on the pipes supplied under
this package.
d) Long term Stiffness – Material creep
Manufacturer or his technology provider should have already carried out the full type
testing following the guidelines of ISO 10468 and analyzed according to ISO 10928,
method B.
Further, the manufacturer shall carry out the reconfirmation test for 1000hrs on the
same pressure class & stiffness class as specified for the pipes under this package.
The test procedure for this reconfirmation test shall remain same as the Long term
Stiffness test stipulated above. The acceptance criteria for this test shall be as given
in Clause 11 of ASTM D 5365 or as per alternative method proposed by
manufacturer subject to Employer’s approval.

CLAUSE NO.
e) Long term Ring bending strain test
Manufacturer or his technology provider should have already carried out the full type
testing using guidelines of ASTM D5365.
Further, the manufacturer shall carry out the short term reconfirmation test in
accordance with ASTM D5365 on the same pressure class & stiffness class as
specified for the pipes under this package.
9.00.00 MARKING
The marking on pipe shall include the following:
a) Standard mark for the pipes conforming to IS / AWWA / ASTM standards to

which they are supplied.
b) The manufacturer's name or trademark
c) The nominal pipe diameter
d) Class of pipe (Pressure & Stiffness)
e) Batch no. or date of manufacture
f) Colour bands for over ground piping
10.00.00 TRANSPORTATION AND DELIVERY OF PIPES
10.01.00 GRP pipe shall be handled, stored and transported in strict accordance to the
Manufacturer’s instructions. Bidder shall have to submit a write up for safe handling
and stacking of pipes during transportation and at site.
10.02.00 All pipes fabricated in the factory and temporarily stacked in the Contractor's yard or
factory shall be transported to site after shop testing & cleaning them internally. The
loading in the factory shall be carried out by means of either a crane, gantry or with
shear legs, so as not to cause any damage to the finished material. Similarly, while
unloading and stacking, great care shall be taken to ensure that the material is not
damaged or dented.
10.03.00 The material being delivered at site shall be jointly inspected by the Employer and
the Contractor. Defective or damaged pipe shall be rejected by Employer or in case
of minor damage, the Employer may allow repair of the pipe by the Contractor to the
satisfaction of the Employer.
10.04.00 Props of proven designs shall be fixed to the pipes during transit to avoid undue
sagging and consequent distortion. After the pipes are carefully stacked, props may
be removed and re-used for subsequent operations.
In case of transport by ship, packing shall be sea worthy so as to ensure safe delivery
till site.

CLAUSE NO.
10.05.00 At site, pipes shall be stacked in such a way that suitable gaps shall be left in the
pipes at intervals to permit access from one side to the other.
11.00.00 LOWERING, LAYING, JOINTING AND HYDRO TESTING (LLJT) OF GRP PIPES
11.01.00 Lowering, laying, jointing and hydro testing of pipe shall take place in the supervision
of pipe manufacturer. Lowering and Laying shall take place only after the trench and
the surface supporting the pipes have been prepared according to the sub-section III
B – 01 (specification for Civil works of GRP pipes / DI pipes.
11.02.00 Before placing a pipe in the trench, it is necessary to clean any remains of earth,
sand or mud from the inside of the socket and from the opposite end bearing the
rubber ring gasket/packing. When cleaning has taken place, run a hand around inside
the socket to ensure that there are no residues of hardened resin which can be
removed readily with a chisel. It is also necessary to check that the groove has an
even depth and has not been damaged.
For a coupling type of joint, two rubber ring gaskets shall be first fixed into the groove
inside the coupling and then the coupling is fixed at the coupling area of the pipe.
11.03.00 Pipes shall be lowered in the trench with appropriate mechanical means like chain
pulley block, excavators etc.
11.04.00 Place the pipe in the trench, taking care to dig a small hollow at each end so that the
groove and the socket are well separated from the sand gravels in the bottom of the
trench.
11.05.00 Anchor the first pipe section laid according to the method described and leave its
ends free along a space enough for insertion of the next section and for checking.
Place the next pipe section in the trench and leave enough space for the operator to
be free to move and to work between the two pipe sections so as to carry out the
cleaning and checking operations.
11.06.00 Clean the coupling area of the joint once more with a cloth and also clean the flared
portion of the lead-in using suitable lubricant.
11.07.00 Clean the groove again, take the rubber ring gasket and lubricate it by running it
between the hands and checking at the same time, it being in good condition. It shall
be ensured that every portion of the ring or inside of the socket must not lacks
lubricant as it will impair good insertion of the pipe.
11.08.00 For socket and spigot type of joint, pass the rubber ring under the pipe until it settles
into the groove, then pull it forcibly upwards and follow the ring with the hands so that
three quarters of it is positioned in the groove, then lift the ring above the upper
generating line of the pipe forcibly and then release it so that it falls into the groove
thus being freed of ant twists.
11.08.01 Run the hands around the pipe to check that the whole of the packing is in its seating
and, in the case of large diameter pipes, smear lubricant again above the inserted
rubber ring gasket/packing.

CLAUSE NO.
11.08.02 Align and bring together the two pipe sections until rubber ring touches the flared
portion of the lead-in.
When this has taken place, examine the position of the ring and above all, ensure
that there are no sand or other foreign bodies present.
11.08.03 Fit the socket onto the spigot very slowly, dwelling halfway along the coupling area,
and check the position of the packing visually.
11.08.04 Proceed with the joint until the socket is halted by the abutment ledge. The next pipe
section shall not be fitted until the previous pipe section has been anchored with an
overlay of sand.
11.09.00 Check the rubber ring gasket/packing after the joint has been coupled. This check
must always be carried out and is performed with a blade of steel or of another metal
having a thickness of 0.4/0.5 mm, a width of 15 mm and any length greater than 200
mm, the blade being inserted into the annular space between the socket and spigot.
This check shall be conducted along the entire circumference where the packing is
compressed so as to ensure that the rubber ring has a homogeneous depth and is
therefore correctly positioned in its seating. If the ring is found to be seated differently
at one point than other points or if there is any doubt, disconnect the joint, check the
rubber ring and replace it if shows any permanent signs of faulty seating, check once
more the coupling area of the joint, the flared lead-in of the socket and the groove on
the spigot. When re-inserting the pipe section, take extra care to align the pipes
perfectly. When uncoupling pipe sections, never use chains or steel cables in direct
contact with the pipes.
Check once again the position of the ring with the blade
11.10.00 Checking the installed pipe - Initial diametrical deflection shall not exceed 3% of
diameter. Bulges, flat areas, or other abrupt changes of pipe wall curvature are not
permitted. Deflection checks shall be done when the first installed pipes have been
backfilled to grade and continued periodically throughout the entire project. Laying
shall not get too far ahead before verifying the installation quality.
Pipes over 3% deflection shall be replaced completely. No attempt to jack or wedge

the installed over deflected pipe into a round condition shall be made to avoid
damage the pipe.
11.11.00 Correcting over deflected pipe - Pipes installed with initial diametrical deflections
exceeding the approved values shall be corrected to ensure the long term
performance of the pipe. Damaged pipe shall be repaired or replaced as directed by
the employer. Recompact/ backfill to grade and check the pipe deflections to verify
they have not exceeded the values to the satisfaction of Employer.
11.12.00 Misalignment of the joint - When for reasons of the lay-out of the line the joint has
to be misaligned (but such misalignment must remain within the limits provided by the
supplier of the pipes),such misalignment at the predetermined angle should be
applied only after having inserted the pipe and the joint is thoroughly checked for its
water tightness.

CLAUSE NO.
11.13.00 Thrust Block - RCC thrust block shall be provided at bends and at places of
reduction in cross section to take care of thrust.
11.14.00 GRP pipes shall cross minor road / nallah through Hume pipes when buried GRP
pipes are crossing roads & nallahs. Sand bags shall be put around GRP pipes within
Hume pipe. For railway crossing and / or high way crossings of underground GRP
pipes, culverts or MS encased pipe with pushing technology shall be adopted.
11.14.00 At the end of each working day and whenever work is interrupted for any period of
time, the free ends of laid pipes shall be protected against the entry of dirt, water or
other foreign matter by means of approved plugs or end caps.
11.15.00 Site lapping of last joint during erection shall be done at a de-humidified condition by
skilled worker to ensure correct curing.
11.16.00 Field Hydrostatic Tests
The pipeline shall be hydro tested in stretches of suitable length at 1.5 times the
pressure class. Water and other facilities as required for such hydro testing shall be
arranged by the Contractor.
Finally entire system shall be hydro tested at 1.5 times the pressure class of the
pipe/fittings when erection is complete and pump charging has been done. The
detailed Filed Hydrostatic Testing Procedure based on International standard shall be
submitted to Employer for Approval.
12.00.00 ANNUAL MAINTENANCE CONTRACT (AMC) TERMS & CONDITIONS
The Contractor tie-up with the GRP pipe manufacturer, to provide Annual
Maintenance Contract (AMC) for 2 years after completion of the warranty period.
The following services shall be included under AMC:
a) Round the clock monitoring of GRP pipe installation for any leakage / rupture /
damage of the pipeline.
b) Arranging all material (temporary & permanent), manpower (including skilled &
unskilled labour), machineries, testing equipment, fixtures, maintenance tools &
tackles consumables etc. for repair, maintenance, re-erection/ re-commissioning
of any or whole portion of GRP piping system.
c) Repairing the damaged pipes / joints, replacing the damaged part of piping/
joints including fittings with new pipes / fittings, wherever necessary, making
good damaged or excavated bed & trench of GRP pipe and restoring the trench
bed to the original specified bed conditions.
d) Recharging, testing and re-commissioning the entire GRP pipe installation to the
satisfaction of the Employer within 24 hours of the reporting of leakage / rupture /

CLAUSE NO.
DATA SHEET FOR GRP PIPES, FITTINGS AND SPECIALS
S.no. Description Units Parameters

1. Pipe Material Glass fibre Reinforced Plastic
Pipe
2. Applicable standards IS / ASTM / AWWA as listed in
technical specification
3. Design Flow m3/hr 3000 (approx.)
4. Working pressure mWC 115 (approx.)
5. Vacuum pressure Kg/cm2 -0.8
o
6. Maximum service C 36
temperature
7. Hazen William’s constant 150
8. Pipe Nominal diameter NB 900
9. Pipe Length Refer Sub-Section-IIA; Scope
of Supply & Services
10. Pressure Class PN15
11. Stiffness Class C
12. Stiffness Value KPa 248 (minimum) at 5%
deflection
13. Glass fiber reinforcement E
class
14. Pipeline Joint type unrestrained sleeve couplings
(Double REKA joint) or un-
restrained double `O’ ring bell-
Spigot joints
15. Pipe Joint type at valves, Flange Joints
pumps and other piping
16. Restrain mechanism at Thrust Blocks
bends, specials etc.
17. Fittings and specials As per technical specification

PART- B
DI PIPES, FITTINGS & SPECIALS

CLAUSE NO.
SPECIFICATION FOR DUCTILE IRON (DI) PIPES, FITTINGS & SPECIALS
1.00.00 GENERAL
This specification covers the specific requirement of design, material, manufacture /

fabrication, constructional features, inspection & testing, transportation, handling,
laying, site testing and annual maintenance contract of Ductile Iron (DI) Pipes,
Joints, fittings and specials.
2.00.00 CODE AND STANDARDS
The material, design, manufacture, dimensions, tolerances, mechanical properties,

internal cement mortar lining, external zinc coating along with bituminous finished
layer, inspection and testing of DI water pipes shall comply with the latest Indian
Standard, “IS 8329 (Centrifugally cast (spun) ductile iron pressure pipes for water, gas
and sewage – specification)” or equivalent international standard unless otherwise
specified elsewhere in this Technical Specification.
The various referred National and International codes generally used in the design,
manufacture and testing of DI pipes are as mentioned below:
S.No. Code No. Code Title

Centrifugally cast(spun) ductile iron pressure pipes for
1. IS 8329
water, gas and sewage - specification
Ductile iron fittings for pressure pipes for water, gas
2. IS 9523
and sewage - specification
Rubber sealing rings for gas mains, water mains and
3. IS 5382
sewers
Specification for Sheet Rubber Jointing and Rubber
4. IS 638
Insertion Jointing
Code of practice for use and laying of Ductile Iron
5. IS 12288
pipes
6. IS 11606 Methods for sampling of Cast Iron pipes and fittings
7. IS 455 Portland slag cement
8. IS 12330 Sulphate resisting Portland cement
9. IS 6452 Specification for high alumina cement for structural use
10. IS 6909 Specification for supersulphated cement
11. IS 8112 43 grade ordinary Portland cement
General requirements for supply of metallurgical
12. IS 1387
materials
13. IS 1500 Methods for Brinell hardness test for metallic materials
14. IS 1608 Mechanical testing of metals – tensile testing
Ductile iron pipes, fittings, accessories and their joints
15. ISO 2531
for water applications
Ductile iron pipes and fittings for pressure and non-
16. ISO 4179
pressure pipelines -- Cement mortar lining
Rubber seals -- Joint rings for water supply, drainage
17. ISO 4633
and sewerage pipelines -- Specification for materials
18. ISO 8179 Ductile iron pipes -- External zinc-based coating -- Part

MAKE-UP WATER PIPES PACKAGE DI PIPES, FITTINGS &
CLAUSE NO.
1: Metallic zinc with finishing layer

Ductile iron pipes -- External zinc coating -- Part 2:
19. ISO 8179
Zinc rich paint with finishing layer
Ductile iron pipelines -- Polyethylene sleeving for site
20. ISO 8180
application
Ductile iron pipelines -- Hydrostatic testing after
21. ISO 10802
installation
22. ISO 10803 Design method for ductile iron pipes
Ductile iron pipes and fittings -- Seal coats for cement
23. ISO 16132
mortar linings
Ductile – Iron pipe and fittings (guideline code for
24. AWWA M 41 design, manufacturing, testing, jointing, laying &
installation etc.)
Ductile iron pipes, fittings, accessories and their joints
25. BS EN 545 for water pipelines - Requirements and test
methods
3.00.00 DUCTILE IRON (DI) PRESSURE PIPES
3.01.00 Design Requirements
3.01.01 Classification
The class of DI pipes to be provided shall be as specified in the data sheet attached
with this sub-section. The external diameter and wall thickness of socket and spigot
pipes for the specified Class shall be as per IS 8329 or equivalent international
standard.
Pressure class and thickness class of pipe flanges shall be as specified in the data
sheet attached with this sub-section and shall conform to the requirements of IS
8329 or equivalent international standard.
3.01.02 Length
Socket and Spigot pipes shall be supplied in standard working lengths of 4m, 5m,
5.5m & 6m and flanged pipes in lengths of 4m / 5m / 5.5m as per requirements.
3.01.03 Tolerances
Tolerances on External diameter, ovality, thickness and length of pipes etc. shall
conform to the provisions of IS: 8329 or equivalent international standard.
3.02.00 Material Requirements
The metal used for manufacturing the pipes shall be of good quality, commensurate
with the mechanical requirements laid down in IS 8329 or equivalent international
standard.
3.03.00 Manufacturing Requirements
3.03.01 Pipes supplied shall be centrifugally cast (spun) Ductile Iron pipes conforming to IS

CLAUSE NO.
The pipes shall be stripped with all precautions to avoid warping or shrinkage
defects, detrimental to their good quality. The pipes shall be sound and free from
surface or other defects.
3.03.02 External layer
The DI pipes supplied shall be provided with external protection of metallic zinc
coating with finishing layer of bituminous paint as per IS 8329 or equivalent
international standard.
3.03.03 Internal lining
The pipes shall be provided with suitable cement mortar internal lining as per IS
3.04.00 Joints
3.04.01 Push-on flexible joints shall be provided for pipe to pipe connection as per IS 8329
or equivalent. Wherever, flange joints are required e.g. at terminal points, valves,
over ground and underground pipe connection etc., Welded on flanges shall be
used.
3.04.02 Rubber gaskets
Rubber gasket used with push-on flexible joints shall conform to the requirements
of IS: 5382 or equivalent.
Rubber gaskets for use with flanged joints shall conform to IS 638 or approved
equivalent.
4.00.00 DI FITTINGS & SPECIALS
4.01.00 Design Requirements
The class of DI fittings to be provided shall be as specified in the data sheet

attached with this sub-section. The external diameter and wall thickness of fittings
for Push-on-joints for the specified Class shall be as per IS 9523 or equivalent.
The Pressure class of flanged fittings shall be as specified in the data sheet
attached with this sub-section and shall conform to the requirements of IS 9523 or
equivalent.
4.01.02 Permissible deviations on length of fittings
The permissible deviations on the length of fittings shall be as per IS: 9523 or
equivalent.

CLAUSE NO.
4.01.03 Tolerances
Tolerances on external diameter, Raised face height, thickness and Flange drilling
of fittings etc. shall conform to the provisions of IS: 9523 or to the provisions of
international equivalent standard to which they are supplied.
4.02.00 Material Requirements
The metal used for manufacturing the fittings shall conform to the appropriate grade
as specified in IS 1865, in commensurate with the requirements of IS 9523 or
equivalent.
4.03.00 Manufacturing Requirements
4.03.01 The fittings shall be stripped with all precautions to avoid warping or shrinkage
defects, detrimental to their good quality. The fittings shall be sound and free from
surface or other defects.
4.03.02 External layer
The DI fittings supplied shall be provided with external protection of metallic zinc
coating or zinc rich paint coating with finishing layer of bituminous paint as per IS
9523 or equivalent.
4.03.03 Internal lining
The fittings shall be provided with suitable cement mortar internal lining as per IS
9523 or equivalent.
4.04.00 Joints between pipe and fittings
4.04.01 Push-on flexible joints shall be provided for pipe to fitting connection as per IS 9523
or equivalent. Flange joints, wherever required, shall conform to the requirements of
IS 9523 or equivalent.
4.04.02 Rubber gaskets
All the Dl fittings shall be provided with rubber gaskets for each socket. Rubber
gasket used with push-on flexible joints shall conform to the requirements of IS:
5382 IS 9523 or equivalent.
Rubber gaskets for use with flanged joints shall conform to IS 638 or equivalent.
5.00.00 TYPE TESTS
5.01.00 The contractor / manufacturer shall carry out the type tests as listed in this
specification on the pipes to be supplied under this contract. The bidder shall indicate
the charges for each of these type tests separately in the relevant schedule of
Section - VII- (Forms & Procedures) and the same shall be considered for the
evaluation of the bids. The type tests charges shall be paid only for the test(s)
actually conducted successfully under this contract and upon certification by the
Employer.

CLAUSE NO.
5.02.00 The type tests shall be carried out in presence of the Employer’s representative, for
which minimum 15 days notice shall be given by the contractor. The contractor shall
obtain the Employer’s approval for the type test procedure before conducting the type
test. The type test procedure shall clearly specify the test set–up, instruments to be
used, procedure, acceptance norms, recording of different parameters, interval of
recording, precautions to be taken etc. for the type test(s) to be carried out.
5.03.00 In case the contractor / manufacturer has already conducted such specified type
test(s), he may submit the type test reports to the Employer during detailed
engineering for consideration of waiver of conductance of such type test(s) or
otherwise as deemed fit by Employer. Such test(s) should have been either
conducted at an independent laboratory or duly approved by accredited third party
agency. The Employer reserves the right to waive conducting of any or all the
specified type test(s) under this contract. In case type tests are waived, the type test
charges shall not be payable to the contractor.
5.04.00 The type test shall be performed whenever a significant change is made in the
design, material or process of manufacture or a new size or size range of the product
is being supplied by the manufacturer.
5.05.00 The following type tests shall be carried out:
5.05.01 Joint Leak Tightness Test
a) Tests for joints (push-on flexible joints) shall be conducted as per the
guidelines of ISO 2531 to establish adequate joint performance with respect
to internal pressure, external pressure and vacuum pressure under both
normal alignment of joints and deflected alignment of joints as dictated in
ISO 2531.
b) Tests for Leak tightness and mechanical resistance of flanged joints shall be
conducted as per ISO 2531.
5.05.02 Cement Lining Smoothness Type Test
The contractor / manufacturer should have carried out Cement Lining Smoothness
test to establish C value (Hazen & William’s constant) of the offered DI pipe as 140.
Necessary certificate for the same shall be furnished to the employer.
In case the contractor / manufacturer has not carried out the test, the same shall be
carried out by the contractor / manufacturer within the scope of this contract.
5.05.03 Ring bend test
Ring bend test for 3% deflection with respect to external diameter of DI pipe offered
shall be conducted by contractor / manufacturer to prove that internal cement
mortar lining does not come off the substrate surface of Ductile Iron on random
basis for each manufacturing lot.
If the contractor / manufacturer of pipes do not have the facility for this type test at
his own works, the same can be arranged by him to conduct and demonstrate the
test.

CLAUSE NO.
6.00.00 TRANSPORTATION AND DELIVERY OF PIPES
6.01.00 Bidder shall have to submit a write up for safe handling and stacking of pipes during
transportation and at site. It shall conform to the requirements stated in IS: 12288 or
equivalent.
6.02.00 All pipes fabricated in the factory and temporarily stacked in the Contractor's yard or
factory shall be transported to site after shop testing & cleaning them internally. The
loading in the factory shall be carried out by means of either a crane, gantry or with
shear legs, so as not to cause any damage to the finished material. Similarly, while
unloading and stacking, great care shall be taken to ensure that the material or lining
inside is not damaged or dented.
6.03.00 The material being delivered at site shall be jointly inspected by the Employer and
the Contractor. Defective or damaged pipe shall be rejected by Employer or in case
of minor damage, the Employer may allow repair of the pipe by the Contractor to the
satisfaction of the Employer as per guideline of IS 8329.
6.04.00 Props of proven designs shall be fixed to the pipes during transit to avoid undue
sagging and consequent distortion. After the pipes are carefully stacked, props may
be removed and re-used for subsequent operations.
In case of transport by ship, packing shall be sea worthy so as to ensure safe delivery
till site.
All the Dl fittings shall be properly packed with jute cloth. Rubber rings shall be
packed in polyethylene bags. Rubber rings in PE bags and nuts, bolts etc. shall be
supplied in separate jute bags.
6.05.00 At site, pipes shall be stacked in such a way that suitable gaps shall be left in the
pipes at intervals to permit access from one side to the other.
7.00.00 MARKING
Each Pipe shall have as cast or stamped or legibly and indelibly painted on it with
the following marks:
a) The Manufacturer's name or trademark on each pipe
b) The nominal diameter of pipes and batch number.
c) Class of Pipes and fittings
d) A white ring line showing length of insertion at spigot end
e) Standard ISI certification mark for the pipes conforming to IS or international

standard mark to which they are supplied.
f) The last two digits of the year of manufacture
h) Any important information that the manufacturer deems fit to be inscribed on pipe.

CLAUSE NO.
8.00.00 LAYING AND JOINTING OF DI PIPES
8.01.00 Laying, erection and jointing of DI pipelines at field / site shall be under the direct
supervision of Manufacturer (Supplier) from whom pipe is sourced / procured.
8.02.00 Laying Underground
Pipes shall be lowered into the trench with tackle suitable for the weight of pipes. For
smaller sizes, up to 250 mm nominal bore, the pipe may be lowered by the use of
ropes but for heavier pipes suitable mechanical equipment shall be used.
All construction debris shall be cleared from the inside of the pipe either before or just
after a joint is made. All persons shall vacate any section of trench into which the pipe
is being lowered.
The assembly for the pipes shall be made as recommended by the pipe manufacturer
and using the suitable tools.
The socket and spigot ends of the pipes shall be brushed and cleaned. The
chamfered surface and the end of the spigot end have to be coated with a suitable
lubricant recommended by the manufacturer of the pipes. Oil, petroleum bound oils,
grease or other material, which may damage the rubber gasket, shall not be used as
lubricant. The rubber gasket shall be inserted into the cleaned groove of the socket. It
shall be checked for correct positioning.
The two pipes shall be aligned properly in the pipe trench and the spigot end shall be
pushed axially into the socket either manually or with a suitable tool specially
designed for the assembly of pipes and as recommended by the manufacturer. The
spigot has to be inserted up to the insertion mark on the pipe spigot. After insertion,
the correct position of the socket has to be tested with a feeler blade.
Deflection of the pipes, if any, shall be made only after they have fully been
assembled. The deflection shall not exceed 75% of the values indicated by
manufacturer.
On gradients of 1:15 or steeper, precautions shall be taken to ensure that the spigot
of the pipe being laid does not move into or out of the socket of the laid pipe during
the jointing operations. As soon as the joint assembly has been completed, the pipe
shall be held firmly in position while the trench is back filled over the barrel of the
pipe. The backfill shall be well compacted.
Special provisions in trench shall be made for accommodating socket (Bell) of each
pipe, as applicable so that barrel is uniformly rested on even trench bed surface,
which is well compacted as recommended in codes / standards.
At the end of each working day and whenever work is interrupted for any period of
time, the free ends of laid pipes shall be protected against the entry of dirt, water or
other foreign matter by means of approved plugs or end caps.
8.03.00 Laying above ground
The following is applicable only when no additional bending moments except that
those due to self weight of pipe and its content are present. If any additional moments

CLAUSE NO.
are present, piping contractor has to suitably support the pipe in consultation with
manufacturer and Employer.
a) Socket and spigot pipes
Socket (Bell) and spigot pipes shall be provided with one support (usually pedestal or
steel pipe support) per pipe. The supports shall be positioned behind the socket of
each pipe.
Pipes shall be fixed to the supports with mild steel straps so that axial movement due
to expansion and contraction resulting from temperature fluctuations is taken up at
individual joints in the pipeline. Joints shall be assembled with the spigot end
withdrawn 5 to 10 mm from the bottom of the socket to accommodate thermal
movements.
The designed anchorage shall be provided to resist the thrusts developed by internal
pressure at bends, tees, etc.
Where a pipeline crosses a watercourse, the design and method of construction shall
take into account the characteristics of the watercourse to ascertain the nature of
bed, scour levels, maximum velocities, high flood levels, seasonal variation, etc.,
which affect the design and laying of pipeline.
b) Flanged pipes
The maximum unsupported span for flanged pipes shall not be more than 8 m. The
supports shall be located at the centre of every second pipe.
The maximum unsupported span at water course shall also be not more than 8 m.
The relative position of pipe joints and pipe supports shall be as per IS 12288 or
equivalent.
The supports of all flanged pipe work spans shall be stable and unyielding due to
movements in the pipeline.
The straps shall prevent any lateral movement or lifting of the pipelines but not restrict
expansions and contractions caused by temperature fluctuations.
8.04.00 Cutting of pipes
The cutting of pipe, if required, for inserting valves, fittings etc. shall be done in a neat
and workman like manner without damage to the pipe or lining so as to leave a
smooth end at right angles to the axis of the pipe. Cutting of pipes shall be reduced to
a minimum required.
Cutting has to be made with suitable tools as per IS 12288 or equivalent and
according to the recommendations of the manufacturer. The spigot end has to be
chamfered again at the same angle as the original chamfered end. If there is no mark
for the insertion depth on the spigot ends of the (cut) pipe it shall be marked again
according to the instructions of the manufacturer.

CLAUSE NO.
8.05.00 Pipeline anchorage
Pipeline shall be securely anchored at dead ends, tees, bends, tapers and valves to
resist thrust arising from internal pressure. Suitable thrust blocks made of concrete
shall be designed and cast-in-situ.
8.06.00 All specials like bends, tees etc. and appurtenances like valves etc. shall be laid in
synchronization with the pipes. The Contractor has to ensure that the specials and
accessories are available at site ready to be installed together with the pipes.
9.00.00 EXTERNAL PROTECTION
9.01.00 The details of soil resistivity data when enclosed with this specification is for general
guidance of the contractor and the accuracy, validity & adequacy of the data shall be
verified by the Contractor.
9.02.00 The contractor shall carry out soil resistivity survey along the ROW of the pipeline
using Wenner’s 4-pin method in the presence of Employer’s representatives.
9.03.00 On completion of all field work, a report incorporating resistivity (on semilog graph
sheets) data shall be prepared by the contractor and submitted to the Employer.
9.04.00 In case of highly corrosive soil (soil resistivity less than 1000 ohm cm), polyethylene
sleeving shall be provided for encasement of the pipes, fittings and joints against
corrosion. This encasement shall be so designed to prevent the contact of pipe,
fittings and joints with the surrounding backfill and bedding material. It shall conform
to the requirements of IS 8329 & IS 12288 or equivalent international standards.
10.00.00 HYDRAULIC TESTING OF PIPELINES
After laying and jointing, the pipeline shall be tested for soundness and leak tightness
of pipes, fittings and joints, and soundness of any construction work. The pipeline
may be tested in sections.
Water and other facilities as required for such hydro testing shall be arranged by the
Contractor. Each section shall be properly sealed-off with special stop ends secured
by adequate temporary anchors. The thrust on the stop ends shall be calculated and
the anchors designed to resist it. All permanent anchors shall be in position and, if of
concrete, shall have developed adequate strength before testing begins.
10.01.00 Hydraulic Testing of Sections
The section under test shall be filled with water, taking care that all the air is
displaced either through vents at the high points or by using a pig or a sphere. After
filling, the pipeline shall be adequately pressurized for a period of time to achieve
stable conditions.
The pipeline is then pressurized up to the full test pressure as stipulated in the data
sheet attached with this sub-section and the section under test completely shall be
closed off. The test pressure shall be maintained for a period of not less than 10
minutes to reveal any defects in the pipes, joints or anchorages. The test pressure
shall be measured such as to ensure that the required test pressure is not exceeded
at any point in the entire pipeline.

CLAUSE NO.
If the test is not satisfactory, the fault shall be found and rectified. Methods employed
for finding faults shall be as per IS 12288.
10.02.00 Hydraulic Testing of Complete Pipeline
After all the sections have been joined together on completion of section testing, a
test on the complete pipeline shall be carried out. This test shall be carried out at a
pressure as specified in the data sheet attached with this sub-section. During the test,
the pressure at any point in the pipeline shall not exceed the pressure as specified in
the data sheet attached with this subsection.
11.00.00 ANNUAL MAINTENANCE CONTRACT (AMC) TERMS & CONDITIONS
The Contractor shall tie-up with the DI pipe manufacturer, to provide Annual
Maintenance Contract (AMC) for 2 years after completion of the warranty period. The
following services shall be included under AMC:
a) Round the clock monitoring of DI pipe installation for any leakage / rupture /
b) Arranging all material (temporary & permanent), manpower (including skilled

& unskilled labour), machineries, testing equipment, fixtures, maintenance
tools & tackles consumables etc. for repair, maintenance, re-erection/ re-
commissioning of any or whole portion of DI piping system.
c) Repairing the damaged pipes / joints, replacing the damaged part of piping/
joints including fittings with new pipes / fittings, wherever necessary, making
good damaged or excavated bed & trench of DI pipe and restoring the trench
bed to the original specified bed conditions.
d) Recharging, testing and re-commissioning the entire DI pipe installation to

the satisfaction of the Employer within 24 hours of the reporting of leakage /
rupture / damage of the pipeline.

CLAUSE NO.
DATA SHEET FOR DI PIPES, FITTINGS & SPECIALS
S.no. Description Units Parameters

1. Pipe Material Ductile Iron (DI) pipe internally
cement mortar lined and
externally coated with metallic
zinc & finishing layer of
bituminous paint
2. Applicable standards IS / ISO / AWWA / BS as listed
in technical specification
3. Design Flow m3/hr 3000 (approx.)
4. Hazen & William’s constant 140
5. Pipe Nominal diameter NB 900
6. Pipe Length m Refer Sub-Section-IIA; Scope
of Supply & Services
7. Pipe Class K9 as per IS 8329 or
equivalent
8. Pipe Joint type Push-on flexible joints as per
IS 8329
9. Pipe Joint type at valves, Flange Joints as per IS 8329 &
pumps and other piping IS 9523
10. Welded-on Flange (as PN 16 (except with valves
applicable) Pressure Class where PN 16 flange can be
provided)
11. DI fittings class K12 as per IS 8329 or
equivalent
12. DI fittings flange (as PN 16
applicable) class
13. Restrain mechanism at Thrust Blocks
bends, specials etc.
14. Maximum field hydrostatic N/mm2
test pressure
a) At each section (not N/mm2 (1.75) or (1.15 + surge
exceeding 1000 m) pressure) whichever is higher
for not less than 10 minutes
b) Complete pipeline N/mm2 2.1
15. Other Requirements As per technical specification

PART- B
VALVES
CLAUSE NO. TECHNICAL REQUIREMENTS
SPECIFICATION FOR VALVES
1.00.00 BUTTERFLY VALVES
1.01.00 DESIGN & CONSTRUCTION FEATURES
1.02.00 Butterfly valves shall be of flanged construction (for sizes 700mm NB and
above) and double flanged or lugged wafer type of low leakage rate (for sizes
less than 700mm NB) and shall be complete with actuating mechanism,
matching counter flange, bolts, nuts, gaskets, lifting lugs, sole plate for
supporting feet in the valve body etc. The valves shall be designed for the
design pressure / temperature as specified and in accordance with AWWA-C-
504 or BS: EN 593.
1.03.00 Fabricated butterfly valves instead of cast body valves are also acceptable for
larger size (700 mm and above). In such a case, the bidder will have to
submit thickness calculation in order to establish the integrity of the fabricated
valve body under the system design pressure.
1.04.00 For sizes not covered in AWWA-C-504, the dimensions given in AWWA-C-
504 shall be extrapolated to arrive at final values.
1.05.00 Type Test of Butterfly Valves
1.05.01 Irrespective of the design standard adopted Type test i.e. Proof of design test
(POD) as per AWWA-C-504 shall be conducted for the butterfly valves having
size 1000mm NB and above. In case POD test has been conducted in the
past, required certified documents such as GA drawing, cross sectional
drawing and test certificate shall be submitted to Employer for approval. In
case such test was not conducted in the past or the certified documents are
found to be unacceptable, the same shall be conducted for this project as per
AWWA C-504 for each design/rating being offered and the documents shall
be furnished for approval.
1.05.02 The POD tested valve can be rebuilt and used provided that it is fully
disassembled and there are no worn areas (body, disc, shaft, or pins) that
may affect the performance of the valve. Additionally, the seat, seat
hardware, bearings, body gaskets, and shaft seals shall be replaced.
Following reassembly, the valve shall be retested as specified else where in
the technical specification.
1.06.00 The valves shall be suitable for installation in any position (horizontal / vertical
etc.).
1.07.00 The valves and all accessories shall be designed so as to guarantee an easy
disassembling and maintenance.
DARLIPALI STPP STAGE-I (2X800 MW)

TECHNICAL SPECIFICATIONS Sub-Section – IIIA-03
MAKE-UP WATER PIPES PACKAGE Page 1 of 9
SECTION VI –Part – B VALVES
BID DOCUMENT NO: CS- 9549-132D-2
1.08.00 All valve components and accessories of the same type shall be perfectly
identical in size and material so as to guarantee interchangeability of the
parts.
1.09.00 The actuator-operated valves shall be designed on the basis of the following
prescriptions:
a) The internal parts shall be suitable to support the stresses due to the
actuator;
b) The valve-actuator unit shall be suitably stiff so as not to cause

vibrations, misalignments, etc.
1.10.00 All flanged ends shall comply with the standard specified. The valve flanges
shall be flat faced.
1.11.00 If the bidder is not able to supply the material with connecting ends machined
and dimensioned in compliance with the specification, the alternative
proposed by him shall be submitted to engineer for approval.
1.12.00 The bidder shall furnish the coefficient of capacity of each valve (CV in metric
units) and submit the characteristic curves (CV vs flow) to the Employer.
1.13.00 The seals, both on the body (sleeve) and on the disc shall be of the material
specified.
1.14.00 Necessary shaft seal shall be provided and adequately designed to ensure
no leakage across the seal. This seal shall be designed so that they will allow
replacement without removal of the valve shaft.
1.15.00 The operating mechanism shall be mounted directly on or supported from the
valve body.
1.16.00 The sealing ring on the disk shall be continuous type and easily replaceable.
1.17.00 For all types of valves, the design with shaft eccentric to the disk is preferred.
1.18.00 The shaft shall be solid type and shall pivot on bushings. Bushings/sleeve
type bearings shall be contained in the hub of valve body.
1.19.00 Butterfly Valves shall be fitted with sleeve type bearing such as PTFE. Valves
of size 350NB and above shall be provided with one or two thrust bearings to
hold the disc securely in the centre of the valve seat without hydraulic or
external axial shaft loads. Sleeve and other bearings fitted into the valves
body shall be of self lubricated materials that do not have any effect on the
fluid handled and other components of the valves. Bearing shall be provided

beyond the shaft seal. The housing for this bearing shall be rigidly attached to
the valve body.
1.20.00 The minimum length of the disk hubs shall be at least 1.5 times the diameter
of the shaft or of the stems.
1.21.00 The shaft shall be connected to the disk through keys or taper pins or screws
of stainless steel.
The connections shall be designed so as to avoid looseness during the

operation; moreover, they shall be provided with suitable disassembling
systems.
The design of the shaft shall be such that it will safely sustain maximum
differential pressure across the closed valve. The shaft and any key (taper pin
or other) for transmitting the torque between shaft and disk shall be capable
of withstanding the maximum torque required to operate the valve.
1.22.00 The disc shall rotate from the full open to the tight shut position. The disc
shall be contoured to ensure the least possible resistance to flow and shall be
suitable for throttling operation. While the disc is in the throttled position,
valve shall not create any noise or vibration.
1.23.00 All butterfly valves shall have permanent arrow inscription on the valve body
indicating direction of flow.
1.24.00 All valves shall be complete with:
a) Graduated position indicator (located in a visible place for the

operation);
b) Arrow indicating the flow direction ;
c) Adjustable mechanical stop limiting devices to prevent over travel of

valve disk in open and closed position.
1.25.00 Manually operated valves shall be provided with reduction gear unit for valves
of size 250 NB and above. Valves provided with motorized or pneumatic
actuator shall be provided with a hand wheel for manual operation.
1.26.00 Hand operated valves shall have the following:
a) Local hand controls;
b) The hand controls shall close the valve with clockwise rotation.
c) The hand controls shall be dimensioned to guarantee an easy

maneuver under most severe conditions.

d) The hand controls shall be provided with locking systems suitable to

avoid the disk assume a not-desired position during the operation.
e) All the butterfly valves shall be provided with hand wheel or lever as
per the requirements.
f) For lever/wrench operated valves, means shall be provided for

positively holding the disc in not less than three intermediate positions.
g) Hand wheel shall be made of malleable iron with arms and rims of
adequate strength. The hand wheel of diameters 300 mm or less shall
be provided with handles for ease of operation. The pulling force
required on the hand wheel rim shall not exceed 30 Kg when operating
the valve under full flow and operating pressure.
1.27.00 Gear reduction units
a) If required, the valves shall be supplied complete with hand actuated

reduction units for valve sizes of 250 mm and above.
b) The reduction units shall be watertight type, complete with lubricators

and position indicator.
c) The reduction unit shall be designed and dimensioned so as to make

the valve operation easier without causing excessive stresses to the
internal parts of the valve itself.
d) The reduction unit shall have suitable irreversibility characteristics.
1.28.00 Actuators operated valves:
a) Actuators will be with Limit and Torque switches for either end of travel
for control and interlocking purpose.
b) The characteristics of the actuators to be located on the valves are

indicated in the actuators specification.
c) Should the actuator be located on the control column, all connecting

accessories shall be supplied (extensions, joints, articulations, etc).
d) The valves 150NB and above shall also be provided with hand wheel
drive arrangement suitable for manual operation. Manual operation of
valve shall be through worm and gear arrangement having totally
enclosed gearing with hand wheel diameter and gear ratio designed to
meet the required operating torque. It shall be designed to hold the
valve disk in intermediate position between full open and full closed
position without creeping or fluttering. Adjustable stops shall be
provided to prevent over travel in either direction.

e) Limit and torque switches shall be enclosed in water tight enclosures

along with suitable space heaters.
1.29.00 The valve operators (Hand-wheel or Gear reduction unit or Motor actuator
shall be designed as per relevant international standard.
1.30.00 MATERIALS
Design details of the butterfly valves shall be as per the Design Data
enclosed as Appendix-1 to this Sub-section. Materials of construction of
various categories of butterfly valves of shall be as indicated below:
a) Body Cast Iron to IS-210 FG-260 / ASTMA - 216CL B

OR
Fabricated steel as per ASTM A-515 GR 60/80/
IS : 2062 GrB /IS : 2002 or equivalent.
b) Disc Cast Iron to IS-210 FG-260/ ASTMA -216CL B
OR
Fabricated steel as per ASTM A-515 GR 60/80
IS : 2062 GrB /IS : 2002 or equivalent.
OR
Ductile Iron – IS:1865, SG 500/7
c) Shaft Stainless steel AISI : 410 or equivalent
d) Body Seat SS-316
e) Disc Seat/ Nitrile rubber, EPDM (Ethylene Propylene
Seat Rings Rubber), Hypalon.
f) Bearing Self lubricated type
1.31.00 SPECIFIC GUARANTEE
1.31.01 For the rubber seated valves; the bidder shall guarantee that in the closed
position and with a disc differential pressure as specified, the valves shall be
water tight.
1.31.02 The bidder shall guarantee that the operating mechanism shall open and
close the valve under the specified maximum differential pressure within the
time specified.
1.31.03 The valve shall be suitable for frequent operation during initial commissioning
operation after a long period of inactivity.
1.32.00 MARKING
a) The mark stated by engineer in the Material Request shall be printed

on the body of all valves and relevant accessories (control columns
and relevant connecting elements to the valve, counter flanges, valves
for the auxiliary control if separately supplied, etc.).

b) The face of each hand wheel shall be clearly marked "Open" and
“Shut" with arrows indicating the direction of rotation to which they
refer. Each hand wheel shall also be fitted with a circular name plate
indicating the service for which the valve is intended and valve tag
number. The name plates shall be engraved in black lettering.
c) Each spare part shall be individually marked with metal plates suitably
punched for an easy identification.
d) The plates shall contain at least the following indications:
i) DN
ii) Type of material
iii) Series (pressure class)
1.33.00 PREPARATION FOR SHIPMENT / TRANSPORTATION
a) At the final assembly stage, all components shall be carefully cleaned

according to the procedures approved by engineer.
b) Inner surfaces shall be protected by protective agents or they shall be

conditioned with the aid of dehydrators. Protection procedures shall
state the brand and chemical analysis of the adopted protective agent.
c) Immediately after cleaning and possible application of a corrosion

inhibitor, all open ends of the components shall be plugged with metal
(unwelded) or wooden plugs or covers to be attached to these ends so
that the components will be protected during transportation and
storage.
d) All parts shall be packed and prepared for shipment and preservation
at site according to the bidder's procedure which shall be submitted to
engineer for approval. Preparation for shipment shall be based upon
the transport and storage conditions and schedules indicated by
engineer.
e) Identification and marking shall be in compliance with the instructions

issued by engineer.
f) Any unassembled components of the unit shall be carefully packaged

and identified by marking so that each item can be immediately and
easily traced for assembly.
g) The bidder shall not ship any components unless he has been
authorised by engineer-In-Charge.

1.34.00 PAINTING
a) All the Equipments shall be protected against external corrosion by

providing suitable painting.
b) The surfaces of stainless steel, Galvanized steel, Gunmetal, brass,

bronze and non-metallic components shall not be applied with any
painting. The Contractor shall clean the external surfaces and internal
surfaces before Erection by wire brushing and air blowing. The steel
surface to be applied with painting shall be thoroughly cleaned before
applying painting by brushing, shot blasting etc as per the agreed
procedure.
c) For all the steel surfaces (external) exposed to atmosphere (outdoor

installation), a coat of chlorinated rubber based zinc phosphate primer
of minimum thickness DFT of 50 microns followed up with undercoat of
chlorinated rubber paint of minimum DFT of 50 microns shall be
applied. Then, intermediate coat consisting of one coat of chlorinated
rubber based paint pigmented with Titanium di-oxide with minimum
DFT of 50 microns and top coat consisting of two coats of chlorinated
rubber paint of approved shade and colour with glossy finish and DFT
of 100 microns shall be provided. Total DFT of paint system shall not
be less than 250 microns.
d) For all the steel surfaces (external) inside the building (indoor
installation), a coat of read lead primer of minimum thickness of 50
microns followed up with undercoat of synthetic enamel paint of
minimum thickness of 50 microns shall be applied. The top coat shall
consist of two coats each of minimum thickness of 50 microns of
synthetic enamel paint and thus total thickness shall be minimum 200
microns.

Appendix-1
DATA SHEETS OF BUTTERFLY VALVES
1 900 mm NB Four (4) numbers manual BFV in GRP /

DI pipes (as applicable)
3 Valve Design Standard AWWA C 504 / BS:EN 593

4 Design Flow 3000m3/hr
5 Normal working pressure As per system design.
6 Maximum Operating As per system design.
Pressure
7 Maximum Differential Same as maximum operating pressure.
pressure
8 Design Pressure Maximum operating pressure
9 Type Double flanged/ refer Technical
Specification
11 End Connection a)End:-
Flanged flat faced machined and drilled
b)For Cast Iron flanges:
End flange shall be Cast Iron (ANSI
Class 125/matching pipe flanges).
c)For Fabricated Valve :
End flange shall be carbon steel (AWWA
–C-207 Class D / matching pipe flanges)
12 Whether Counter flanges NO
(where applicable) are to be
Supplied?
2.00.00 AUTOMATIC AIR RELEASE VALVES
2.01.00 A suitably sized & numbers of automatic air-release-cum-vacuum breaker

valve(s) shall be provided on the pipelines based on transient analysis study
conducted by contractor. Each Air release Valve shall be provided with an
Isolation Valve (Gate type). Air release valves shall be of automatic type as
per IS: 14845 with minimum PN 16 rating. The Isolation valve of air release
valve shall be of Cast Iron or Cast steel Body with Stainless steel trim as per
relevant IS code. The Air release valve in the makeup water pipelines shall
be provided with a suitable enclosure/protection arrangement with locking
arrangement so that the same is not tampered.
2.02.00 Details of air release valve shall be as follows:
a) The air release valves shall be double air valve/kinetic air valve with
two orifices and two floats. The float shall not close the valve at higher
air velocities. The Orifice contact joint with the float shall be leak tight
joint.

b) The valve shall efficiently discharge the displaced air automatically

from ducts/ pipes while filling them and admit air automatically into the
duct/ pipes while they are being emptied. The valve shall also
automatically release trapped air from ducts/ pipes during normal
working at the normal working pressure.
c) Material of construction for air release valve shall be as per IS: 14845.
DATA SHEETS OF AIR RELEASE VALVES
1 Quantity 82 nos. (Eighty Two)

2 Valve Design Standard IS 14845
3 Size 200NB
4 Pressure Rating PN16
5 Type Double air valve/kinetic air valve with two
orifices and two floats.
6 Isolation valve Gate type and of Cast Iron or Cast steel
Body with Stainless steel trim as per
relevant IS code.

PART- B
HYDRAULIC TRANSIENT ANALYSIS

CLAUSE NO.
1.00.00 HYDRAULIC TRANSIENT ANALYSIS
A detailed hydraulic transient analysis based on the method of characteristics shall

be carried out for the system comprising of make-up water pipes & pumps using a
computer programme. This study shall be carried out by a reputed consultant/
institutes. The following shall be decided based on the results of hydraulic transient
study.
 Pump discharge valve closing time and pump starting / stopping sequence
 Conditions arising due to stopping/ tripping of pumps
 Size, location and quantity of air release valves in the make up water piping.
 Pump discharge valve opening time during start-up condition and pump
starting sequence.
The report of transient analysis should consist of methodology adopted,

characteristic curves/ data for various boundary conditions, complete input data
used for execution of software for various events and the results of the programme.
The report shall be submitted to the Employer for approval. Based on the
recommendations of such a study, Bidder shall take corrective measures and
provide suitable surge suppression devices in the make up water system.
2.00.00 PUMP PARAMETERS
Following parameters of pump shall be used for carrying out the Hydraulic Transient
Analysis. Pump characteristics curves shall be available during detail engineering.
Sl. DESCRIPTION PARAMETERS

NO.
1. Designation : Makeup water pumps
2. Total Number of Pumps : Three (3)
3. Number of operating : Two (2)
pumps
4. Number of stand by pump : One (1)
5. Guaranteed Flow : 2950 Cu.M/hr
6. Total head (Guaranteed) : 115 MWC
7. Operating Speed : 1000 rpm (max)
8. Location of pumps : Indoor

9. Nos. of stages of pumps : Single/multi stage
10. Service of duty : Continuous
11. Type of pump : Vertical wet pit &
Non Pull out type.
12. Type of Working Fluid : Refer Raw water Analysis in
“Project Information” in sub-section I
of Part-A of Section VI.

MAKE-UP WATER PIPES PACKAGE HYDRAULIC TRANSIENT
BID DOCUMENT NO: CS- 9549-132D-2 ANALYSIS
CLAUSE NO.
13. Type of Discharge : Above Floor discharge

14. Type of impeller : Closed/ Semi- open
15. Suction condition : Submerged
16. Minimum Water level : 179.83M
(at sump)
17. Maximum Water level : 192.024m
(at sump)
18. Pump Delivery Point 224.0M
(at plant end)
19. Type of shaft coupling : Flexible / Rigid
20. Pump-Motor GD2 During Detail Engineering

MAKE-UP WATER PIPES PACKAGE HYDRAULIC TRANSIENT
BID DOCUMENT NO: CS- 9549-132D-2 ANALYSIS
PART – B
CIVIL
PART- B
SUB-SECTION – III B-01
EXCAVATION AND FILLING

CLAUSE NO.
CHAPTER – 1
1.00.00 GENERAL REQUIREMENT
1.01.00 Content
This section of the specification covers the technical requirements for excavation
and filling including, excavation below water table, filling using selected excavated
materials, selected borrowed material (soil, sand, stone aggregate, gravel), handling,
transportation, compaction and disposal of surplus soils and / or stacking them
properly as directed by the Engineer.
1.02.00 Codes and Standards
1.02.01 Some of the relevant Indian Standards, Acts and Codes are referred to here below:
IS:383 : Specification for coarse and fine aggregates from natural

sources for Concrete.
IS:2720 : Methods of test for soils
IS:3764 : Safety code for Excavation work.
IS:4081 : Safety code for blasting and related drilling operations.
IS:4701 : Code of practice for earthwork on canals.
IS:9759 : Guide lines for dewatering during construction.
IS:10379 : Code of practice for field control of moisture and

compaction of soils for embankment and sub-grade.
Indian Explosives : as updated.

Act 1940
2.00.00 EXCAVATION
The earthwork shall be classified under the following categories and measured
separately for each category:
2.01.01 All kind of soils
Generally any strata, such as sand, gravel, loam, clay, mud, black cotton, moorum,
shingle, river or nallah bed boulders, siding of roads, paths etc. and hard core,
macadam surface of any description (water bound, grouted tarmac etc.), lime
concrete, mud concrete and their mixtures which for excavation yields to application
of picks, showels, jumper, sacrifiers, ripper and other manual digging implements.
2.01.02 Rock

TECHNICAL SPECIFICATIONS Sub-Section – III B-01 Page
MAKE-UP WATER PIPES PACKAGE
SECTION VI –Part – B EXCAVATION & FILLING 1 of 8
Bid Document no: CS- 9549-132D-2
CLAUSE NO.
a) Ordinary rock
Generally any rock which can be excavated by splitting with crow bars or
picks and does not require blasting, wedging or similar means for excavation
such as lime stone, sand stone, hard laterite, hard conglomerate and un-
reinforced cement concrete below ground level.
If required light blasting may be resorted to for loosening the materials but
this will not in any way entitle the material to be classified as ‘Hard rock’.
b) Hard rock
Generally any rock or boulder for the excavation of which blasting is required
such as quartzite, granite, basalt, reinforced cement concrete (reinforcement
to be cut through but not separated from concrete) below ground level and
the like.
c) Hard rock (blasting prohibited)
Hard rock requiring blasting as described under (b) but where the blasting is
prohibited for any reason and excavation has to be carried out by chiseling,
wedging, use of rock hammers and cutters or any other agreed method.
2.01.03 Rock level
After complete removal of soil overburden, the Contractor shall inform the Engineer
about the rock level. The excavation in rock by mechanical means shall proceed
only after establishing the rock level by Engineer and complete removal of soil over
burden by Contractor. The blasting in rock (requiring blasting) shall proceed only
after establishing the level of such by Engineer and complete removal of upper rock
by mechanical means by Contractor.
2.02.00 Levelling
Bottoms of excavation shall be cut sharp and true to line and level. Undercutting
shall not be permitted. The bottom of excavation before reaching the required level
shall be excavated carefully by such equipment or manually so that the founding
strata is not disturbed and the required final level is in natural condition. In case of
excavation in rock, the methodology of excavating the rock at founding level without
disturbing the natural strata, shall be as advised by the specialized agency. The
bottom of all excavations shall be trimmed to required levels and when excavation is
carried below such levels, by error, it shall be brought back to specified level by
filling with bed material/backfill material by the Contractor at its own cost.
2.03.00 Water other than Ground water (i.e. Surface water)
The Contractor shall control the ground in the vicinity of all excavations so that the
surface of the ground will be properly sloped or dyked to prevent surface water from
running into the excavated areas during construction. The Contractor shall have to
constantly pump out any water collected in excavated pits and other areas due to
rain water, springs, drain, river, nala, reservoir etc. and maintain dry working
conditions at all times until the excavation, concreting and backfilling is completed.

CLAUSE NO.
The Contractor shall remove all slush / muck from the excavated areas to keep the
work area dry. Sludge pumps, if required, shall be employed by the Contractor for
this purpose.
2.04.00 Stacking
The excavated soil shall be stacked within a distance of 1.50 m from the edge of
excavation or one third (1 / 3) of the excavation depth, whichever is more. Material to
be kept for subsequently filling / backfilling shall be stacked properly.
2.05.00 Blasting
2.05.01 General Requirement
a) Contractor shall engage an agency expert in blasting such as, CMPDIL,

CMRI, Dept. of Mining of Govt. Institutions, etc. to design detailed blasting
scheme and get the same approved from Engineer before carrying out the
blasting operation. All blasting shall be done as per the approved blasting
scheme and initial blasting operations shall be done under the supervision
and guidance of the representative of the blasting expert.
b) All the statutory laws, (Explosives Act etc.) rules, regulations, Indian
Standards, etc. pertaining to the acquisition, transport, storage, handling and
use of explosives, etc. shall be strictly followed.
c) The Contractor shall obtain Licenses from Competent Authorities for

undertaking blasting work as well as for procuring, transporting to site and
storing the explosives as per explosives act. The Contractor shall be
responsible for the safe transport, use, custody and proper accounting of the
explosive Materials.
d) The Contractor may adopt any method of blasting as permitted according to

explosives act / rule consistent with the safety and job requirements (after
approval from the Engineer) and so as not to injure men or damage materials
/ structures during blasting operations.
e) The magazine for the storage of explosives shall be built by the Contractor to
the designs and specifications of the Explosives Department concerned and
located at the approved site. No unauthorised person shall be admitted into
the magazine which, when not in use, shall be kept securely locked. No
matches or inflammable material shall be allowed in the magazine. The
magazine shall have an effective lightning conductor and the following shall
be displayed in the lobby of the magazine.
i) A copy of the relevant rules regarding safe storage, both in English

and in the language(s) with which the workers concerned are familiar.
ii) A statement of up to date stock in the magazine.

CLAUSE NO.
iii) A certificate showing the last date of testing of the lightning

conductor.
iv) A notice stating that smoking or inflammable material is strictly

prohibited.
f) The Contractor shall also observe any specific instructions given by the
Engineer. The Contractor shall be responsible and liable for any accident and
injury / damage which may occur to any person or property of the project or
public on account of any operations connected with the storage,
transportation, handling or use of explosives and the blasting operations. The
Engineer or his authorised representative shall frequently check the
Contractor's compliance with these precautions and the manner of storing
and accounting of explosives. The Contractor shall provide necessary
facilities for this.
g) All materials, tools and equipment used for blasting operations shall be of
approved make and type.
h) The blasting powder, explosives, detonators, fuses, etc., shall be fresh and
not damaged due to dampness or any other cause. Explosives shall be kept
dry and shall not be exposed to direct rays of the sun or be stored in the
vicinity of fire, stoves, steam pipes, or heated metal, etc. They shall be
inspected before use and damaged articles shall be totally discarded and
removed from site immediately.
i) Controlled blasting shall be done by a specialised agency duly approved by

Engineer. All controlled blasting shall be done by using time delay detonators
(i.e. excel type).
2.05.02 Operations
a) The blasting operations shall remain in the charge of a responsible,

competent, authorised and experienced supervisor (called Man-in-Charge)
and workmen who are thoroughly acquainted with the details of handling
explosives and blasting operations and with the rules governing such work.
b) All rules under the Explosives Act and other local rules in force shall be fully
observed. All blasting works shall be done in accordance with the stipulations
contained in IS: 4081. Blasting shall only be carried out at certain specified
times preferably during the mid-day lunch time or at the close of work as
directed in writing by the Engineer. The hours when blasting will be done,
shall be made known to people in the vicinity. All the charges shall be
prepared by the Man-in-Charge only. Proper precautions for safety of
persons and property shall be taken.
c) Prior to blasting, red danger flags shall be displayed prominently around the
area to be blasted and shall be kept in position until blasting work is
completed. All people, except those who actually light the fuses, shall be
prohibited from entering the area. The flags shall be planted 200 metres from
the blasting site and all persons including workmen shall be evacuated from
the flagged area at least 10 minutes before the firing. A warning whistle /
siren shall be sounded for this purpose.

CLAUSE NO.
d) Sandbags and / or earth bags, etc. shall be used on top of the blast holes to
prevent the rock fragments from causing damage to adjacent structures and
property. Provision of sensors shall be made to assess the impact of blast on
the adjacent structures and carrying out the suitable adjustment in the
quantum of charge to prevent damage to adjacent structures. At all stages of
blasting operations, precautions shall be taken to preserve the rock in the
soundest possible condition below and beyond the lines specified for the
excavation. The quantity and strength of explosives used shall be such as
will neither damage nor crack the rock outside the limits of excavations. Any
method of blasting which leads to overshooting shall be discontinued.
e) No explosive shall be brought near the work in excess of the quantity

required for a particular amount of firing to be done and surplus left after
filling holes shall be removed to the magazine. A careful and day to day
account of the explosives shall be maintained by the Contractor in an
approved manner and in an identified register; which shall be open to
inspection by the Engineer at all times.
f) At a time not more than ten such charges shall be prepared and fired. The
Man-in-Charge shall blow the whistle / siren in a recognised manner for
cautioning the people. The number of blasts to be fired and the actual
number of shots heard shall be compared and the person responsible shall
satisfy himself by examination that all blasts have exploded before any
person working in the area is permitted to re-approach the work site.
Sufficient time shall be allowed to account for delayed blasts. The Man-in-
Charge shall inspect all the charges before Lighting and determine the
missed charge. The withdrawal of the unexploded charge shall not be
permitted under any circumstances. After tamping, the unexploded charge
shall be flooded with water and the hole marked in a distinguishable manner.
Another hole shall be drilled at a distance of 450 mm from the old hole and
fired in the usual way. This process shall be continued till the original blast is
exploded. The Man-in-Charge shall at once report to the Contractor's office
and the Engineer, all cases of misfire, the cause for the same and what steps
where taken in connection therewith.
g) If a misfire is found to be due to defective materials, the whole quantity in the

box from which the defective materials was taken must be sent to the
Authority directed by the Engineer for inspection to ascertain whether any of
the remaining materials in the box are also defective.
2.05.03 In case there is overblasting/ overbreak, leading to over-excavation below the

founding level, the bottom of excavation shall be brought back to specified level by
filling with bed material/backfill material by the Contractor at its own cost.
2.06.00 Dressing of Bottom of Excavation Pit
2.06.01 Excavations which have been done either by mechanical means or by controlled
blasting, any outcrop or unevenness at the bottom of excavation, shall be dressed
upto the required level either by manual chiselling or mechanical means as required
vide clause 2.02.00, above. No separate measurement shall be done for this and the
cost of the same to be included in the relevant item(s).

CLAUSE NO.
3.00.00 LIFT
3.01.00 The Contractor is required to excavate upto any depth as shown on the drawings or
as directed by the Engineer.
4.00.00 DISPOSAL & CARRIAGE
a) If directed by the Engineer, excavated material can be used directly for back
filling purposes by pushing and spreading by mechanical means.
b) Land for disposal of surplus excavated material shall be arranged by the

Contractor at its own cost. The disposed off material shall be neatly dressed
at the disposal site. Contractor shall transport the excavated materials by
mechanical means only.
5.00.00 EXCAVATION BELOW GROUND WATER TABLE
5.01.00 The Contractor shall dewater and maintain dry working conditions by maintaining the
water table at least 0.5m below the bottom of the excavation level by suitable
dewatering method. Contractor shall continue dewatering i.e. maintain dry working
condition till excavation, concreting, back filling / filling, testing and all other
operations included in the scope of work, which require dry condition in the area, are
completed.
6.00.00 FILLING AND BACKFILLING
For details of backfilling, refer Cl. No. 12.00.00 of Sub-section IIIB-02 “Laying of
piping works”.
6.01.00 Excavated material
6.01.01 Material
a) Materials to be used for backfilling / filling purposes shall consist of soil,

broken stone, sand or other inorganic materials and they shall be clean and
free from shingle, organic matter, large roots and excessive amount of sod,
lumps, concrete or any other foreign substances which could harm or impair
the strength of the pipe in any manner. All clods shall be suitably broken to
small pieces.
b) When the material is mostly rock boulders, these shall be broken into small
pieces not larger than 200 mm size.
c) Filling / back filling shall begin only with the written approval of the Engineer.
d) Filling / back filling shall be accurately finished to line, slope, cross section
and grade as shown on the drawings. Finished surface shall be free of
irregularities and depressions. Filling / backfilling shall be compacted to the
required degree of compaction and level as shown in drawing.

CLAUSE NO.
6.01.02 Watering and Compacting
a) All sides of excavation shall be filled to the specified level after making
allowance for settlement. Fill shall be placed in horizontal layers not
exceeding 300mm compacted thickness. Each layer shall be watered and
compacted with proper moisture content and with such equipment as may be
required to obtain a compaction / density as specified. The methods of
compaction shall be subject to the approval of the Engineer.
b) The degree of compaction of compacted fill in place will be verified by tests

as the work progresses, and the Contractor shall conduct such tests as per
the approved Field Quality Plan.
6.01.03 Dressing
After filling, the top surface shall be dressed by light rolling.
6.02.00 Borrowed material
6.02.01 Material
a) For materials to be borrowed from pits / quarries, then it shall be the

Contractor's responsibility for identification and arranging of such quarry
areas, obtaining approval for their use from concerned authorities, the
Contractor shall pay any levies, royalties, etc., that may have to be paid for
utilisation of borrow areas.
b) Sand for filling shall be clean, medium grained and free from impurities.
Fines less than 75 microns shall not be more than 20%.
c) Selected soil brought from borrow area shall be free from stone, boulders
and other organic material. It shall be non-expansive type of soil free from
presence of harmful chemical, salt, vegetation, etc.
d) Stone / gravel used for filling shall be broken hard stone of specified nominal
size and shall be free from all types of organic materials.
e) Moorum brought from borrow area shall be free from stone, boulders and
other organic material.
6.02.02 Filling
Filling shall begin only after approval of the Engineer of the borrow area and the
material to be used for filling.
6.02.03 Transportation
Selected borrowed material will involve excavation / quarrying, loading and carriage
of such material for all leads and lifts, unloading etc.
6.02.04 Watering & Compaction
Filling, watering and compacting, dressing and consolidating of selected soil brought

CLAUSE NO.
from borrow area shall be done in the same manner as specified for the filling using
the selected excavated material.
6.02.05 Dressing
After filling, the top surface shall be dressed by light rolling.
7.00.00 SAMPLING TESTING AND QUALITY CONTROL
7.01.00 Frequency of sampling, testing and quality assurance including the methods for
conducting the tests acceptance criteria and construction tolerances shall be as
given in Part `C' of this specification.
08.00.00 Measurements & Payments

No separate measurement & payments shall be made for this item as the cost of
same is deemed to be included in quoted rate of civil works associated with laying of
pipes.

PART- B
LAYING OF PIPING WORKS

CLAUSE NO.
CHAPTER – 1
1.00.00 PIPING WORKS
1.01.00 This section of the specification covers the technical requirements of design,
preparation of general arrangement drawing and working drawings, supply of
materials and execution of all work associated with laying of water piping works.
1.02.00 The work to be performed under this specification consists of providing all labour,
materials, plant, equipments, temporary works, constructional plant, fuel supply,
transportation and all incidental items not shown or specified but reasonably implied
or necessary for the proper completion of the work, all in strict accordance with the
specifications and including revisions and amendments thereto as may be required
during bidding.
1.03.00 Land For Pipe Corridor
The contractor is required to perform his construction activity within the width of
acquired land set aside for construction of pipeline or within the Right-of-way area as
decided by the Owner. The pipe line shall be buried either in the embankment or
shall be buried in the natural ground or to be supported over pedestals or to be
supported over steel structure/ bridge.
2.00.00 SCOPE OF WORK
2.01.00 The scope of works shall include design, preparation of drawings and getting the
same approved from the Owner and execution of all works associated with the
laying of complete water pipe lines including construction of thrust block at bend
locations, if required. The nature of work shall generally include clearing, grading,
stripping/marking, excavation, backfilling, disposal, dewatering, road & drain cutting
other than NH/SH and railway line, laying of RCC Hume pipe or culver under road,
canal, drain etc. and rectification of damaged structure due to excavation. Bidder
shall restore original ground profile and include all other incidental items though not
mentioned specifically but required to complete the work including the additional
requirement of right of way and access thereto, restoration of work areas etc.
2.02.00 The tender drawing are preliminary drawings for bidding purposes only and are by
no means the final drawing or show the full range of the work under the scope. Work
has to be executed according to the drawings prepared by the Bidder and approved
by Engineer.
2.03.00 The work under this specification shall consist of but not limited to items mentioned
below:
2.03.01 Clearing and grading of work area including requirement of work areas and access
there to and stacking of reference markers.
2.03.02 Trenching for Laying of pipe
DARLIPALI STPP STAGE-I (2X800 MW) Sub-Section – III B-02

MAKE-UP WATER PIPES PACKAGE LAYING OF PIPING
Bid Document no: CS- 9549-132D-2 WORKS
CLAUSE NO.
Top of pipe shall be minimum 1.0 M below Finished Ground level (FGL) / Natural
Ground Level (NGL) as the case may be.
2.03.03 Backfilling shall be done with the material as specified in subsequent clauses.
2.03.04 Supplying and installation of permanent pipeline concrete markers at every 1.0 km
and at change of direction including grouting of marker.
2.03.05 Clean up and restoration of work areas/embankment.
Bidder shall restore the embankment & road work, and all sites used for construction
of pipelines, water crossings and other structures in accordance with Engineer's
instruction and deliver them to the satisfaction of Owner.
3.00.00 SUBMITALS
The contractor shall submit to NTPC the following documents for approval at least
one month before start of work:
 Construction methodology
 Trench Excavation section
 Design of Anchor/ Thrust block, Pedestal
 Scheme to cross road, river, nala etc.
4.00.00 GROUND WATER TABLE
For design of pipe line, the water table shall be considered at finished ground level
or actual water Table level, whichever is higher.
5.00.00 FOUNDATION SYSTEM
5.01.00 Buried Pipe
Pipes shall be laid on firm soil/ compacted bedding material. The compacted
bedding & backfilling material shall be as per the relevant specification clauses for
different pipe material. Minimum soil cover on the top of buried pipe shall be 1.0 M
unless specified otherwise.
5.02.00 Thrust Blocks/ Anchor blocks
Thrust Block/ Anchor block shall be provided at location of all change in direction, if
required. The grade of concrete block shall be minimum M25. The concreting shall
meet the requirements given in IS: 456. Reinforcement shall be high strength
deformed TMT bars of grade Fe 500 conforming to IS:1786 with minimum elongation
of 14.5%.
The minimum depth of foundation shall be 1.5M below NGL.
6.00.00 LOADING

CLAUSE NO.
6.01.00 Thrust Block/ Anchor Block
The thrust block shall be designed for hydraulic thrust in pipe as applicable.
6.02.00 Pit and Pipes
The pit and pipes shall be designed for earth pressure with a surcharge of 2.0 T/m2.
The earth pressure shall be estimated based on relevant provisions of IS Codes.
6.03.00 Entire length of buried pipe line shall be checked against buoyancy & provided with
suitable saddles, counter weights to overcome buoyancy effect, if applicable.
6.04.00 For all other load and load combination IS: 875 (Pt.I to V) shall be followed.
7.00.00 DESIGN CRITERIA AND DRAWINGS
7.01.00 The pipe shall be designed based on appropriate IS Codes. In case of non-
availability of IS Codes, relevant Internationals codes & manufacturers
recommendations shall be followed subject to Owner's approval.
7.02.00 Whenever floating of the pipeline is to be reckoned with, anti-buoyancy measures

shall be provided by Bidder using one or a combination of the following methods as
specified.
a) Extra weight by applying a continuous concrete encasement around the pipe;
b) Extra weight by installing saddle weights;
The above provisions shall be in accordance with the relevant specifications and/or
job standards/drawings.
8.00.00 CONSTRUCTION REQUIREMENT AND ACCESS TO WORK AREAS
8.01.00 Contractor shall notify to the Engineer well in advance during work progress, the
method of construction for crossing road, pipeline, cable, railway, river, canals, utility
lines and other existing obstacles.
8.02.00 Contractor shall not commence work on such crossings before having obtained
approval from the authorities and land owners concerned to the satisfaction of the
Engineer. The work at crossings shall meet at all times requirements and conditions
of the permit issued by the authorities concerned. In the absence of any specific
requirements by authorities, Bidder shall comply with Engineers' instructions.
8.03.00 Where the work areas comes within the area of influence of high voltage electrical
installations, contractor shall propose and provide adequate safety measures for all
personnel working. No work is allowed in such areas without Engineer's prior
approval.
9.00.00 WORK AREAS - REFERENCE MARKER
9.01.00 Contractor shall also establish all required lines and grades necessary to complete
the work and shall be responsible for the accuracy of such lines and grades.

CLAUSE NO.
9.02.00 Prior to clearing operations contractor shall:
a) Install Bench Marks, Intersection Points and other required survey pillars.
b) Set out a reference line with respect to pipeline centerline at a convenient

location. Markers on reference line shall be at a distance of maximum 100
metres for straight line sections and maximum 10 m for horizontals bends.
10.00.00 CLEARING AND GRADING
10.01.00 Any obstacle which may hinder the construction and laying of the pipeline along the
pipeline route shall be removed.
10.02.00 All stumps if met with shall be removed for a continuous strip, with a width equal to
trench top with plus two meters on either side, centered on the pipeline centerline.
10.03.00 All stumps, timber, bush, undergrowth and roots cut removed from the work area
shall be disposed of in a manner and method satisfactory to Engineer, and
Government Authorities having jurisdiction. In no case shall it be left to interfere with
the grading and laying operations. Whenever stumps are removed and a hole is left
in the ground, contractor shall back-fill the hole and compact it to prevent water from
gathering in it and making a big hole.
10.04.00 Bidder shall grade the pipeline work area as required for proper installation of the
pipeline, for providing access to the pipeline during construction, and for ensuring
that the pipeline is constructed in accordance with the latest engineering and
construction practices.
10.05.00 Contractor shall grade sharp points, to allow the pipe to be bent and laid within the
limits set forth in these specifications, and shall drill, or excavate any rock or other
material which cannot be graded off with ordinary grading equipment in order to
make an adequate working space along the pipeline.
10.06.00 No temporary / permanent deposit or of any kind of material resulting from clearing
and grading shall be permitted in the approach to roads, railways, streams, ditches,
drainage ditches and any other position which may hinder the passage and/or the
natural water drainage.
10.07.00 In the case of natural or artificial deposits of loose soil, sand, heaps of earth, or other
fill materials, these shall be removed till stable natural ground level is reached so as
to ensure the construction of the pipeline trench in stable ground.
10.08.00 Wherever the pipeline work area runs across, through or alongside farmyards, built-
up areas, groups of trees, groves, horticultural spreads, gardens, grass-fields, river,
nallahs, ditches, dikes, roads, paths, railways or any other area with restrictions of
some kind, Contractor shall work with all caution necessary for digging the pipeline
trench and constructing the pipeline. In the said places Bidder shall carry out the
works in such a way that damage resulting from the pipeline construction is kept to a
minimum.
10.09.00 Provision of Detours

CLAUSE NO.
10.09.01 Contractor shall make all necessary arrangements to permit the passage of its men
and equipment. It is understood that the bidder has recognised restrictive features of
the work area and shall provide the necessary detours and execute the works
without any extra cost of owner. Public travel shall not be inconvenienced nor shall it
be wholly obstructed at any point.
10.09.02 Contractor at his own cost shall furnish and maintain watchman, detours, lanterns,
traffic lights, barricades, signs, wherever necessary to fully protect the public.
10.09.03 Contractor shall be responsible for moving its equipment and men across or around
watercourses. This may require the construction of temporary bridges or culverts.
Temporary bridging or access if required for crossing water courses shall be
constructed. Contractor shall ensure that such temporary works shall not interfere
with normal water flow, avoid overflows, keep the existing morphology unchanged
and shall not unduly damage the banks of water courses. No public ditches or drains
or canals shall be filled or bridged for passage of equipment until contractor has
secured written approval of the authorities having jurisdiction over the same.
10.10.00 Work Area Damages
10.10.01 Contractor shall confine all its operations within limits of the Work Area. Any damage
to property within and outside the work area shall be restored or settled at the
Contractor expenses.
10.10.02 Contractor shall promptly settle all damage claims. Should contractor fail to do so,
Owner shall give written notice to the bidder and if contractor does not settle such
claims within seven days after such notice, Owner shall have the authority to settle
claims from the account of contractor.
11.00.00 PIPE LINE TRENCH
11.01.00 Location
Contractor shall excavate and maintain the pipeline trench on the Centre-line of the
pipeline taking into account the curves of the pipeline. Irrespective of soil conditions
and/ or the topography of the ground, the trench shall be excavated and finished to
the minimum dimensions and cover as specified below including de-watering, if
required.
11.02.00 Size of the Trench
11.02.01 For MS Pipes and DI Pipes, the free working space shall conform to IS:5822 and
IS:12288 respectively. Generally it shall not be less than 200 mm on either side or
one third of diameter of the pipe flange whichever is greater. The trench shall be
excavated so as to provide minimum cover of 1000 mm between the top of the pipe
and finished grade, or as shown in approved drawings. Clear spacing between two
pipes shall be 1000mm.
11.02.02 For GRP pipes, Installation shall conform to IS: 13916. However, trench shall be
excavated minimum depth of 150mm below invert level and 300 mm on either side
of the pipe. The trench shall be excavated so as to provide minimum cover of 1000
mm between the top of the pipe and finished grade. Clear spacing between two

CLAUSE NO.
pipes shall be 1000mm. The final dimensions shall be as per construction drawings
submitted by contractor and approved by Engineer.
11.03.00 In steep slope areas before commencing the works, proper barriers or other
protection shall be provided to prevent the removed materials from rolling down
slope.
11.04.00 On slopes-wherever there is danger of landside, the pipeline trench shall maintained
open only for the time strictly necessary.
11.05.00 In certain slope sections, before the trench cuts through the water tables, proper
drainage shall be ensured both near and trench and the work area in order to
guarantee soil stability.
11.06.00 All sewers drain, ditches and other natural waterways involved in the execution of
the works shall be maintained open and functional. The same applies to canals,
irrigation canals, pipelines and buried facilities crossed by the trench for which
temporary pipelines shall be laid, if required, and proper temporary installations
provided.
11.07.00 Extra Depth and Clearance
11.07.01 At points where the contour of the earth may require extra depth to fit the minimum
radius of the bend as specified or to eliminate unnecessary bending of the pipe
according to customary good pipelines, practice, or where a deep trench is required
at the approaches to crossings of roadways, rails, rivers, streams, drainage ditches,
and the like, contractor shall excavate such additional depth as may be necessary.
11.07.02 Contractor shall excavate to additional depth where the pipeline approaches and
crosses other pipelines, sewers, drain pipes, water mains, telephone conduits, and
other underground structures, so that the pipeline may be laid with at least 500
millimeters free clearance from the obstacle or as specified in the drawings, or such
greater minimum clear distances as may be required by authorities having
jurisdiction.
11.07.03 Where the pipeline crosses areas, which specifically require greater than normal
depths of cover, the trench shall be excavated to extra depth in accordance with the
Right-of-Way Agreements or as required.
11.07.04 Additional excavation should be made at each coupling /joint to ensure that the pipe
will have continuous support. The pipe shall not rest on the coupling for support.
However, it shall be assured that the coupling area is properly bedded and backfilled
after the joint assembly is completed.
11.08.00 Grades, Bends and Finish of Trench
The trench is to be cut to a grade that will provide a firm, uniform and continuous
support for the pipe. Bends shall be made in the pipe at significant changes in grade
of the trench. The owner reserves the right to set the grade of the trench and locate
the bends if so desired, in which case contractor shall excavate, at no extra cost, the
trench and bend the pipe to such a grade. Number of field bends to lay the pipe to
conform to the general contour of the ground and maintain a normal cover shall be
kept to a minimum. This can be accomplished by cutting the trench slightly deeper at

CLAUSE NO.
the crest of ridges and by gradually deepening the trench in approaches to

crossings.
11.09.00 Encroachments and working near other utilities
11.09.01 In locations, where pipelines has to be laid in the body of a road, canal, dyke, nallah
etc. or other locations under jurisdiction of Government/Public Bodies, the bidder
shall perform such work without extra compensation, according to the requirement of
concerned Authorities. When it becomes necessary that contractor has to resort to
hand digging, well point dewatering, sheet piling or any other special construction
method in these areas, no extra compensation shall be paid. Contractor shall
contact the Authorities concerned in order to become familiar with their
requirements.
11.09.02 In locations, where the pipeline has to be laid more or less parallel to existing
pipeline, cable and/or other utilities in the Work Areas, contractor shall perform the
work to the satisfaction of the Owner/Authority of the existing pipeline cable/utility. In
such locations contractor shall perform work in such a way that even under the
weather and flooding conditions, the existing pipeline/utilities shall remain stable and
shall neither become undermined nor have the tendency to slide towards the trench.
11.09.03 Contractor shall be liable for any damage occurring to other pipelines, underground
structures/utilities.
11.10.00 Protection of Trench
11.10.01 Contractor shall keep the trench in good condition until pipe is laid, and no claim is to
be made to the Owner for reasons of its caving either before or after pipe is laid.
11.10.02 All timber, sheet-piling jacks or other materials that may be necessary to shore the
trench, in order to prevent caving are to be furnished and removed by contractor
after completion of laying.
11.10.03 The Contractor shall have to arrange at his cost bailing or Pumping out all water,
which may accumulated in the trench during the progress of the work, either by
percolation, seepage, spring, rain or any other cause. Similarly, he shall also have to
arrange diverting surface flow if any, by providing earthen bunds or by other means
at his own cost.
11.11.00 Blasting
Wherever blasting is required, controlled blasting technique to be adopted. For

details of blasting, refer Cl. No. 2.05.00 of Sub-Section III B-01 “Excavation &
Filling”.
11.12.00 Protection of underground utilities and special methods
11.12.01 Contractor shall obtain plans and full details of all existing and planned underground
services from the relevant Local Authorities & Owner and shall follow these plans
closely at all times during the performance of work. Contractor shall be responsible
for location and protection of all underground lines and structures.

CLAUSE NO.
11.12.02 Temporary under-pinning or any other type of supports and protective devices
necessary to keep the interfering structure intact shall be provided by the contractor
at his own cost and shall be of such design as to ensure against their possible
failure.
11.12.03 Despite all precautions, should any damage to any structure/utility etc. occur, the
Owner/Authority concerned shall be contacted by the Contractor and repair shall
forthwith be carried out by contractor at his expense under the direction and to the
satisfaction of Engineer, the concerned Owner/Authority. If contractor fails to repair
in reasonable time, Owner reserves the right to have the repair executed at the cost
of the contractor.
12.00.00 BACKFILLING
12.01.00 Backfill Material for Mild Steel/ Ductile Iron Pipes
Prior to lowering and laying pipe in any excavated trench, the bottom of the trench
may require to be back filled and compacted (or as the case may be) so as to be
proved an acceptable bed for placing the pipe. Bed preparation in general shall be
as per IS: 5822 & IS 3114 for MS and IS: 12288 for DI pipes respectively.
Bed preparation and back filling of excavated trenches for buried pipes depend on
type of soil. Soil types are classified into following 3 categories:
(a) Rocky Soil
(b) Sandy/ Silty soil (including non-expansive clay)
(c) Expansive soil (including water logged/ marshy soil)
The bidder shall note that the piping may travel underground through all types of
soils and combination of soils described above. The type of trench preparation/
bedding and back filling for each are specified below.
In case of agricultural land, it is suggested that the soil may be classified as fertile
(top strata) and non fertile (sub strata). During the excavation for laying the pipeline
both these layers may be heaped separately so that while back-filling the non-fertile
soil is filled first followed by the fertile strata, thus restoring the fertility of the soil in
the excavated area our right of way.
(a) Rocky Soil
(1) Trench shall be excavated to a depth of 100mm below pipe invert.
(2) A bed of 100mm shall be laid with granular material (passable

through 12.5mm aperture sieve - IS-2405 part-2) which shall be well
rammed to form a fair and clean bed for pipe.
(3) Back filling shall be done with the excavated material/ borrow earth
after ensuring that it is free of cinders, ashes, slag, refuse, lumpy/
frozen material, rocks etc. to the satisfaction of the Project Manager.
The back fill from pipe invert upto 300mm above pipe crown shall be
done with material passable through 20mm aperture sieve (as per IS-

CLAUSE NO.
2405 part-2 1980). Total mass of loam and clay shall not be more
than 10%. Back fill above this zone upto trench top shall be with
similar material but may contain stones with 200mm as their
maximum dimension.
(4) Back filling upto 300mm above pipe crown shall be done by hand
without moving or injuring the pipe. Above this zone upto trench top
back fill may be by hand/ approved mechanical method.
(5) Any extra/ additional back-filling resulting from unintended rock

blasting even while carrying out controlled blasting shall be done by
the Contractor without any extra cost to the Employer.
(b) Sandy/ Silty Soil
(1) Trench shall be excavated to the exact gradient required by the pipe
invert so that no bedding is required. The trench bottom shall be
made free of refuse and stones etc. so as to provide a smooth,
uniform and continuous bearing surface
(2) Back filling shall be done with the excavated material after ensuring
that it is free of cinders, ashes, slag, refuse, lumpy/ frozen material,
rocks etc. to the satisfaction of the Project Manager.
(3) Back filling upto 300mm above pipe crown shall be done by hand
without moving or injuring the pipe. Above this zone upto trench top
back fill may be by hand/ approved mechanical method.
(c) Expansive/ Poor Support Soil
(1) Laying of pipes in such soil shall be avoided as far as possible. One
possible method is to increase trench depth in case the expansive
soil occurs at the surface. The method can then be one of the above
(a or b) depending on soil encountered below the layer of expansive
soil. The expansive soil shall not however, be used for back filling the
trench bottom to 300mm above the pipe crown. This shall however,
be studied techno-economically (i.e., the aspect of increasing the
trench depth to encounter non-expansive soil and follow a or b above
for bed preparation and back filling).
(2) Where expansive soil occurs at a great depth the trench & bed shall
be prepared as at a (1) & (2) above.
(3) Back filling around pipe upto 300mm above top of pipe crown shall
then be done with sand/ gravel conforming to clause 8.2.1/ 8.2.2 of
IS-3114 or with borrow earth. However, expansion soils having
medium degree of expansion or having marginal degree of severity,
as per IS:1498, may be used for backfilling around pipes with
approval of Engineer.
(4) In case of marshy/ water logged soil, the pipes shall be laid on
underground concrete pedestal (M25) installed at a spacing to
ensure that the pipe is adequately supported. Prior to construction,
design of the pedestal shall be got approved from Enginer-in-Charge.

CLAUSE NO.
12.02.00 Bedding & Backfill Material for GRP Pipes
(i) The pipe bedding zone starts from the bottom of trench to the invert level of
pipe. This depth may vary with pipe diameter/ soil strata/ combination of loading but
minimum depth of 150mm shall be provided. The bedding material below pipe shall
be sound granular material not greater than 12.5 mm aperture sieve (as per IS-2405
part-2) and well rammed. Total mass of loam and clay shall not be more than 10%.
(ii) The back fill from pipe invert upto 300mm above pipe crown shall be done
with sound granular material of size not greater than 25 mm aperture sieve
(as per IS-2405 part-2) and well rammed. Total mass of loam and clay shall
not be more than 10%. This shall be compacted to 85% of relative density/
85% maximum dry density.
(iii) Back fill above this upto trench top shall be with the excavated material after
ensuring that it is free of cinders, ashes, slag, refuse, lumpy/ frozen material,
rocks etc. to the satisfaction of the Project Manager. Maximum size of stones
shall be 200 mm.
(iv) Back filling upto 300mm above pipe crown shall be done by hand without
moving or injuring the pipe. Above this zone upto trench top back fill may be
by hand/ approved mechanical method.
(v) Any extra/ additional back-filling resulting from unintended rock blasting even
while carrying out controlled blasting shall be done by the Contractor without
any extra cost to the Employer.
(vi) Bedding, backfilling and compaction shall conform to IS:13916.
12.03.00 During backfilling, it shall be made certain that the granular material flows completely
under the pipe to provide full support. Proper backfilling shall be done in 150mm to
300 mm lifts, depending on backfill material and compaction method. Between each
lift, the proper compaction shall be attained to ensure that the pipe will have
adequate side support.
12.04.00 Backfilling shall not be done until the pipe and appurtenances have the proper fit and
the pipe is following the trench profile at the required depth. Backfilling of trench in
water courses shall be carried out as per the relevant specifications.
12.05.00 Backfilling shall be carried out immediately after the pipeline has been laid in the
trench, inspected and approved by the Engineer, so as to provide a nature
anchorage for the pipeline, thus avoiding long exposure of coating to high
temperature, damaging actions of adverse weather conditions, sliding down of
trench sides and pipe movement in the trench. In generals the trench shall be dry
during backfilling. The surplus material shall be neatly crowned directly over the
trench and the adjacent excavated areas on both sides of the trench to such a height
which will, in the opinion of the Engineer, provide adequately for future settlement of
the trench backfill during the maintenance period and thereafter. Surplus material,
left from this operation shall be disposed off to the satisfaction of Engineer-in-Charge
beyond the Work Area to a place suitably identified by the contractor himself at no
extra cost to the Owner.

CLAUSE NO.
12.06.00 At the end of each day's work, backfilling shall not be more than 500 meters behind
the head end of lowered-in pipe, which has been padded and approved for backfill.
The backfill shall be maintained against washouts etc., until the completion and final
acceptance of the work by engineer.
12.07.00 When backfilling the trenches the sloping terrains or steep areas, where in the
opinion of the Engineer the backfill may be washed out of the trench, sheet piling or
other effective water breakers across the trench shall be provided. This is to divert
the flow of water away from the trench into normal drainage followed before laying of
the pipe line. In no case, the water is to be drained via the trench or via channels
other than those followed before the line was laid.
12.08.00 Contractor shall leave the pipe uncovered at certain locations to allow the engineer
to survey the centre line of the pipe and the level of the pipeline in the backfilled
trench.
12.09.00 Temporary markers shall be installed during backfilling to locate the pipeline axis.
These markers shall then the replaced with permanent pipeline markers.
12.14.00 Anchor Blocks/ Encasement
RCC thrust blocks should be provided at bends and at places of reduction in cross
section to take care of thrust forces as per approved designs/ drawings. Thrust
blocks are to be installed at all locations where movement of pipe is envisaged.
If higher water table is encountered, uplift to shall be checked for pipe empty
condition and if there is any uplift, pipe shall be encased with reinforced cement
concrete (M25) of minimum 250 mm thick around the pipe.
13.00.00 PERMANENT MARKERS
Permanent pipe line markers made of concrete (of grade M25) shall be installed at
every 1.0 Km and at every bend/turning point. The markers shall be 500 mm wide
and 75 mm thick and shall project 1200 mm above ground level. The marker shall be
grouted in M-10 cement concrete mixture to correct line, level and direction all-along
the pipe line. The work also includes necessary excavation for grouting of marker,
cleaning, painting etc. The bidder shall furnish drawing of marker to Engineer for his
approval before installation of the same. The mark shall show name of Owner,
Chainage of pipe line, Ground elevation, invert level of pipe, direction of flow, etc.
14.00.00 CLEAN-UP AND RESTORATION OF WORK AREAS
14.01.00 Bidder shall restore the Work Areas and all sites used for the construction pipelines,
water crossings and other structures in accordance with the instructions of the
engineer.
14.02.00 Disposal
14.02.01 All surplus and defective materials supplied/ excavated by contractor and all trash,
refuse and spoiled materials shall be collected and disposed off to the satisfaction of
Engineer-in-Charge beyond the Work Area to a place suitably identified by the
contractor himself at no extra cost to the Owner.

CLAUSE NO.
14.02.02 The Work Areas shall be cleared of all rubbish, broken skids, empty cans, card
board, sacks, stumps, trash, and leftover construction material. All burnable matter
shall be burned, but only after obtaining appropriate permits for such burning. If
burning is not allowed, bidder shall haul the clean-up material to an approved
dumping area. All scrap metal and unburnable material shall be disposed off, in an
appropriate manner, but never be buried in the Work Areas.
14.02.03 Surplus soil can only be removed from the work area after authorisation by
Engineer.
14.02.04 All dumping fees connected with the disposal of materials shall be to the account of
contractor.
14.02.05 All loose stones and rock exposed by the construction operations and scattered over
the Work Areas or adjacent ground shall be removed and transported to a location
considered suitable by land-owner and/or tenant, or by authorities having
jurisdiction, for satisfactory disposal. For gravel or other hard material which may be
buried in the trench, the provisions of the specifications shall apply with the
understanding that the use of the land by the land-owner and/or tenant will not be
interfered with.
14.03.00 Temporary Structures
14.03.01 All auxiliary structure such as bridges, culverts, sheet piling, posts, signs, etc., which
were erected or installed by bidder as temporary measure, shall be removed.
14.04.00 Repair of Damages
14.04.01 Damages to roads, bridges, private property shall be repaired by contractor. All
fences and other structures which are damaged during construction shall be
restored to original condition.
14.04.02 Slopes, water course sides or banks which have been partially or totally demolished
during the execution of the works shall be properly consolidated and restored
without waiting for their naturals consolidation and settling.
14.04.03 All boundary stones which have been moved or removed during the work must be
reset in their original location to the specification of the land-owner concerned.
14.05.00 On completion of clean-up, the work areas shall be restored to such stable and
usable condition as may be reasonably consistent with the condition of the Work
Areas prior to laying the pipeline. The Owner shall be completely indemnified and
held harmless by contractor from any and against all claims, demands, losses,
expense etc. that may arise on this behalf. The Engineer may require from the
contractor signed Releases from land owners regarding satisfactory indemnification
and restoration of their lands.
15.00.00 CUTTING AND REMOVAL OF PAVING/ WATER BOUND MACADEM ROAD
15.01.00 Whenever it is permitted by Authorities and/or Owner to open cut a paved/WBM

road crossing, or where the line is routed within the road pavement, bidder shall
remove the paving in accordance with the restrictions and requirements of the
authorities having jurisdiction there of or as directed by the Engineer. After laying

CLAUSE NO.
the pipeline, backfilling shall be immediately performed and all the area connected
with the works shall be restored.
15.02.00 Throughout the period of execution of such works, contractor shall provide and use
warning signs, traffic lights or lanterns, barricades, fencing, watchman etc. as
required by the local authorities having jurisdiction and/or owner.
15.03.00 For all roads, paths, walkways etc. which are open-cut, contractor shall provide
temporary diversions properly constructed to allow the passage of normal traffic with
the minimum of inconvenience and interruptions.
The paving/ WBM shall be restored to its original condition up to the satisfaction of
concerned authorities/ Engineer after the pipeline is installed.
16.00.00 WATER COURSE CROSSINGS
For water crossings a standard drawing shall be prepared by bidder or a separate

detailed approved drawing for individual crossing shall be prepared for approval of
the Owner.
Whenever water crossings in the Work Area are to be crossed, Contractor shall
install temporary bridges if required and comply with provisions as laid down in this
specification.
In crossings of water courses with either moderate flow rate or of torrential nature
with marked and unpredictable flooding, and adequate survey shall be carried out
before starting the work with the object of determining what precautions are
necessary and the most favourable period for executing the work.
In case of crossing of water courses for which no special methods of laying are
required, a pipe section of a suitable size as per the approved drawings shall be
assembled and subsequently laid.

pipes.

PART- - B
CAST-IN-SITU CONCRETE AND

ALLIED WORKS
CLAUSE NO. CAST-IN-SITU CONCRETE AND ALLIED WORKS
CHAPTER-3
CAST-IN-SITU CONCRETE AND ALLIED WORKS
1.00.00 GENERAL REQUIREMENTS
1.01.00 Contents
The section covers the technical requirement for cast-in-situ concrete, pre-cast
concrete, reinforcement, formwork, embedded parts, anchor fasteners, admixtures,
grouting / underpinning, joints in concrete, water proofing, dismantling, etc., at all
levels, for all types of work in all kinds of working conditions.
1.02.00 Codes and Standards
1.02.01 Some of the relevant applicable Indian Standards, Codes, etc. applicable to this
section of the specification are listed below:
IS : 383 Specification for Coarse and Fine Aggregates from natural sources
for Concrete.
IS : 432 Specification for Mild Steel and Medium Tensile Steel Bars and Hard
drawn Steel Wire for Concrete Reinforcement.
IS : 456 Code of Practice for Plain and Reinforced Concrete.
IS : 516 Method of Test for Strength of Concrete
IS : 702 Specification for Industrial Bitumen
IS : 1199 Methods of Sampling and Analysis of Concrete
IS : 1489 Specification for Portland-Pozzolana Cement -
(Part I) Fly Ash based
IS : 1786 Specification for High Strength deformed Steel Bars and Wires for
Concrete Reinforcement
IS : 1791 Specification for Batch type Concrete mixers.
IS : 1834 Hot applied sealing compound for joints in Concrete
IS : 1838 Specification for Preformed fillers for expansion joints in Concrete

pavements and structures (non-extruding and resilient type)
IS : 2062 Steel for general structural purposes
IS : 2386 Methods of Test of Aggregates for Concrete.
IS : 2502 Code of Practice for bending and fixing of Bars for Concrete
Reinforcement.

MAKE-UP WATER PIPES PACKAGE CAST-IN-SITU CONCRETE
BID DOCUMENT NO: CS- 9549-132D-2 AND ALLIED WORKS
IS : 2505 General Requirements for Concrete vibrators, immersion type.
IS : 2506 General Requirements for Concrete vibrators, screed boards type.
IS : 2571 Code of Practice for laying in-Situ Cement-Concrete flooring.
IS: 2645 Specification for Integral Cement Water proofing compounds.
IS : 2750 Specification for Steel scaffoldings
IS : 2751 Code of Practice for welding of Mild Steel Plain and deformed Bars
for Reinforced Concrete construction.
IS : 3370 Code of Practice for Concrete structures for the storage of liquids.
IS : 3414 Code of Practice for design and installation of joints in buildings.
IS : 3696 Safety code for scaffolds and ladders.
IS : 3812 Specification for fly Ash for use as Pozzolana and Admixture.
IS : 4014 Code of Practice for Steel tubular scaffolding.
IS : 4031 Methods for physical Tests for hydraulic Cement.
IS : 4082 Recommendation on stacking and storage of construction materials

and components at site.
IS : 4130 Safety Code for demolition of buildings.
IS : 4326 Code of Practice for earthquake resistant design and construction of

buildings.
IS : 4656 Specification for form vibrators for Concrete.
IS : 4925 Specification for Concrete Batching and mixing plant.
IS : 4926 Specification for ready-mixed Concrete.
IS : 4990 Specification for plywood for Concrete shuttering Work.
IS : 5121 Safety code for piling and other deep foundations.
IS : 5256 Code of Practice for sealing joints in Concrete lining on canals.
IS : 5525 Recommendations for detailing of Reinforcement in Reinforced

Concrete Work.
IS : 5892 Concrete transit mixer and agitators.
IS : 6461 Glossary of terms relating to Cement Concrete.

IS : 6494 Code of Practice for Water Proofing of underground Water reservoirs

and swimming pools.
IS : 6509 Code of Practice for installation of joints in Concrete pavements.
IS : 7293 Safety code for Working with construction machinery.
IS : 7861 Code of Practice for extreme weather concreting
IS : 8112 Specification for 43 grade Ordinary Portland Cement.
IS : 9103 Specification for Admixtures for Concrete.
IS : 9417 Recommendations for welding cold-Worked Steel Bars for Reinforced

Concrete construction.
IS : 9595 Recommendations for metal-arc welding of carbon and carbon

manganese Steels.
IS: 11384 Code of Practice for composite construction in Structural Steel and
Concrete.
IS : 11817 Classification of joints in buildings for accommodation of dimensional

deviation during construction
IS : 12118 Specification for two-Parts ploy sulphide.
IS : 12200 Code of Practice for provision of Water stops at transverse

contraction joints in masonry and Concrete dams.
IS : 13311 Non-destructive Testing of Concrete.
IS : 13920 Code of Practice for ductile detailing of Reinforced Concrete

structures subjected to Seismic forces.
IS : 14687 Guidelines for false Work for Concrete structure.
SP : 7 National Building Code - Structural Design of Pre-Fabrication and

system building. (Pt.VI / Sec.7)
2.00.00 CAST-IN-SITU CONCRETE
2.01.01 This part of the specification covers the requirements for plain and/ or reinforced
cement concrete for all kinds of work such as building up of piles, pile cap,
foundations including machine foundations, pedestals, columns, beams, slabs,
lintels, floors, roofs, parapets, facia, flooring, under bed, screed concreting,
concreting over metal decking, encasement of structures, area paving, trenches,
drains, pits, sumps, rigid foundation for rail-tracks, manholes, culverts, walls, tanks,
coping, jambs, waist slabs, soffits of stairs, risers, treads, canopy, portico, grid slab,
decks supported on vibration isolation system, basement, cable vault, etc.

2.01.02 The provisions of IS: 456 shall be followed as general guidance, along with all other
relevant Indian Standards, unless otherwise specifically mentioned.
Contractor shall deploy mechanised system for production, transportation and

placement of concrete.
At least one week before commencing the construction of any large concrete
section, the Contractor shall submit, for approval of the Engineer, detailed proposals
for placing the concrete to demonstrate the suitability of the methods.
2.02.00 Materials
2.02.01 Cement
Cement shall be ordinary Portland cement (grade-43) conforming to IS: 8112 and /
or fly ash based Portland Pozzolona cement conforming to IS: 1489 (Part-I) and / or
any other type of cement, meeting IS: 456 requirement.
2.02.02 Aggregates
a) Aggregates mean both coarse and fine inert materials used in the
preparation of concrete. Aggregates shall consist of natural sand and / or
crushed stone from a source known to produce satisfactory aggregate for
concrete and shall conform to IS: 383.
b) For reinforced concrete work, aggregates conforming to IS: 383 having a

maximum size of 20 mm shall be used. For certain reinforced concrete
works, aggregates having a maximum size of 12.5 mm shall also be used.
However, for lean concrete provided as mud mat below structural concrete,
maximum size upto 40 mm shall be used.
c) Petrographic examination of aggregate shall be carried out by the contractor

at National Council for Cement and Building Materials (NCB), Ballabgarh, or
any other approved laboratory to ascertain the structure and rock type
including presence of strained quartz and other reactive minerals for machine
foundations, etc., and other structures as specified in schedule of items.
Moreover, in case, the coarse aggregate sample is of composite nature, the
proportions (by weight) of different rock types in the composite sample and
petrographic evaluation of each rock should also be ascertained. While
determining the rock type, special emphasis should be given on identification
of known reactive rocks like chalcedony, opal etc. The procedure laid down
in IS: 2430 for sampling of aggregates may be followed.
The laboratory shall determine potential reactivity of the aggregate, which

may lead to reaction of silica in aggregate with the alkalis of cement and / or
potential of some aggregates like limestone to cause residual expansion due
to repeated temperature cycle. If the same is established, the contractor shall
further carry out alkali aggregates reactivity test as per IS: 2386 (Part-VII)
and/ or repeated temperature cycle test to establish the suitability of the
aggregates for the concrete work. The test results, with the final
recommendations of the laboratory, as to a suitability of the aggregate, for
use in the concrete work for various structures and suggested measures, in

case of results are not satisfactory, shall be submitted to the Engineer for his
review, in a report form.
In case in the report, it is established, that the aggregates contain reactive

silica, which would react with alkalis of the cement, the contractor shall
change the source of supply of the aggregate or take measures as
recommended in the report as instructed by Engineer. In case aggregates
indicate residual expansion, under repeated temperature cycle test (from 100
Celsius to 650 Celsius and for 60 temperature cycles) the material shall not
be used for concreting of TGs', BFPs', Fans, mills and other equipment
foundations which are likely to be subjected to repeated temperature cycle.
The contractor shall use aggregates free from residual expansion under
repeated temperatures cycle test.
2.02.03 Pozzolanas (Fly Ash)
Fly ash for use in concrete and allied works shall conform to Grade-1 of IS: 3812.
The fly ash shall be collected in closed container from below the existing ESP / Dry
Fly Ash Silos and tested for Blaine’s fineness (value should be more than 3200
sq.cm. /gm.). Mixing of fly ash for making concrete shall be done in proportion as per
the mix design.
2.02.04 Water
Water used for mixing and curing shall be as per clause 5.4 of IS: 456.
If the water proposed to be used for mixing in concrete or curing does not satisfy the
codal requirements and / or contains an excess of acid, alkali, sugar, salt or other
deleterious substances, then the same shall not be used.
Seawater shall not be used for mixing in concrete and for curing.
2.03.00 Concrete
2.03.01 Grades of Concrete
Grade of concrete shall be as per schedule of Items and construction drawings.
All concrete shall be "Design Mix Concrete" as defined in IS : 456, except for plain
cement concrete of grade M-7.5 and M-10 which shall be nominal mix concrete.
Concrete of grade M-15 can be nominal mix or design mix.
2.03.02 Types of Mix
2.03.03 Nominal mix Concrete
Nominal mix concrete shall conform to clause 9.3 of IS: 456. Proportions for nominal
mix concrete shall be as per table 9 of IS: 456.
2.03.04 Design Mix Concrete
a) Contractor shall get the initial concrete mix design done from established
laboratory such as National Council for Cement and Building Materials,

National Test House, Shri Ram Test House, Central Building Research
Institute, Roorkee. The mix design shall be done considering various
combinations starting with minimum cement contents as per IS:456 for the
respective grade, with or without super plasticizer for different slumps
suitable for pumping and with varying percentage of fly ash mix with cement
viz., 0%, 10%, 15%, and 20%.
b) The concrete mix shall be designed for all grades of concrete to obtain the
required workability and the characteristic strength as per clause 9.2 of IS:
456.
c) In batching concrete, the quantity of cement, aggregates and admixtures

shall be determined by mass. Water shall be either measured by volume in
calibrated tanks or weighed. All measuring equipment at site, shall be
maintained in a clean and serviceable condition, and their accuracy shall
conform to requirement of clause 10.2.2 of IS: 456 and shall be periodically
checked.
d) To increase the workability and to improve other properties of concrete,

wherever required, as per mix design, super-plasticizers shall be used.
e) Minimum cement content and maximum free water-cement ratio for various
grades of concrete shall be as per Table-5 of IS: 456 corresponding to the
respective grade and exposure condition.
Adjustments to minimum cement content for aggregates other than 20 mm

nominal size shall be as per Table-6 of IS : 456.
f) At least four trial mixes are to be made for each grade of concrete and
minimum six test cubes taken for each trial mix noting the slump for each
mix. The cubes shall then be properly cured and three cubes for each mix
shall be tested at 7 days and others at 28 days for obtaining the compressive
strength. The design mix particulars shall indicate with the help of graphs and
curves etc. the extent of variation in the grading of aggregates, which can be
allowed. While designing mixes, over wet mixes shall be avoided. Where
assessment of early strength is required, the concrete cubes shall also be
tested for early age strength at 1 day and 3 days for establishing the values.
g) The contractor shall submit the test reports of mix design to the Engineer for
his review, indicating design criteria, analysis and proportioning of materials,
etc. On the basis of the above test reports, a mix proportion by mass and the
water-cement ratio, shall be determined by the contractor such that concrete
prepared with this mix will yield the desired characteristic strength and shall
have suitable workability. The proportions, once decided for different grades
of concrete, shall be adhered to, during all concreting operations as long as
the quality of the materials does not change. If, however, at any time, the
quality of materials being used has changed from those for initial mix design,
or there is a change either in the required strength of concrete, or water-
cement ratio or workability, the contractor shall have to make similar trial
mixes and perform initial tests to ascertain the revised mix proportions and
water-cement ratio to be used for obtaining the desired strength and
consistency.

h) In the situations, like casting of piles, where the compaction of concrete is not
possible by vibration, the method of compacting concrete cubes of
preliminary / trial mixes and work tests shall be in the same manner as the
method of compacting concrete at site is proposed.
2.03.05 Workability of Concrete
The concrete shall be of adequate workability suitable for the placing conditions of
concrete. The suggested ranges of values of workability of concrete measured in
accordance with IS: 1199 shall be as per clause no. 7 of IS: 456.
2.03.06 Mixing of Concrete
a) All structural (Reinforced) concrete mixing shall be done at central batching

plants, conforming to IS: 4925, situated within the area allocated to the
contractor. Batching Plant shall also have provision to mix fly ash (by weight).
The batching plant shall have a mechanically operated mixer of an approved
size and type, capable of ensuring a uniform distribution of the materials
throughout the mass as well as uniformity of the colour and consistency of
the mass. Digitised recording of the material consumed along with the
quantity of concrete produced for every shift of eight hours shall be submitted
to the Engineer.
b) However, for PCC work of M-7.5, M-10 and M-15, Engineer may permit the
use of independent mechanical mixer with weigh batching machine.
2.03.08 Concrete Conveying
Concrete shall be handled and conveyed as rapidly as practicable, from the place of
mixing to the place of final laying, by transit mixers to maintain the consistency of the
mix. However, where use of independent mechanical mixer is permitted by
Engineer, conveying of concrete can be by means other than transit mixer.
2.03.09 Concrete Placing and Compaction
a) General placement of all reinforced (structural) concrete shall be by pumping.

Placement of concrete in piles shall be through tremie pipe fed by pumping.
However, placement of non-structural concrete (PCC) such as in flooring,
plain / lean concreting, etc. can be by either pumping or other means as
approved by Engineer.
b) Concrete shall not be dropped from a height or handled in a manner, which

may cause segregation. The maximum permissible free fall of concrete shall
be 1.5 m.
c) For concrete placed by pumping, the consistency shall be the minimum

necessary for such conveyance of concrete. Before commencement of
regular pumping, the pipeline shall be lubricated with cement mortar and
once pumping commences, stoppages shall be avoided.
d) Concrete shall not be placed in foundations on soft areas or where there is

standing water or debris. Such soft areas shall be removed and standing
water / debris cleared before placing the concrete.

e) Concrete shall be placed continuously in horizontal layers of 150mm or

higher thickness as directed by the Engineer and thoroughly compacted
before placing next layer. The thickness of each layer shall be such that it will
be deposited before the previous layer has stiffened. When placing the
concrete through reinforcing steel, care shall be taken to prevent segregation
of the coarse aggregates.
f) Concrete shall normally be poured in one operation. In special

circumstances, with the approval of the Engineer, it can be poured in more
than one operation subject to provision of construction joint. Bleeding of
under layer, if any, shall be effectively removed.
g) Compaction of concrete shall conform to Clause 13.3 of IS: 456.
h) Surface vibrators and form-attached vibrators shall not be permitted under

normal conditions. Their use shall require written approval of the Engineer.
i) Vibrators shall penetrate both the layer poured and the under layer to ensure
good bond and homogeneity and to prevent the formation of cold joints.
Immersion vibrators shall not be allowed to come in contact with steel
reinforcement after start of initial set. Also, they shall not be allowed to come
in contact with forms or finished surfaces.
j) Immersion vibrators shall have a 'no load' frequency, amplitude and

acceleration as per IS: 2505 depending upon the size of the vibrator.
Immersion vibrators shall be operated by experienced men. These vibrators
shall be immersed not more than 450 mm apart and withdrawn when air
bubbles cease to come to the surface. Such vibrators shall in no case be
used to push concrete inside the forms and vibrators shall be withdrawn
slowly.
k) No concrete shall be placed in wet weather or on a water-covered surface. If

there has been any sign of washing of cement or sand, the concrete shall be
entirely removed immediately. Suitable precautions shall be taken in advance
to guard against possible rains before leaving the fresh concrete unattended.
l) Concrete in works other than top decks of machine foundations, when

placed, shall have a temperature of not less than 5°C and not more than
40°C. When depositing concrete in very hot weather, precautions shall be
taken so that the temperature of wet concrete does not exceed 40°C while
placing. This shall be achieved by stacking aggregates under the shade and
keeping them moist, using cold water, starting curing before concrete dries
out, etc. However, before mixing / placing concrete, when the above
temperature conditions vary on either side, approval of the Engineer shall be
obtained for the method of execution.
m) During hot weather (atmospheric temperature above 40°C) or cold weather

(atmospheric temp at 5°C and below) the concreting shall be done as per the
procedures and Precautions set out in IS: 7861 (Parts I and II).

n) Base raft of turbo-generator and other machine foundations and top decks of
all machine foundations shall be cast in a continuous operation without any
construction joint.
2.03.10 Protection and Curing of Concrete
a) Newly placed concrete shall be protected by approved means from rain, sun
and wind. Concrete placed below ground level, shall be protected from falling
earth, during and after placing. Concrete placed in ground containing any
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.
b) The ground water around newly poured concrete shall be kept down to an
approved level by pumping or other approved means of drainage. Adequate
steps shall be taken to prevent floatation or flooding. Steps, as approved by
the Engineer, 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.
c) Curing shall be as per Clause 13.5 of IS: 456.
2.03.11 Cleaning and finishing of Concrete
a) All concrete surfaces shall have an even and clean finish free from
honeycombs, air bubbles, fins or other blemishes, unmarred and reasonably
smooth. The formwork joint marks on concrete work exposed to view
including machine foundations of TGs', BFs', Fans & Mills shall be rubbed
with carborandum stone. The finish shall be made to the satisfaction of the
Engineer. Concrete surfaces to be subsequently plastered or where brick
work is to be built against them, shall be adequately hacked as soon as the
form is stripped off so that proper bond can develop.
b) Immediately after removal of forms, the concrete shall be inspected and

defective areas as pointed out by the Engineer shall be removed partially or
entirely as directed. Holes, left by form bolts, etc. shall be filled up and made
good with cement sand mortar of approved mix. All superficial defects such
as honeycombing, rough patches, etc. shall be similarly made good. If the
defective area is at a vulnerable location, eg., at the ends of beams &
columns, etc. then it may be necessary to cut out the member completely or
in part and reconstruct as directed by the Engineer. If epoxies have to be
used, the same shall be subject to the approval of the Engineer. Poured
concrete affected by faulty formwork shall be totally removed and replaced. If
so directed, the contractor shall have to resort to grouting.
c) A smooth finish shall be obtained with the use of forms having smooth and
even surfaces and edges. Panels and form linings shall be of uniform size
and be as large as practicable and installed with closed joints. Upon removal
of forms, the joint marks shall be smoothened off and all blemishes,
projections etc. removed leaving the surfaces reasonably smooth and
unmarred.

d) Where integral cement concrete finish is called for, the surface shall be
compacted and then floated and treated with a straight edge and any high
and low spots eliminated. The work shall be carried out as per IS : 2571.
2.03.12 Rendering
The defect in concrete surfaces shall be rendered by 1: 3 (cement: sand) mortar to

give an even and clean finish to the concrete surfaces.
2.03.13 Rectification of defects in concreting observed by UPV Testing
Defects in concreting including cavities / voids, honeycombing in concrete, observed

by UPV testing need to be rectified by cement / epoxy grouting or a combination of
both without any additional cost to owner.
a) Cement grout - cement grouting shall be done in structures / foundations

where large-scale voids or honeycombing are observed. The cement grout
with non-shrink admixture and or plasticizer shall be used. Water cement
ratio needs to be controlled and it shall be preferably less than 0.5. Nipples
shall be fixed in the locations where grouting has to be carried out. Cement
grout shall be injected at a pressure of 2.5 to 3.0 Kg / Sq. Cm.
b) Epoxy grout - epoxy grouting shall be carried out in critical locations from
serviceability as well as structural point of view. In addition, this shall be
carried out in locations where narrow passage is available for free flow of
grout.
The proportion of resin to hardener shall generally by 100: 30. However, the
actual proportion shall be as per manufacturer's recommendations. The
epoxy system shall be non-shrink, low viscosity and free flowing. The epoxy
grout shall be injected at a pressure of 3.0 to 4.0 Kg / Sq. Cm.
2.04.00 Temperature Control of Concrete in top decks of machine foundations (i.e. of

TGs, BFPs, Fans, etc.)
The temperature of fresh concrete shall not exceed 25°C when placed and a
suitable measuring device / gauge for measuring the temperature of concrete as
approved by the Engineer shall be used.
For maintaining the limiting temperature of 25°C, ice shall be used in mixing water.
The contractor shall establish the quantity of ice to be mixed in order to achieve the
limiting temperature of 25°C. In addition to mixing of ice, other methods for control of
temperature like cooling of aggregates may also be resorted to.
2.05.00 Admixtures (super plasticizer)
Admixtures in concrete for promoting workability, retarding setting, reduction in

permeability, facilitating pumping of concrete, etc., shall be used as per the
approved mix design after approval from the Engineer. Admixtures shall conform to
clause 5.5 of IS: 456. These shall be free from injurious amount of chloride, etc.
Addition of admixtures should not reduce the specified strength or durability of
concrete and should not have detrimental effect on reinforcement.

The admixtures shall conform to IS: 9103 or ASTM C-494 and shall be proven
performance record make and from a reputed manufacturer. Calcium chloride as
accelerating admixture is not permitted to be used.
Admixtures shall either be naphthalene based or any other material approved by the
Engineer. Ligno-sulphonate based materials shall not be used. Admixtures shall be
used in liquid form only, quantity of which shall be as per manufacturer's
recommendation and approved mix design.
2.06.00 Construction Joints
2.06.01 Construction joints shall conform to clause 13.4 of IS: 456. However, for water
retaining structures, provision of IS: 3370 shall also be followed.
2.06.02 When work has to be interrupted, the concrete shall be rebated and / or keyed at the
joint to such shape and size as may be required by the Engineer or as shown on the
drawings. 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. In the case
of water retaining structures, basements, tunnels, etc. water stop of approved
material shall be provided, if so specified on the drawings or as directed by the
Engineer.
2.06.03 Construction joints shall be located as shown or described on the drawings. Where it
is not described, the joints shall be in accordance with the following guidelines.
i) In a column, the joints shall be formed about 75mm below the lowest soffit of
the beams framing into it, including haunches, if any. In flat slab construction,
the joint shall be 75 mm below the soffit of the column capital.
ii) Concrete in a beam shall be placed throughout without a joint. If unavoidable,

the joint shall be vertical and within the middle-third of the span. The joints
shall be vertical throughout the full thickness of the concrete member with
suitable shear key wherever shown on the drawing.
iii) A joint in a suspended floor slab shall be vertical at one-quarter points of the
span and at right angle to the principal reinforcement.
iv) Construction joints in equipment foundations shall not be provided without

specific concurrence of the Engineer.
v) Construction joints in water retaining structures shall not be provided unless

shown on the drawings or permitted by the Engineer.
However, if the contractor desires any adjustments in the location of

construction joints (to suit site conditions) from those shown on drawings or
from those explained above, he shall obtain prior approval from the Engineer.
2.06.04 Before fresh concrete is placed, the cement skin of the partially hardened concrete
which was poured earlier, shall be thoroughly removed and the surface made rough
and aggregate exposed, by wire brushing, hacking, water jetting, air jetting or any
other method as directed by the Engineer. The rough surface shall be thoroughly
wetted for about 1 / 2 hour and shall be dried and coated with 10 to 15mm thick layer
of 1: 1 freshly mixed cement and sand slurry. 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.
2.06.05 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 they will have to be approved by the Engineer. The Contractor's
proposals shall include the location of construction joints, the sequence of pouring,
formwork details and their stripping times and any other relevant detail.
2.06.06 For multiple lift work, a suitable gap shall be maintained between the setting of the
earlier placed concrete and the next concrete pour. After depositing concrete in
columns, piers or walls, a time gap of minimum 4 hours, Preferably 24 hours shall be
maintained, before depositing concrete in beams, girders or slabs, supported
thereon, in order to avoid cracking due to settlement.
2.07.00 Hot Applied Bitumen Treatment
Where shown on the drawings or directed by the Engineer, the external plastered /
unplastered concrete surface below ground shall be carefully cleaned, cured and
allowed to dry for sometime before the application of hot Bitumen of the Industrial
grade 85 / 25 conforming to IS:702 against ground water seepage. Rate of
application of Bitumen shall not be less than 1.7 kg / m2 and it should be heated to
about 120°C before application and shall be applied in minimum two coats. Anti-
stripping compound shall be added. Anti-stripping and adhesion improving agent
shall be 100% miscible in Bitumen. The stripping value tested as per IS: 6241 should
be nil when recommended quantity of anti-stripping compound is mixed. Minimum
mix proportion of the anti-stripping compound shall be 1 percent by weight of
Bitumen. However, actual mix proportion shall be as per the manufacturer's
recommendation.
3.00.00 REINFORCEMENT
3.01.00 General Requirements
3.01.01 This part of the technical specification covers the requirement of reinforcement for all
reinforced concrete works (cast-in-situ as well as pre cast) including piling.
3.01.02 The contractor shall prepare and furnish to the Engineer, bar bending schedules for
all R.C.C works for his review and approval. No work shall commence without the
approval of bar bending schedules by the Engineer, in writing.
The contractor shall have to obtain prior written approval from the Engineer, if he
desires any adjustments in diameter or spacing of reinforcement.
3.02.00 Reinforcement Steel
3.02.01 Mild steel and medium tensile steel bars and hard drawn steel wire shall conform to
Grade-1 (Fe-250) of IS:432 (Part-1). All high strength deformed steel bars shall be
thermo-mechanically treated Bars and shall conform to grade Fe-500 of IS:1786
(with minimum percentage of elongation of 14.5%). Rolled steel shall conform to
grade 'E250A' of IS : 2062. Hard drawn steel wire fabrics shall conform to IS:1566.
3.03.00 Bending and Placing

3.03.01 a) This shall generally conform to clause No. 12 and 26 of IS: 456.
b) Reinforcing bars supplied bent or in coils, shall be straightened before these

are cut to size. Straightening of bars shall be done in cold and without
damaging the bars. This is to be considered as a part of reinforcement
bending.
c) Unless otherwise specified, reinforcing steel shall be bent in accordance with

procedure specified in IS: 2502 and / or as approved by the Engineer. Unless
specified otherwise or directed by the Engineer, the detailing of
reinforcement shall be in accordance with IS: 5525 and SP: 34.
d) Welding of reinforcement, where permitted, shall be carried out as per IS:

2751 and IS: 9417 and according to the best practices.
e) Bundled bars shall be provided wherever shown on the drawing to facilitate

concreting.
f) The placing of reinforcement shall be completed well in advance of concrete

pouring. Just prior to concrete pouring, the reinforcement shall be checked
by the Engineer, for accuracy of placement and cleanliness. Necessary
corrections as directed by the Engineer shall be carried out. Care shall be
taken to ensure that projecting ends of ties and other embedded metal do not
encroach into the concrete cover.
3.04.00 Binding in Position
Bars intended to be in contact at crossing points, shall be securely bound together at

all such points by two numbers annealed steel wire of 0.9 mm to 1.6 mm size
conforming to IS : 280 in such a manner that they do not slip over each other at the
time of fixing & concreting. The tying of bars shall be in cris-cross manner.
3.05.00 Concrete Cover Blocks
Where concrete blocks are used for ensuring the cover and positioning of
reinforcement, these shall be made of mortar 1:2 (1 Cement: 2 sand) by volume and
cured for at least seven days. The sizes and locations of the concrete blocks shall
be approved by the Engineer. The 28 days crushing strength of cover blocks shall
be at least equal to the specified strength of concrete in which the blocks will be
embedded.
3.06.00 Chairs and Spacers
All reinforcement shall be accurately fixed and maintained in position as shown on

the drawings by such approved means as steel chairs or spacers as per IS: 2502.
The vertical distance between successive layers of bars shall be maintained by
providing chairs / spacer bars. These shall be so spaced that the main bars do not
sag perceptively between adjacent chairs / spacers.
3.07.00 Cover to Reinforcement

This shall be as per Table 16 and Clause 26.4 of IS: 456 considering moderate
exposure for outdoor condition and mild exposure for indoor condition unless
otherwise specified and / or shown on the drawings.
3.08.00 Laps and Anchorage
Laps and Anchorage length of reinforcing bars shall be in accordance with IS : 456,
unless otherwise specified. Location of laps and development lengths, shall be as
indicated on the drawings. If the bars in a lap are not of the same diameter, the
smaller diameter will guide the lap length. Laps shall be staggered as far as
practicable and as directed by the Engineer and not more than 50% of bars shall be
lapped at a particular section.
4.00.00 FORM WORK
4.01.01 This part of the specification covers the requirements for providing and fixing form
work and staging required for all cast-in-situ concrete works including making of
pockets / block outs.
4.01.02 The contractor shall supply, fabricate, erect and dismantle (after use) all staging
whatsoever is required. He shall prepare the scheme and submit along with the
supporting calculations for approval of the Engineer and get them approved before
the start of work. Form work shall conform to IS: 14687-False Work for Concrete
structures - Guidelines.
4.01.03 Materials and accessories for false work (form work) shall conform to clause no. 6 of
IS: 14687.
4.01.04 Staging, unless specified otherwise, shall generally be of mild steel tubes, steel
beams and channels etc., and of modular construction.
4.02.00 All formwork shall be formed using approved quality BWP type, compreg (densified)
plywood with suitable overlay (film faced) and conforming to IS:3513 Part-III and
IS:4990 to produce a perfectly levelled, uniform and smooth surface. Reuse of such
forms may be permitted only after inspection and approval by the Engineer, for each
such reuse. Any damage to film face shall be caused for rejection. The faces of
plywood with suitable overlay shall be dense, smooth and without blisters and patch
marks. It shall be of uniform colour. Film face shall have minimum 250 GSM (Grams
/ Sq.M.) coating.
4.03.00 Form Work and Staging
4.03.01 Form Work shall conform to clause no. 11 of IS : 456. Form Work shall consist of all
materials required for forming the boxing to pour concrete, including steel / plywood
forms, ties, anchors, hangers, inserts, etc. Form Work shall be so constructed that
vertical and horizontal adjustments can be made as required. The design and
engineering of formwork including staging as well as its erection and dismantling
shall be the responsibility of the contractor.
4.03.02 The staging shall be true and rigid and thoroughly braced in both directions as well
as cross braced, strutted and propped such that it will not deform unduly under

weight of concrete and other loads due to men, equipment, etc. Vertical members or
props should not be supported on an un-propped lower suspended floor or beam
unless it is ensured by the Contractor that the lower floor or beam can safely carry
the loads. No propping shall take place until the Engineer's approval has been given
to the contractor's scheme submitted along with supporting calculations.
4.03.03 The forms and staging shall be sufficiently strong to carry without undue
deformation, the dead weight of green concrete as well as anticipated working loads.
Where the concrete is vibrated, the form work shall be strong enough to withstand
the effects of vibration, without appreciable deflection, bulging, 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.
4.03.04 To achieve the desired rigidity, ample studs, braces, bolts, spacer blocks, wires,
clamps, ties, straps, shores, etc. shall be used to hold the form in proper position
without undue distortion. These shall be approved by the Engineer but they must in
no way impair the strength of concrete or leave stains or marks on the finished
surface. Bolts passing completely through liquid and or earth retaining walls / slabs,
basement walls etc. for the purpose of securing and aligning the form work, shall not
be permitted.
4.03.05 Beveled strips shall be provided 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 these are necessary and as may be directed by the Engineer. The
temporary openings shall be so formed that they can be conveniently closed rigidly
when required and must not leave any mark on the concrete.
4.04.00 Cambering
The contractor shall maintain necessary camber in centering for all floor slabs and
beams in all spanning directions, so as to offset the deflection and assume correct
shape.
4.05.00 Cleaning
All forms shall be thoroughly cleaned of old concrete, dirt and dusts sticking to them
before these are fixed in position. All rubbish, loose concrete, chippings, etc. shall be
scrupulously removed from the interior of the forms before concrete is poured. Wire
brushes, brooms, compressed air jet and / or water jet etc. shall be kept handy for
cleaning. Before form work is placed in position, the form surfaces, that will be in
contact with concrete shall be treated with form releasing agent (mould oil) as per
clause no. 6.3 of IS : 14687. The mould oil shall be a solution of preservative in a
heavy mineral oil with a viscosity of 70-80 centipoise. This shall be free from dark
and other suspended particles and shall be of light gray colour.
4.06.00 Design and Erection
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 beam bottoms
and their supports in position. Re-propping of beams shall not be done except with

the approval of the Engineer. Formwork for columns and walls at each stage of
concreting shall be erected only upto the particular lift of construction. 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 jerking
the concrete.
4.07.00 Removal of Forms and Staging
4.07.01 This shall generally conform to Clause No. 11.3 of IS : 456 and 9.5 of IS: 14687.
4.07.02 The contractor shall remove formwork only after approval of the Engineer. He shall
place on record the dates on which the concrete is placed in different parts of the
work and the dates of removal of formwork therefrom. The contractor shall be
responsible for the safe removal of formwork. The Engineer may delay the time of
removal if he considers it necessary. Any work showing signs of damage through
premature removal of formwork, shall be entirely removed and reconstructed by the
contractor at no extra cost to the owner.
4.07.03 In normal circumstances and where ordinary Portland Cement is used, forms may
generally be removed after the expiry of the minimum periods specified in Clause
No. 11.3 of IS : 456 and 9.5 of IS : 14687. In case of mixing of fly ash with OPC
(ordinary Portland Cement) and where fly ash based Portland Pozzolana Cement is
used, the stripping time of formwork shall be suitably increased by Engineer based
on the results of cube test on the rate of development of design strength. In absence
of the above information the stripping time shall be increased by 50% more than that
being adopted for OPC.
4.07.04 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 slab, beam or arch as the case may be
together with any live load likely to occur during curing or further construction.
4.07.05 Where the shape of the element is such that the formwork has re-entrant angles, the
formwork shall be removed as soon as possible after the concrete has set, to avoid
shrinkage cracking occurring due to the restraint imposed.
4.07.06 In case of cantilever slabs, the removal of forms shall begin from the outer edge and
proceed towards the support, where as in the case of slabs supported on two / four
sides, the removal of forms shall begin from centre to supports.
4.07.07 The formwork declared unfit or unserviceable by Engineer shall not be used.
4.08.00 Concrete Volute (CV)
Concrete Volute (CV) pump sub-structure shall have a curved profile in RCC.
Portion of the formwork shall be supplied by the pump manufacturer. The GA
drawings of sub-structure shall also be supplied by pump manufacturer through the
Owner. Fixing/installation of CV formwork, its support arrangement, concreting as
well as formwork removal shall be done by the Contractor under the supervision of
Owner / equipment supplier. The quoted rate under CV formwork fixing & removal
etc. as stated in Schedule of Items shall include the cost of all such activities
incidental to concrete work in concrete volute pumps.

5.00.00 EMBEDDED PARTS (INCLUDING LAYING OF RAILS) AND ANCHOR

FASTENERS
5.01.01 This part of the technical specification covers the requirement of transportation and
erection of embedded steel parts furnished by the owner, providing and installation
of mild steel / PVC pipes, providing and fixing of anchor fasteners, laying of rail
tracks, etc.
5.01.02 For fabrication and erection of insert at site, specification for structural steel work
shall be referred to.
5.01.03 Embedded steel parts supplied by the owner shall be furnished anywhere within the
project area and the contractor shall transport the same to the work site.
5.01.04 Embedded steel parts shall include items such as, but not limited to, foundation
grillages, anchor bolts, pipe sleeves, equipment mounting plates, steel pieces with /
without lugs, auxiliary framing for equipment supports, miscellaneous frames, etc.,
deformed steel bars shall not be used for lugs.
5.01.05 Concreting of the adjacent area of the embedded parts shall be done carefully to
avoid displacement of the embedded parts and honeycombing / voids.
5.02.00 Material
Rolled steel and Structural steel shall conform to IS: 2062. Mild Steel pipes shall
conform to IS: 1161. Unless otherwise specified, medium class pipes shall be
provided. PVC pipes shall conform to IS: 4985. Minimum pressure rating for PVC
pipes shall be 2Kgf / cm2.
5.03.00 Embedded Steel Parts
5.03.01 The contractor shall transport to site and erect accurately in position all embedded
steel parts furnished by Engineer including layout, welding, bolting and drilling.
Exposed surfaces of embedded parts other than holding down bolts, are to be
painted with primer painting with chlorinated rubber based zinc phosphate.
5.03.02 During erection, the contractor shall provide necessary strong temporary bracings
and supports to ensure proper installation of the embedded parts which shall be
erected at the true location as shown on the drawings and these shall be in plumb
and level (unless otherwise shown on drawings).
5.04.00 Mild Steel / PVC pipes
5.04.01 For fabrication and erection of the pipe embedment, specification for structural steel
shall be referred to.
5.04.02 IS: 7634 (Part-III) shall be followed for PVC pipe Works.
5.04.03 The pipes shall be installed accurately in position and if required, temporary
supports shall be provided to ensure that these are not disturbed during concreting
and other related works.

5.05.00 Railway Track
5.05.01 Rail tracks, as directed by the Engineer, shall be erected by the contractor under
supervision of a specialised agency appointed by owner. It shall be ensured by the
contractor that the rails are installed true to line, level and gauge. The rail along with
the fish plates, wherever required, shall be supplied by the owner.
5.06.00 Anchor Fasteners
5.06.01 Expansion fasteners shall be used for fixing of steel members, embedments,
equipment mounting frames and similar other parts subsequent to concrete work.
Fasteners shall be of appropriate type, size and capacity as per manufacturer's
specification, and shall be installed by drilling holes of appropriate size in the
concrete.
5.06.02 The anchor fasteners shall be of two types viz. medium duty for carrying tensile load
(uplift) upto 1.0 MT per fastener and heavy duty for carrying tensile load of more
than 1.0 MT and upto 5.0 MT per fastener.
5.06.03 a) The safe tensile load carrying capacity of the anchors shall be arrived by
providing the minimum factor of safety of 2.5 on the characteristic load of the
anchor. Minimum size of anchors shall be M8.
b) All anchors shall be from established and approved manufacturers.
c) Anchors shall be fixed in position as recommended by the manufacturer and

as approved by the Engineer.
d) Anchor fasteners can be of mechanical bonding such as keying, friction,

combined friction-keying or chemical bonding.
e) Capacity of the anchors shall be established after considering the effect of

concrete grade, embedded depth, concrete thickness, anchor spacing and
edge distance from the concrete edge.
f) The selection for the particular type of bonding for the anchors shall be made
after considering the concrete grade, available embedment depth, load to be
transferred, space available for installing anchors.
5.06.04 Bonding of anchors can be either mechanical and / or chemical
a) The mechanical bonding anchors are torque controlled anchors made from
carbon steel of grade 8.8 as per IS : 1367 Part III. Anchors in bolt as well as
nuts version are acceptable. The bolt version anchors consist of bolt, washer,
sleeves, plastic section, expansion sleeves and a cone. Nuts version anchors
consist of nuts, threaded rod, washer, sleeve, plastic section, expansion
sleeve and a cone. All steel components of anchors shall be electro
galvanized to minimum 5 micron coating thickness. The plastic section shall
be of Polyacetal Derlin 100 or equivalent.
b) Chemical bonding anchors shall consist of foil capsule and threaded rod. The
foil capsule shall contain the resin and hardener. The threaded rod shall have

chiseled tip. The anchors shall be tested for its behaviour under fire as per
heating curve ISO : 834 for upto 120 minutes and furnish the test result.
Anchors of size M8 to M24 shall conform to grade 5.8 and M27 to M39
anchors shall conform to 8.8 grade. The grades are as per IS : 1367 Part-III.
All steel components of the anchors shall be electro galvanized to minimum 5
micron coating thickness.
5.06.05 These anchors shall comprise of studs, nuts, washers and expansion sleeves. The
one end of the stud shall have thread and the other end shall have cold formed
conical head. All steel component of the anchors shall be electro galvanised to
minimum 5 micron coating thickness. The expansion sleeve shall preferably be of
stainless steel of SS316. The anchors shall conform to min grade of 5.8 as per IS:
1367.
6.00.00 GROUTING
6.01.01 This part of the specification covers the requirements of grouting of block outs,
pockets, foundation bolt holes, and of spaces below the base plate and machine
bases, etc.
6.01.02 Crushing strength of grout shall be one grade higher than the foundation concrete.
Minimum crushing strength shall be 30 N / Sq. mm, unless otherwise specified.
6.01.03 The contact area between the grout and base plate shall not be less than 80%
6.02.00 Materials
6.02.01 Cement shall be Ordinary Portland Cement conforming to IS : 8112.
6.02.02 Sand shall be clean and well graded conforming to IS 383. For fluid mix grout, sand
conforming to zone-4 grade shall be used. Coarse aggregate wherever used shall
also conform to IS: 383.
6.02.03 Clean potable water as recommended for concrete mix shall be used.
6.02.04 Admixtures
a) Anti-shrinkage ready mix admixtures of approved make shall be used.
b) Plasticiser conforming to IS : 9103 shall be used to increase the workability,

wherever required.
6.02.05 Types of Mix
a) This shall be of following types:
i) Cement-Sand Grout (Fluid mix and / or plastic mix):
The proportion of cement to sand shall generally be 1:2, unless

otherwise specified.

ii) Cement aggregate grout (stiff mix):
The approximate proportions of cement, sand and coarse aggregate

shall be 1:1.25:2 by weight, with a maximum size of aggregate as 10
mm. This mix shall generally be used for grout thickness above 40
mm for dry pack application.
b) Depending upon the case of placement and method of application there shall
be following three grout consistencies.
i) Fluid Mix:
Water-Cement ratio shall be 0.6(max.). Plasticiser shall be added to

increase workability. This grout mix shall be suitable for application
with low-pressure grouting equipment or self-flowing and suitable for
grouting of pockets / blockouts, etc.
ii) Plastic Mix:
Water-Cement ratio shall be about 0.5. This grout mix shall be

suitable for application with trowel or rod.
iii) Stiff Mix:
Water-cement ratio shall generally be 0.4. This grout mix shall be

suitable for dry-pack application. The consistency should allow
pressurising into firm hard ball without cracking.
6.03.00 Surface Preparation
6.03.01 The blockouts, bolt holes, underside of the base plate, concrete surfaces, gap
between the concrete top surface and underside of base plate etc. shall be cleaned
thoroughly by use of compressed air, just prior to taking up the grouting operations.
6.04.00 Mixing
6.04.01 Cement, sand, aggregate, and anti-shrinkage admixture of approved quality and
proven make shall be first blended thoroughly in the required propor-tion as per
manufacturer's specifications. Grout shall then be prepared by mixing this admixture
with water and plasticizer. Any grout which has been mixed for a period longer than
half an hour shall not be used on the work.
6.05.00 Placing
6.05.01 In case of fluid mix / plastic mix, a grout of suitable mix shall be poured immediately
after preparation, into the blockouts, pockets, bolt holes, the space between the top
surface of the foundation concrete and the underside of the base plate either from
the sides or through the holes provided for this purpose in the base plate, by using
special equipment for pressure grouting. It shall be ensured by rodding and by
tapping of bolts that the blockout is completely filled with grout without leaving any
voids. The pouring shall cease as soon as each hole is filled and any excess grout
found on the surface of the concrete foundation shall be completely removed and
the surface dried. Grouting, once commenced, shall be done continuously. Grout

shall be worked from one end to the other (to prevent air entrapment) until the grout
oozes out through the grout holes provided in the base plates.
6.05.02 In case of stiff mix, the space between the top surface of foundation concrete and
the underside of the base plate shall be dry packed by firmly pressing or ramming
into place against fixed supports.
6.05.03 When it is clear that the center of base has been properly filled, the grout outside the
base plate shall be briefly rammed to ensure compaction below the edges. Shims
provided for the alignment of bases shall be positioned at the edges of the base to
permit subsequent removal, which shall take place not less than 7 days after the
grouting has been executed. The resulting cavities shall be made good with the
same grade of grout as has been used for grouting under the rest of the base plate.
6.06.00 Curing
The work shall be cured for a period of at least 7 days commencing 24 hours after
the completion of the grouting. The curing shall be done by covering the surfaces
with wet gunny bags and flooding.
7.00.00 JOINTS IN CONCRETE
7.01.01 This part of the specification covers the requirements for providing and installation of
bitumen-impregnated fibreboard, PVC water stops, sealing compound, expanded
polystyrene board, hydro swelling joint sealing flexible strip, cement slurry modified
with acrylic polymer, etc.
7.01.02 These shall be used along with items like precast coping, creating / cutting of groove
in concrete, precast tile cover, dowel bars, metal cover strips, etc., to make
construction and expansion joints of different types.
7.02.00 Materials
7.02.01 The bitumen impregnated fibre board, a preformed material shall conform to
IS:1838.
7.02.02 PVC water stops shall generally meet the stipulations of IS : 12200.
7.02.03 The bitumen sealing compound shall be of grade-A and shall conform to the
requirements of IS : 1834.
7.02.04 The two-part polysulphide sealant shall conform to IS : 12118. Materials shall consist
of polysulphide polymer and a curing agent. Gun grade material shall be used
unless otherwise specified.
7.02.05 Metal cover strips shall be made from anodised aluminium sections as shown on
drawings. The minimum thickness of aluminium strips shall be 3 mm.
7.02.06 Expanded polystyrene board shall conform to IS: 4671. This shall be of non-self-
extinguishing type (type1).Nominal apparent density shall be 2 kg/m3. Minimum

compressive strength at 10% deformation shall be 0.9 kg/cm2. Moisture absorption

percentage shall not be more than 1%.
The nominal panel size of each board and thickness shall be as specified in the
schedule of items.
Tolerance in length, width and thickness of the polystyrene board shall be + 2 mm.
7.02.07 Hydro swelling joint sealing flexible strip shall be of nominal size 20 mm x 5 mm and
made of hydrauphillic expanding rubber combined with chloroprene rubber. The
material shall expand when comes in contact with water. Expansion ratio shall be 10
times when in contact with potable water. Tensile strength shall be 70 kg/cm2 (min.)
and elongation 600% (min.)
7.02.08 Acrylic polymer to be used with cement slurry shall be as approved by the Engineer.
7.03.00 Installation
7.03.01 The bitumen impregnated fibre board may be secured to vertical concrete by nails in
the first placed concrete. The joint filler shall be coated on both faces with coal-tar
pitch conforming to IS:216 or bitumen of suitable grade conforming to IS:73 or
IS:702.
7.03.02 In PVC water stops, splice joints will be allowed only under unavoidable
circumstances and with the specific approval of the Engineer. The method of forming
these joints, laps, etc. shall be as specified by the manufacturer and / or approved
by the Engineer, taking particular care to match the center and the edges accurately.
Particular care shall be taken for the correct positioning of the water stops to prevent
any faulty installation which may result in joint leakage.
Adequate provisions shall be made to support the water stops during progress of
work and to ensure their proper embedment in the concrete. The symmetrical halves
of the water stops shall be equally divided between the concrete pours adjacent to
the joints.
Maximum density and imperviousness of the concrete shall be ensured by

thoroughly working in the vicinity of joints. However, particular care should be
exercised in use of vibrators in the proximity of joints to avoid dislodging of the water
stops.
7.03.03 When directed, the groove of specified dimensions for sealing purpose (for
construction / contraction joints) shall be formed in the concrete. The gap in joints
shall be thoroughly cleaned and then filled with sealing compound as per
manufacturer's specification and approved drawings. Primer shall be applied as per
manufacturer's specification.
7.03.04 The metal cover strips shall be screwed (using stainless steel / aluminium alloyed
screws) at one end on the normal circular hole and on the other end with a slotted
hole. Welding of aluminium shall be in accordance with IS : 2812.
7.03.05 Precast coping, creating groove in concrete, precast tile cover, dowel bar, metal
strips, sealing compound, etc, which are required for joints in the concrete are
covered elsewhere in this specification.

7.03.06 Expanded polystyrene board shall be provided to create the gap between the
building foundations and the machine foundations and held in position by suitable
independent support and or nailed to adjoining shuttering. This shall be left in
position as it is after completion of the concreting work. Shuttering shall not be put
on the face of the concrete foundations separated by expanded polystyrene board.
7.03.07 Prior to the installation of the sealing strip, the surface of the joint shall be completely
dry, whenever necessary a hot air blower shall be used. After cleaning dry surface,
glue shall be applied both on the concrete and the sealing strip. Strip shall be
applied with the even side towards the existing concrete surface and then pressed
into the tacky glue. Additionally, it shall be nailed to prevent slip during concreting. It
shall be placed in the middle of the joint, between the inner and outer reinforcement
bars. Nominal length of the sealing strip shall be 15 m and the ends of the two
continuous strips shall be butted together.
7.03.08 For application of polymer modified cement slurry for providing bond between
hardened concrete and fresh concrete, acrylic polymer shall be mixed with neat
cement. Normally 1 litre (1 kg) of polymer compound shall be mixed with 3 kg of
cement and 1 litre of water. Minimum 2 kg of this mix shall be provided per
sq.m.area of the concrete surface. This dose shall be based on nominal solid
polymer content of 43% in the polymeric compound. In case, actual polymer content
is less, the dose of polymeric compound shall be proportionally increased.
The concrete surface shall be prepared to achieve a clean sound surface with a
good mechanical key. Laitance shall be removed by mechanical means and
thoroughly washed with clean water.
Immediately before priming with cement slurry, the concrete sub strata shall be
thoroughly dampened with water. Concrete shall be poured when the slurry is still
tacky. This shall preferably be carried out within fifteen minutes.
8.00.00 DISMANTLING AND CHIPPING WORK
8.01.01 The dismantling implies, breaking up of a structure / member, in part or full, without
damage to balance or adjoining structure.
8.01.02 The chipping work shall include removing of the concrete from the surface, making
grooves of specified size, etc., in concrete members.
8.01.03 All materials obtained from dismantling and chipping shall be the property of the
owner.
8.01.04 All dismantling work shall be carried out in conformity with the local safety
regulations, extreme caution being exercised to avoid damage to the work and the
equipment, which are to be left intact. Necessary precautions shall be taken to keep
the dust nuisance down. Safety requirements stipulated in IS : 4130 shall also be
followed.
8.01.05 Making of circular/slit type opening, of the specified diameter/size, at the specified
position and level, shall be done by using the coring/sawing machine. Before making
the opening, the location of the reinforcement bar in the concrete shall be detected

by using rebar detector. In case the cutting of the reinforcement bars is involved in
creating the opening, then the specific clearance shall be obtained from the
Engineer before proceeding with the cutting of reinforcement or creation of opening.
8.02.00 Stacking and Disposal
All serviceable materials obtained, shall be separated out and stacked properly upto
a lead of 500 metres and all unserviceable materials, rubbish etc., shall be disposed
off as directed by the Engineer upto a lead of 2 km beyond the plant boundary.
The dismantled / chipped materials shall be lowered to the ground and not thrown
and then properly stacked as directed by the Engineer.
8.03.00 Propping & Shoring
Necessary propping, shoring and under-pinning shall be provided for the safety of
the adjoining work or property which is to be left intact, before dismantling / chipping
work.
8.04.00 Cutting of Reinforcement
This shall be done by hacksaw / gas/coring/sawing or as approved by Engineer.
8.05.00 Enclosure
Wherever required, temporary enclosures shall be erected to minimise the

disturbance to the people working in the adjoining area.
9.00.00 PRECAST CONCRETE
9.01.00 General
9.01.01 This part of the specification covers the requirement of all types of pre-cast concrete
units for all kinds of works.
9.01.02 Pre-cast concrete units shall generally be in the form of trench / floor cover, drain
cover, fin, facia, coping, lintel, chhajja, wall panel, blocks for road edging, kerb block,
separator block for road, roof unit, etc.
9.02.00 Grade of Concrete
The grade of the concrete shall be M-25. Mixing, batching, compacting, curing, etc,
of concrete shall conform to IS : 456. The size of aggregate shall be 20 mm / 12.5
mm / 10 mm as required.
9.03.00 Form Work
The formwork for the pre-cast units shall be made up of plywood so as to obtain a
smooth surface after the forms are struck.
9.04.00 Reinforcement
The reinforcement shall be provided as indicated on the drawings.

9.05.00 Casting
The casting of precast unit shall be done in a yard developed by the contractor
specifically for casting of precast units in the project site. This precasting yard shall
have hard and levelled platform. The contractor shall arrange for all the necessary
facilities like shed, casting bed, curing tank, handling equipment, storage,
transportation, etc. complete. Casting of precast unit shall be done in a way similar
to placing cast-in-situ concrete.
Each pre-cast unit shall be suitably marked to indicate the top of the unit and its
location and orientation in the structure and date of casting in order to facilitate in
distinguishing the dates of casting of various units.
9.06.00 Finishing
Top surface shall be rendered wherever required with cement sand mortar (1: 3) to
give smooth surface.
9.07.00 Steel Embedments / Inserts
Steel embedments / inserts shall be provided in various pre-cast members as

indicated on the drawings.
9.08.00 Handling
To ensure minimum damage during handling, the contractor shall provide suitable
cranes capable of lifting the heavy pieces on to the curing tanks, stacking shed and
on to the places of erection. The responsibility for any damage for whatsoever
reasons it may be, shall be that of the contractor and he shall replace the damaged
units.
9.09.00 Curing
Either natural curing with water or an accelerated curing using steam shall be
followed. Water curing shall be carried out for a period specified for cast-in-situ
concrete. This shall be done in a curing tank wherein the pre-cast members shall be
immersed.
9.10.00 Erection
9.10.01 The erection of precast units to the specified location shall be done as indicated on
the working drawings. The contractor shall provide erection scheme indicating the
deployment of crane, etc, to the Engineer before commencement of erection.
9.10.02 The pre-cast roof units / slabs shall generally rest on the steel / concrete structure.
Precast blocks for road edging / kerb / separator shall be laid on prepared sub-
grade.
9.10.03 The pre-cast units resting on to the structural steel shall be welded in position.
9.10.04 After the erection of the precast elements at site, the hooks provided for lifting
purpose shall be cut and finished smooth.

9.10.05 Setting in position
The precast element shall be set in position with 1:3 cement mortar. After erection,
the gaps between pre-cast units shall be filled with cement mortar 1:3 or with
concrete of mix M-30 i.e. one grade higher-than that of precast unit.
10.00.00 RECORDS OF CONSTRUCTION
All records of concreting, reinforcement, testing of materials, as-built dimensions,

tolerances, the details of the rectification etc, shall be maintained as given below.
Four copies of such record in a bound form shall be submitted to owner for their
record and future reference.
a) Testing data of aggregates
b) Mix design details.
c) Testing records of admixture including dosage, workability and setting time.
d) Approved scheme for concreting.
e) Quantity of ice used for temperature control of concrete for top decks of
machine foundations.
f) Hourly records of concreting including pour card.
g) Protocol indicating the dimensional tolerance and details of inserts.
h) Records giving the details of rectification giving the location of grouting, the
quantity of grout used at each location, type of grout used.
i) Bar bending schedule.
j) Location and details of mechanical anchoring used for reinforcement.
k) Protocol giving the details of checking of reinforcements before concreting

and conformance to the reinforcement details as shown in the construction
drawings.
l) Photographs showing the areas where rectification works have been carried
out. Photographs should be taken before and after rectification.
m) Report on petrographic examination & potential reactivity of aggregate and

the repeated temperature cycle tests.
11.00.00 SAMPLING, TESTING, ACCEPTANCE CRITERIA INCLUDING CONSTRUCTION

TOLERANCES
11.01.00 Frequency of sampling, testing and quality assurance including the method of
conducting the tests, acceptance criteria and construction tolerances shall be as
given in Part-C of this specification.


pipes.

PART – B
QUALITY ASSURANCE
PART- B
SUB-SECTION – III D-01
GRP PIPES
CLAUSE NO.
Quality Assurance
QA REQUIREMENTS FOR GRP PIPES, FITTINGS AND

SPECIALS
Following tests / inspections to be carried out on the finished pipes as

per relevant IS/ AWWA/ ASTM standard:
A. Pipes produced are subject to following checks on 100% basis;

1. Visual Inspection for workmanship, marking, visual defect etc.
2. BARCOL Hardness
3. Dimension
 Inside Diameter
 Outside Diameter
 Wall Thickness
 Squareness of Pipe ends
 Length of Pipes
4. Hydrostatic Leak Tightness to be carried out at 2 times of rated
pressure class.
B. Following control checks to be performed on representative

samples (minimum one sample / 100 pipes for each type, size,
grade etc) taken from finished product of each class and size on a
random basis;
1. Pipe Stiffness
2. Ring Deflection Test without damage/ structural failure for level A
and B.
3. Hoop Tensile strength
4. Axial/ longitudinal Tensile Strength
5. Beam Strength Test
C. Marking:
1. Manufacturer’s name or trade name
2. Nominal Pipe Diameter
3. Class of Pipe( pressure & Stiffness)
4. Batch Number or date of manufacture
D. UV Exposure test-to be carried out as per relevant standard.
E. Couplings – Hydrostatic leak tightness on coupling shall be done.
DARLIPALI STPP STAGE-I (2X800 MW) TECHNICAL SPECIFICATIONS

Sub-Section – IIID-01
SECTION VI-PART- B Page
QUALITY ASSURNACE & 1 of 1
INSPECTION
PART- B
DI PIPES
CLAUSE NO.
Quality Assurance
QA REQUIREMENTS FOR DI PIPES, FITTINGS AND SPECIALS
Following tests / inspections to be carried out on the finished pipes, Joints, Gaskets,
DI Fittings & specials as per relevant IS/ ISO standard:
1. Pipes produced are subject to following checks;
a. Visual Inspection for workmanship, marking, visual defect etc.
b. Mechanical Properties as per relevant governing Standard
c. Dimension
 Inside Diameter
 Outside Diameter
 Wall Thickness
 Ovality of Pipes
 Length of Pipes.
 Straightness
d. Hydrostatic Leak Tightness to be carried out as per relevant standard.
e. Zn coating & Bituminous painting on external layer DI pipes shall be carried
out as per relevant standard /Technical Specifications.
f. Identification- Manufacturer Logo, Nominal Diameter, Class, length indication
for cutting of pipe at site, ISI certification mark, pipe no.
2. Internal lining of suitable cement mortar shall be done as per relevant standard /
Technical Specifications..
3. Rubber gaskets shall confirm to the requirement of relevant standard / Technical
Specifications.
4. Joints for pipe, DI Fittings & specials shall be as per relevant standard /
Technical Specifications.
5. Type Tests: Please refer relevant sections of Engineering portion of technical
Specification.
DARLIPALI STPP STAGE-I (2X800 MW) TECHNICAL SPECIFICATIONS

MAKE-UP WATER PIPES PACKAGE Sub-Section – IIID-02
SECTION VI-PART-B Page
BID DOCUMENT NO: CS- 9549-132D-2 DI PIPES, FITTINGS &
QUALITY ASSURNACE & SPECIALS 1 of 1
INSPECTION
PART- B
VALVES
Quality Assurance
VALVES
All Tests as per relevant Std

Functional/operational Test
Tests/Check
Hydraulic / Water Fill Test
Assembly Fit up
WPS/ WQS/PQR
Pneumatic Test
Ultrasonic Test
DPT/MPI / RT
Material Test
Dimensions
Other Tests
REMARKS
Items /
Components
1 Cast Butterfly Valves Y Y Y Y Y1

(Low Pressure)
Body Ya Yb
Disc Ya Yb
Shaft Ya Y Yc
2 Fabricated Butterfly
REFER NOTE 2
Valves
NOTES (MEANING OF SUPERSCRIPTS)
a One per heat/heat treatment batch/lot.
b On machined surfaces only for castings and on butt welds.
c For shaft/spindles > or = 50 mm
1 Hydraulic Test of Body, Seat and disc-strength shall be carried out in accordance with
governing design standard in presence of owner’s representatives. Actuator operated valves
shall be checked for Seat Leakage by closing the valves with actuator. Seat Leakage Test
shall be carried out in both directions. For Proof of Design Test refer respective chapters of
engineering portion in the technical specification
2 In addition of all tests as indicated for Cast Butter Fly valve being applicable for fabricated
butterfly valves, following test shall be done for Fabricated Butter Fly Valve:
a. UT as per ASTM A-435 on plate material for body and disc shall be carried out for
plate thickness 20mm and above.
b. 100% RT and DPT as per ASTM, Section-VIII, Division-I, on butt joins of body and
disc. 10% DPT on other welds shall be done.
c. Post weld heat treatment as per ASME, Section-VIII, Division-I on butt joints of body
and disc.
d. Welders and WPS shall be qualified as per ASME- section IX
3 Seat Leakage Test for Actuator Operated Valves, shall be done with by closing the valves with
actuator.
4 Blue matching, wear travel for gates valves, pneumatic seat leakage, and reduced pressure
test for check valves shall be done as per relevant standard
5 Air release Valve and its Isolating valves shall be tested as per Relevant Design Standard”.
DARLIPALI STPP-I (2X800MW) TECHNICAL SPECIFICATIONS Sub-Section –

Page
MAKE-UP WATER PIPES PACKAGE SECTION VI-PART-B III D-03
1 of 1
BID DOCUMENT No.:CS- 9549-132D-2 QUALITY ASSURNACE & INSPECTION Valves
PART- B
LAYING OF MAKE-UP WATER PIPES

Quality Assurance
Followings are the Quality Assurance Requirements for LAYING of MUW pipes that
covers
A. DI Pipes
B. GRP Pipes
RECEIPT OF ITEMS AT SITE

Check for completeness of supply and visual check for damage of followings
after receipt at site:
i. DI Pipes, GRP Pipes fittings, flanges, couplings, bolts and nuts, fasteners,
plugs, sleeves etc.
STORAGE
Check for proper storage of following items as per manufacturer recommendations
/ storage manual
i. DI Pipes, GRP Pipes fittings, flanges, couplings, bolts and nuts, fasteners,
plugs, sleeves etc.
LAYING OF GRP PIPES, DI PIPES

Following checks shall be carried out during Laying of GRP and DI Pipes
i. Ensure proper alignment & fit up

ii. Ensure correct joining of pipes
iii. Ensure installation of supports (as applicable)
iv. Hydraulic Test of section and complete pipeline
DARLIPALI STPP-I (2X800MW) TECHNICAL SPECIFICATIONS Sub-Section –

MAKE-UP WATER PIPES PACKAGE SECTION VI-PART-B III D-04 Page
LAYING OF MAKE-UP 1 of 1
BID DOCUMENT No.:CS- 9549-132D-2 QUALITY ASSURNACE & INSPECTION
WATER PIPES
PART- B
QUALITY ASSURANCE FOR CIVIL

WORKS
CLAUSE NO.
Quality Assurance for Civil Works
1.0.0 INTRODUCTION
1.1.0 This part of the specification covers the sampling, testing and quality assurance
requirement (including construction tolerances and acceptance criteria) for all civil and
structural works covered in this specification.
1.2.0 This part of the technical specification shall be read in conjunction with other parts of the
technical specifications, general technical requirements & erection conditions of the
contract. Wherever IS code or standards have been referred they shall be the latest
revisions.
1.3.0 The rate for respective items of work or price shall include the cost for all works,
activities, equipment, instrument, personnel, material etc. whatsoever associated to
comply with sampling, testing and quality assurance requirement including construction
tolerances and acceptance criteria and as specified in subsequent clauses of this part of
the technical specifications. The QA and QC activities in all respects as specified in the
technical specifications/ drawings / data sheets / quality plans / contract documents shall
be carried out at no extra cost to the owner.
1.4.0 The contractor shall prepare detailed construction and erection methodology scheme
which shall be compatible to the requirements of the desired progress of work execution,
quality measures, prior approvals if any and the same shall be got approved by the
Engineer. If required, work methodology may be revised/ reviewed at every stage of
execution of work at site, to suit the site conditions by the contractor at no extra cost to
the owner.
2.0.0 QA AND QC MANPOWER
2.1.0 The contractor shall nominate one overall QA coordinator for the contract detailing the
name, designation, contact details and address at the time of post bid discussions. All
correspondence related to Quality Assurance shall be addressed by the contractor’s QA
coordinator to NTPC. NTPC shall address all correspondence related to Quality issues to
the contractor’s QA coordinator. The contractor’s QA coordinator shall be responsible for
co-ordination of Quality activities between various divisions of the contractor and their
sub-vendors on one hand & with NTPC on the other hand.
2.2.0 The contractor shall appoint a dedicated, experienced and competent QA&QC in-charge
at site, preferably directly reporting to the Project Manager, supported as necessary by
experienced personnel, to ensure the effective implementation of the approved QAP. An
indicative structure of contractor’s QA&QC manpower required to be deployed at site is
enclosed at Annexure-I. Based on the finalized L-2 network and the approved Field
Quality plan, the contractor shall finalize and submit a deployment schedule of QA&QC
personnel along with their details to NTPC for approval/ acceptance and further shall
ensure their availability well before the start of the concern activity.
2.3.0 The QA&QC in-charge shall have the organizational freedom and authority to implement
the requirements of these quality assurance arrangements, free from commercial and
programme restraints. The QA&QC setup of the contractor shall consist of qualified and
experienced Civil, Electrical, Mechanical Engineers and Laboratory assistants with their
supporting staff both at their works and site.
DARLIPALLI STPP STAGE-I (2X800 MW) TECHNICAL

Sub Section – IIID-05
MAKE-UP WATER PIPES PACKAGE SPECIFICATIONS Page 1 of 18
CIVIL WORKS
BID DOCUMENT NO: CS- 9549-132D-2 SECTION-VI, PART-B
CLAUSE NO.
2.4.0 The deployment of man power for QA & QC set up shall be affected on the basis of
agreed manpower deployment schedule, which shall be prepared by the contractor
based on the L-2 network and the same shall be submitted to the engineer-in-charge for
acceptance.
3.0.0 SAMPLING AND TESTING OF CONSTRUCTION MATERIALS
3.1.0 The method of sampling for testing of construction materials and work / job samples shall
be as per the relevant IS / standards / codes and in line with the requirements of the
technical specifications / quality plans. All samples shall be jointly drawn, signed and
sealed wherever required, by the contractor and the engineer or his authorized
representative.
3.2.0 The contractor shall carry out testing in accordance with the relevant IS / standards /
codes and in line with the requirements of the technical specifications / quality plans.
Where no specific testing procedure is mentioned, the tests shall be carried out as per
the best prevalent engineering practices and to the directions of the Engineer. All testing
shall be done in the presence of the engineer or his authorized representative.
3.3.0 Before execution of any civil work the contractor shall conduct full-scale suitability tests
on various construction and building material such as fine and coarse aggregates,
cement, reinforcement, construction chemicals, supplementary cementitious materials
and construction water to ascertain their suitability for use and the concrete mix designs
conducted from reputed institutes such as NCB-Ballabgarh, CSMRS-Delhi, selected
IIT’s, etc. as agreed by the engineer. A list of NTPC acceptable specialist laboratories is
enclosed at Annexure-II. The test samples for such full scale testing shall be jointly
sampled and sealed by the engineer and contractor, thereafter these shall be sent to the
concerned laboratory through the covering letter signed by field quality assurance (FQA)
representative of the engineer. Format for sampling and testing of cement, coarse
aggregate, fine aggregate, chemical admixture, fly ash, water, concrete mix design is
enclosed at Annexure-III.
3.4.0 The contractor shall timely initiate the action with regard to the evaluation of aggregates
and other building material including concrete mix design, so as to ensure completion of
these tests before start of civil works at site, thereby not affecting any project work. The
test reports and recommendations for suitability of the materials including concrete mix
design shall be promptly submitted by the contractor to the engineer.
3.5.0 Evaluation of aggregate shall be carried out as per following scope of work
a) To carry out different tests on coarse aggregate sample i.e. specific gravity, water
absorption, sieve analysis, deleterious material; soundness, crushing value, impact
value, abrasion value, elongation index and flakiness index, as per IS: 2386.
b) To carry out different tests on fine aggregate sample i.e. specific gravity, water
absorption, sieve analysis, deleterious material, soundness, silt content, clay
content and organic impurities as per IS: 2386.
c) To prepare evaluation report based on test results of a) and b) above and to advise
regarding suitability of fine and coarse aggregates.
4.0.0 LABORATORY AND FIELD TESTING
4.1.0 The field laboratory for QA and QC activities shall be constructed and set-up by the
contractor in line with the indicative field QA&QC laboratory set-up enclosed at

CIVIL WORKS
CLAUSE NO.
Annexure-IV. The Laboratory building shall be constructed and installed with the
adequate facilities to meet the requirement of envisaged test setup. Temperature and
humidity controls shall be available wherever necessary during testing of samples. The
quality plan shall identify the testing equipments/ instrument, which the contractor shall
deploy and equip the field quality laboratory for meeting the field quality plan
requirements. The contractor shall furnish a comprehensive list of testing equipments/
instrument required to meet the planned/scheduled tests for the execution of works for
NTPC acceptance/ approval. The contractor shall mobilize the requisite laboratory
equipment and QA&QC manpower at least 15 days prior to the planned test activity as
per the schedule of tests.
4.2.0 All equipments and instruments in the field shall be calibrated before the commencement
of tests and then at regular intervals, as per the manufacturer’s recommendation and as
directed by the NTPC. The calibration certificates shall specify the fitness of the
equipments and instruments within the limit of tolerance for use. Contractor shall arrange
for calibration of equipments and instruments by an NABL / NPL accredited agency and
the calibration report shall be submitted to NTPC.
4.3.0 The tests which cannot be carried out in the field laboratory shall be done at a laboratory
of repute. This includes selected IITs, NCB, CSMRS, reputed government / autonomous
laboratories / organizations, NITs and other reputed testing laboratories. The test
samples for such test shall be jointly selected and sealed by the engineer and thereafter
these shall be sent to the concerned laboratory through the covering letter signed by
NTPC engineer. The test report along with the recommendations shall be obtained from
the laboratories without delay and submitted to NTPC.
4.4.0 Based on the schedule of work agreed with the engineer-in-charge and the approved
FQP, the contractor shall prepare a schedule of tests and submit them to the engineer-
in-charge and organize to carry out the tests as scheduled / agreed.
5.0.0 PURCHASE AND SERVICE
Structural / Reinforcement steel supply if in the scope of the contractor shall be procured
from Main Steel Producers like SAIL, TISCO, RINL, Jindal Steel & Power and Jai Balaji
Industries Ltd, Durgapur (for 8-40mm reinforcement steel only).
6.0.0 MANUFACTURING QUALITY PLAN AND FIELD QUALITY PLAN
Well before the start of the work, the contractor shall prepare and submit the Field Quality
Plans (FQP) on the format No. QS-01-QAI-P-09/F2-R1, and obtain approval of NTPC,
which shall detail out for all the works, equipments, services, quality practices and
procedures etc in line with the requirement of the technical specifications to be followed
by the contractor at site. This FQP shall cover for all the items / activities covered in the
contract / schedule of items required, right from material procurement to completion of
the work at site. An Indicative Field Quality Plan for civil works is enclosed at Annexure –
V.
7.0.0 GENERAL QA REQUIREMENTS
The contractor shall ensure that the works, BOIs and services under the scope of
contract whether manufactured or performed within contractor’s works or at his sub-
contractor’s premises or at the NTPC’s site or at any other place of work are in
accordance with the NTPC technical specification, applicable standards / codes,

CIVIL WORKS
CLAUSE NO.
approved drawings / data sheets / quality plans and BOQ. All the works, BOIs and
services shall be carried out as per the best prevalent engineering practices and to the
directions of the Engineer.

CIVIL WORKS
CLAUSE NO.
ANNEXURE-I
QA&QC ORGANISATION SETUP
Project Manager
Manager (QA&QC)
Civil Engineer for Laboratory-In-

Concrete / Earth Charge
/Road works
Field Lab-Assistant and

Supervisors other skilled Staff
NOTE:
1. The above organization setup is minimum however their deployment shall be as

per the agreed deployment schedule. The contractor shall prepare a manpower
deployment schedule in line with the finalized work plan and the same shall be
submitted to the engineer-in charge for acceptance/ approval.
2. The contractor shall mobilize the QA& QC manpower in line with the finalized
manpower deployment schedule and shall ensure their availability well in
advance (15 days approx.) of the beginning of the concerned activity/ work.
3. The contractor shall further mobilize required number of skilled & supporting staff
and additional resources, if any to meet the work schedule.
4. * For concrete work 2 Nos ( one for foundation work & one for superstructure)
5. ** For lines and levels - 1 No.
6. *** For Finishes and cladding work - 1 No

CIVIL WORKS
ANNEXURE-II
LIST OF SPECIALIST INSTITUTES / ORGANIZATIONS FOR TESTING AND EVALUATION OF BUILDING MATERIALS
Sl No. Name of the Institute Contact Person Test Facilities Special Studies / Investigation
1 Indian Institute of Technology Head, Deptt of Civil Engg, Mix design and material properties on In situ non destructive testing (UPV) of
Bombay, Phone : 022 25722545 selective basis concrete structures, design of mass
Powai, Mumbai - 400076 concrete, temperature studies, distress
assessment
2 Indian Institute of Technology Head, Deptt of Civil Engg. Selective specialised studies such as design
Madras, Chennai- 600 036 Phone: 044 22574266/5255 of fly ash concrete and special concrete, non
destructive testing (UPV) of structures
3 Indian Institute of Technology Head, Deptt of Civil Engineering, Testing and evaluation of cement (physical In situ non destructive testing (UPV) of
Guwahati -781039 Phone : 0361 2582401, 258 2442, and chemical), aggregates (mechanical concrete structures (selective basis),
258 2440 properties), fly ash (physical and chemical), design of mass concrete, studies on
admixtures, water, steel reinforcement, properties of fly ash concrete
petrography, alkali aggregate reactivity, mix
design
4 Indian Institute of Technology Kanpur Head, Deptt of Civil Engineering, Testing and evaluation of cement (physical Non destructive testing (UPV) on concrete
(UP) - 208016 Phone: 0512 2597346 and chemical), aggregates (mechanical structures, structural health assessment
properties), fly ash (physical and chemical),
admixtures, water, mix design
5 Indian Institute of Technology Head, Deptt of Civil Engineering, Testing and evaluation of cement (physical
Kharagpur (WB) -721302 Phone: 03222 283421 and chemical), aggregates (mechanical
admixtures, water, mix design, petrography
6 Indian Institute of Technology Delhi, Head, Deptt of Civil Engineering, Testing and evaluation of cement (physical In situ non destructive testing (UPV) of
Hauz Khas, New Delhi - 1100 016 Phone:01126591191 and chemical), aggregates (mechanical concrete structures (selective basis)
7 Indian Institute of Technology, Head, Deptt of Civil Engineering, Testing and evaluation of cement(physical Various tests on other building materials
Roorkee - 247667 Phone: 01332 285439, 273560 and chemical), aggregates (mechanical), fly such as silica fume, mass concrete, steel,
ash (physical and chemical), admixtures, bricks, tiles, doors, ferrocement covers,
water, steel reinforcement, mix design, pipes, bridge bearings, PVC water tanks,
petrography, alkali aggregate reactivity etc
8 Indian Institute of Science Head, Deptt of Civil Engineering, Design of roller compacted concrete, IISc basically involved in r&d activities
Bangalore 560012 IISC Bangalore radiation shield concrete, high volume fly ash relatred to civil enginnering and may only
concrete, fire bahavior of concrete, micro be contacted in case of specific studies /
cracking of concrete, non destructive testing consultancy.
(research & development) activities, behavior
of concrete under shrinkage and creep,
assessment of fire damaged concrete
9 Institute of Technology, Banaras Head, Deptt of Civil Engineering, Testing and evaluation of cement physical
Hindu University (BHU) Varanasi Phone: 0542-2307016 properties), aggregates (mechanical
(UP) -221005 properties), admixtures, water, mix design,
petrography

DARLIPALLI STPP STAGE-I (2X800 MW) CIVIL WORKS
MAKE-UP WATER PIPES PACKAGE TECHNICAL SPECIFICATIONS Page 6 OF 18
BID DOCUMENT NO: CS- 9549-132D-2 SECTION-VI, PART-B 0000-999-QOG-R-002 REV 01 DATE 31.10.2013
ANNEXURE-II
10 Central Building Research Institute Head, Structural engineering division, Testing and evaluation of cement (physical Fire rating of doors, non destructive testing
(CBRI), Roorkee - 247667 Phone: 01332 283382 and chemical), aggregates (mechanical), fly of structures, various tests on other
ash (physical and chemical), admixtures, building materials such as bricks, steel,
water, mix design, alkali aggregate reactivity tiles,etc
11 Central Soil and Materials Research Joint Director Testing and evaluation of cement (physical Various tests on other building materials
Station (CSMRS), Near IIT Phone: 011 26962608 and chemical), aggregates (mechanical such as steel, geotextiles, geomembrane,
Delhi, Olof Palme Marg, New Delhi - properties), fly ash (physical and chemical), soil, instrumentation, monitoring, etc
110016 admixtures, water, petrography, alkali
aggregate reactivity, mix design
12 National Council for Cement and Head, Center for Construction Testing and evaluation of cement (physical In situ non destructive testing (UPV) of
Building Materials (NCB), 34 KM Development & Research and chemical), aggregates (mechanical concrete structures and special studies,
Stone, Delhi Mathura Road Phone : 0129 2246173 properties), fly ash (physical and chemical), testing of bricks, paving blocks, steel bars,
Ballabgarh(Har) admixtures, water, petrography, alkali silica fume, etc
aggregate reactivity, temperature cycle test,
XRD, steel reinforcement, mix design
13 National Council for Cement and General Manager, Testing and evaluation of cement (physical In situ Non destructive testing (UPV) of
Building Materials (NCB), NCB Phone 040 23000344, 040- and chemical), aggregates (mechanical concrete structures (selective basis)
Bhawan, Old Bombay Road 23000343 properties) , fly ash (physical and chemical),
Hyderabad 500008 admixtures, water, petrography, alkali
aggregate reactivity, steel reinforcement, mix
design
14 National Test House, Taramani S.O.(Civil) Testing and evaluation of cement (physical Various tests on other building materials
Chennai 600 113 Phone:04422432374, and chemical) , aggregates (mechanical such as paving blocks, Gi pipes, wires,
Fax:04422433158 properties) , fly ash (physical and chemical), steel plate, flush doors, salt spray test, etc
admixtures, steel reinforcement, water, mix
design
15 National Test House, Block CP S.O. (Civil), Testing and evaluation of cement(physical Various tests on other building materials
Sector V, Salt Lake city Phone:033 2367 3870 and chemical), aggregates (mechanical such as paving blocks, GI pipes, wires,
Kolkata-700 091 properties) , fly ash (physical and chemical) , steel plate, flush doors, etc
admixtures, water, steel reinforcement, mix
design
16 National Test House (NTH), S.O. (Civil), NTH Ghaziabad Testing and evaluation of cement (physical Timber, clay products, water proofing
Kamla Nehru Nagar, Ghaziabad and chemical), aggregates (mechanical compound, flush doors, laminated sheets,
(UP) properties), fly ash (physical and chemical), plywood, etc
admixtures, water, stel reinforcement
17 Structural Engineering Research Head, Department of Material Testing and evaluation of cement (physical In situ Non destructive testing (UPV) of
Centre (SERC), Testing, and chemical) , aggregates (mechanical concrete structures (selective basis) and
Taramani, Chennai 600 113 Phone: 044 22549152, 22541735 properties), fly ash (physical and chemical), special studies such as cement admixture
admixtures, steel reinforcement water, mix compatibility, design of special concrete,
design evaluation of structures

ANNEXURE-II
18 Vishveswaraiya National Institute of Director, VNIT Nagpur, Testing and evaluation of cement (physical In situ non destructive testing (UPV) of
Technology(VNIT), Phone:0712 2223710, 2222828 and chemical), aggregates (mechanical concrete structures and soil tests
Nagpur (MH) - 440010 properties), fly ash (physical and chemical),
admixtures, water, mix design, petrography
19 Anna University, Department of Head, Deptt of Civil Engineering Testing and evaluation of cement (physical
Structural Engineering, and chemical) , aggregates (mechanical
Chennai - 600 025 properties) , fly ash (physical and chemical) ,
20 Shriram Institute for Industrial Dr (Mrs) Laxmi Rawat, Testing and evaluation of cement (physical Various tests on other building materials
Research, 19 University Road, Delhi Asstt Director & Chief and chemical), aggregates (mechanical such as steel, geotextiles, geomembrane,
110007 Phone:011 27667267 properties), fly ash (physical and chemical), soil, bricks, tiles, etc
21 Spectro Analytical Lab, E-41, Okhla Phone: 011 26383048-49 Testing of cement (physical and chemical), Chemical and physical tests on steel
Indl Area, Ph II, New Delhi 110021 Fax: 40503150, 40503151 aggregates (mechanical properties), fly ash reinforcement
(physical and chemical), admixtures, water
22 Motilal Nehru National Institute of Director, MNIT Allahabad, Testing and evaluation of cement (physical In situ non destructive testing (UPV) of
Technology (MNIT), Allahabad - Phone: 0532 2271305, Fax: 0532 and chemical) , aggregates (mechanical concrete structures.
211004 2545341 properties), fly ash (physical and chemical),
admixtures, steel reinforcement water, mix
design
23 Govt Enginering College, Jalpaiguri Head Deptt of Civil Engg, Testing and evaluation of cement (physical ),
(WB) - 735102 Fax: 03561256143 aggregates (mechanical properties), water,
mix design
24 College of Engineering Head Deptt of Civil Engg, Testing and evaluation of cement (Physical &
Pune - 411005 Phone No : 02025507067, Chemical properties), fly ash (Physical &
Fax : 02025507299 Chemical properties), aggregates
(Mechanical properties except alkali
aggregate reactivity & Petrography), water,
admixtures and mix design
25 Maulana Azad National Institute of Head Deptt of Civil Engg, Testing and evaluation of cement (physical ), In situ non destructive testing (UPV) of
Technology, Bhopal (MP) Phone No : 07554051390 aggregates (mechanical properties),water, concrete structures and soil tests.
mix design

CLAUSE NO.
ANNEXURE - III
Format of Request Letter for Evaluation of Materials
Ref:_____________ Date:_____________
To,
Sub.: Evaluation of materials and concrete mix design
Dear Sir,
We have awarded the work of …………………… on M/s ……………….. vide our LOA No.
……………………….dated…………………for execution of Civil Works. Based on provisions of
contract, M/s ………………….. are expected to get the following tests/ evaluation done through
your laboratory and accordingly the tests have been described below.
M/s ………………… have been advised to deposit the requisite evaluation/ testing charges and to
deliver the test samples of quantities, specified below.
1. Evaluation of Cement:
a) To carry out different physical tests on cement samples i.e. Blaine’s fineness, initial and final
setting time, soundness and compressive strength at 3, 7 and 28 days as per IS: 4031 and
drying shrinkage and specific gravity in case of PPC.
b) To carry out chemical analysis of the cement samples as per IS: 4032, including the total alkali
content of the cement (Na2Oequivalent).
c) To advise the suitability of cement based on the test results of a) and b) above.
2. Evaluation of Aggregates:
a) To carry out different tests on coarse aggregate sample i.e. specific gravity, water absorption,
sieve analysis, deleterious material; soundness, crushing value, impact value, abrasion value,
elongation index and flakiness index, as per IS: 2386.
b) To carry out different tests on fine aggregate sample i.e. specific gravity, water absorption,
sieve analysis soundness, deleterious material, silt content, clay content and organic
impurities as per IS: 2386 and mica content.
c) To prepare evaluation report based on test results of a) and b) above and to advise regarding
suitability of fine and coarse aggregates to be used with the cement of 1) above.
3. Evaluation of Flyash Sample:

a) To carry out various physical and chemical tests on fly ash sample i.e. Blaine’s fineness, lime
reactivity, specific gravity, loss on ignition and other chemical tests as per IS: 3812,
conforming to grade-I.
b) To advise the suitability of fly ash sample based on the test results of a) above.
4. Evaluation of water: To carry out various physical and chemical tests as per IS:456 and
IS:3025.
5. Evaluation of admixtures: To carry out various physical and chemical tests as per IS:9103.
Note: Test certificate shall be obtained from the supplier to compare the values given in Table 2 of
IS:9103 i.e. uniformity requirements.
6. Concrete Mix Design: Based on the provisions of technical specification, the Following
may be specified by site CCD/FQA **
a) For RCC Work
i) Grade of concrete
ii) Slump required, mm:
CIVIL WORKS
CLAUSE NO.
iii) Cement- Type and grade

iv) Max Size of Aggregates, mm
v) Exposure conditions
vi) Maximum water-cement ratio
vii) Minimum cement content
viii) Plasticizer/ admixture to be used or not (If yes, specify the brand/ type/batch no. of
plasticizer)
ix) Fly ash to be used or not (If yes, indicate % of fly ash to be used)
b) For PCC work: Same as i) to ix) of a) above

c) For piling work(if required): Same as i) to ix) of a) above
7. Details of material sampled: In order to facilitate the above mentioned tests, specified
quantities of samples have been collected and sealed jointly (by NTPC-FQA and contractors’
representative) is being sent for testing. The impression of seal has also been punched below.
a) Quantity of material required for each mix-design:

Sl. Material Description Quantity Required
No.
i) Cement 2bags (sealed in double polythene bags)
ii) Coarse Aggregates 100Kg of each fraction as explained below :

e.g.; If Maximum size of aggregates (MSA) is
20mm, then 100 Kg each of 20-10mm and
10mm down are required. If MSA is 40mm then
100Kg each of 40-20mm, 20-10mm and 10mm
down are required.
iii) Fine Aggregates 200Kg
iv) Chemical Admixtures 2 Litres
v) Water 100 Litres
vi) Fly ash (If decided to be 100Kg

used)
b) Impression/ Punch Mark of seal:
You are requested to kindly forward us the test reports along with the recommendations
regarding the suitability of materials to us at the earliest.
Thanking you, Yours faithfully,
Name:
Contact Number:
Email ID:
(FQA Representative of NTPC)
Note:
1. Based on provisions of technical specification, the testing charges for all the above
mentioned tests shall be borne by the contractor.
2. The content of the letter is for guidance only, and if required may be suitably modified to
suit the specific requirements of the package in consultation with QA-Civil.
** This line may be deleted in the letter sent to the institute.

CIVIL WORKS
CLAUSE NO.
ANNEXURE - IV
TYPICAL QA/QC LAB EQUIPMENT
Project: Package:
S.No Equipment Nos.
1 Vicat Apparatus with deskpot 2
2 Le Chatelier flask 2
3 Le Chatelier Mould 2
4 Cube Moulds for cement testing 12
5 Vibration Machine 1
6 Length comparator 2
7 Shrinkage Bar mould 2
8 Sieve shaker 1
9 Sieves for sand, coarse & fine aggregate 1 set for each
10 Sieves for coarse aggregate for Road 1 set
11 Proctor testing equipment 2 sets + 18 cores
12 Slump testing equipment 6 sets
13 Oven 2
14 Physical balance 1
15 Rapid moisture meter 2
16 Thermometer 4
17 Burret 2
18 Measuring cylinders 9
19 Measuring flasks 3
20 Compression testing machine 2 sets of 2000 kN capacity
each
21 Cube moulds 30
22 Electronic balance 2 (12 kg capacity), 2(
200 mg capacity)
23 pH balance As per requirement
25 Mechanical weighing machine 1 (100 kg capacity)
Note :
1. The equipments listed above are indicative and required to be mobilised
as minimum requirement. additional equipment if any ,required for
successful completion of work shall be provided /arranged by the
contractor.
2. All test reports/ inspection reports have to be computerized and
maintained on LAN with an access to the owner
3. Computers - 2 Nos shall be deployed with Windows operating system
and connected to the NTPC server
4. Based on the schedule (L2/L3 Network), Quality control & Quality
Assurance work plan shall be finalized by the contractor and the same
shall be submitted to the engineer-in-charge for acceptance/approval.
The Finalized work plan shall be maintained on the computer to be
accessed by the owner for database and day to day monitoring.

CIVIL WORKS
SUPPLIERS NAME AND INDICATIVE FIELD QUALITY PLAN
ADDRESS: ANNEXURE- V
PROJECT:
ITEM : CIVIL WORK
LOGO QP NO. : 1
REV. NO .: 0 PACKAGE:
SUB-SYSTEM : DATE : CONTRACT NO.
PAGE : MAIN CONTRACTOR
Sl. No Activity and operation Characteristics / instruments Class of Type of Check Quantum Of check Reference Document Acceptance Format of Remarks
check Norms Record
1 2 3 4 5 6 7 8 9 D* 10
1 GENERAL REQUIREMENTS
A Setting up of Field QA&QC A Physical Once prior to start of work SR  Functioning of laboratory equipment in
laboratory As agreed / required Tech Specs and Const. Drawings proper working condition to be verified on
monthly basis
B Avialablility of requisite A Physical Once prior to start of SR 
laboratory set up and work and thereof
equipment in good working monthly
As agreed / required Tech Specs and Const. Drawings
condition well before
commencement of concerned
activity
C Submission of QA & QC - A Physical Once prior to start of 
manpower deployment work
Tech Specs and Const. Drawings
schedule based on agreed L-2
network .
D Availability of QA& QC - A Physical Once prior to start of SR 
manpower based on work and thereof Tech Specs and Const. Drawings
deployment schedule . monthly
E Sampling for testing of buliding A Physical As specified in FQP for SR/TR  Test report along with the
materials, concrete mix design As agreed / required various materials Tech Specs and Const. Drawings recommendations from specialist agency
etc. to be submitted to NTPC.
F Stacking and storage of As per IS:4082 B Physical Random SR 
Tech Specs and Const. Drawings and IS:
construction materials and
4082
components at site
G All bought out items to be B Verification of TC 100% SR/LB  The TC submitted should bear proper
procured from the approved and/or Testing identification or correlation with the batch
vendor and on approval of - NTPC Tech. Spec. /BOQ of material supplied and same shall be
Quality plans by NTPC as per brought out in the challan/ consignment
inspection Category note .
H Submission of list of Bought out A Physical One time SR/LB
items and their vendors for
each of the bought out item To be submitted to CQA for approval with
- NTPC Tech. Spec. /BOQ
identified for approval within the a copy to site .
period agreed in LoA.
2 EXCAVATION AND FILLING

Excavations-
2.1 Nature, type of soil/rock before and B Visual Random in eah shift SR
during excavations
2.2 Initial ground level before start of B Measurement 100% SR 
excavations
2.3 Final shape and Dimensions of B Measurement 100% SR 
excavations. As agreed / required Tech Specs and Const. Drawings
2.4 Final excavation lelvels B Measuement 100% SR 

2.5 Side slope of final excavation As agreed / required B Measurement Random in eah shift Tech Specs and Const. Drawings SR 
2.6 Excavation in Hard Rock- If required
12 of 18
PROJECT:
ITEM : CIVIL WORK
LOGO QP NO. : 1
check Norms Record
1 2 3 4 5 6 7 8 9 D* 10
i Receipt, Storage, accountability of B Physical Random in each week Indian Explosive Act 1940/all statutory SR  NTPC approved specialist blasting agency
Explosive As agreed / required such as CMRI, NIRM shall be deployed at
norms, Tech Specs and Const. Drawings
As agreed / required IS:4081, Tech Specs and Const. site for trial blasts, design blasts, blast
ii
iii Execution ofofBlasting
Submission BlastingOperation
report to EIC B
C Physical Random eah shift
Eachinblast SR  vibration monitoring etc. Seismographs
shall be deployed at site for monitoring of
blast operation vibrations.
2.7 Excavation in Hard Rock (Blasting B Physical 100% As per approved drawing/ scheme, Tech SR 
Prohibited) As agreed / required
Specs and Const. Drawings
Fill/ Backfill -
2.8 Suitability of fill material
i Grain size analysis, liquid limit, plastic Set of Seives, B Physical Once per each type of SR/TR 
IS:2720 (Pt.IV), IS:13916, IS: 5822 & IS:
limit Hydrometer etc. source or change of
12288 , Tech Specs and Const. Drawings
source
2.9 Standard proctor Test Optimum moisture content and max. dry As per IS: 2720, B Physical One in every 2000 cum SR/TR 
IS 2720 (Pt.VII), Tech Specs and Const.
density before fill Proctor needle for each type and source
Drawings
apparatus,etc. of fill materials
2.10 Moisture content Moisture content of fill before compaction As per IS: 2720, B Physical One in every 2000 cum SR/TR 
IS 2720 (Pt.II), Tech Specs and Const.
balance, oven etc. for each type and source
Drawings
of fill materials
2.11 Degree Of Compaction Of Fill / Backfill
i Dry density by core cutter method As per IS: A Physical SR/TR 
2720/compaction test IS 2720 (Pt. XXIX), Tech Specs and
---- OR---- (core cutter), balance Const. Drawings
etc.
Dry density in place by sand Once in 1000 sqm SR/TR
IS 2720 (Pt. XXVIII), Tech Specs and 
displacement method Const. Drawings
ii Relative density (Density Index) As per IS: 2720, A Physical IS 2720 (Pt. XIV), Tech Specs and Const. SR/TR 
balance oven etc. Drawings
iii Dry Density by proctor needle As per IS-2720, proctor B Physical Random SR/TR 
penetration nedle apparatus etc. Tech Specs and Const. Drawings
2.12 Bed Preparation for Trench

i Grain size analysis, liquid limit, plastic Set of Seives, B Physical
limit Hydrometer etc. IS:2720 (Pt.IV), IS:13916, IS: 5822 & IS:
12288 , Tech Specs and Const. Drawings
ii Dry density by core cutter method As per IS: B Physical SR/TR 

2720/compaction test IS 2720 (Pt. XXIX), Tech Specs and
---- OR---- (core cutter), balance Const. Drawings
etc. Once in 1000 sqm
Dry density in place by sand IS 2720 (Pt. XXVIII), Tech Specs and SR/TR 
displacement method Const. Drawings
iii Relative density (Density Index) As per IS: 2720, A Physical IS 2720 (Pt. XIV), Tech Specs and Const. SR/TR 
balance oven etc. Drawings
iv Slope & alignment Water level & as C Physical SR/TR
required
3.0 MATERIALS
Expert openion regarding suitability of construction materials shall be taken from Specialist Institute (Identified during pre award)
13 of 18
PROJECT:
ITEM : CIVIL WORK
LOGO QP NO. : 1
check Norms Record
1 2 3 4 5 6 7 8 9 D* 10
3.1 CEMENT
Retesting of cement as per IS:4031 A Testing At Random As per relevant IS Codes Test  Each consignment of cement shall be duly
Report correlated with manufactureres TC,in case
the cement is supplied by the contractor
one sample from each lot shall be tested
for stetting time and compressive strength
. Acceptance norms shall be as per
relevant IS. If cement is
stored more than 60 days in godown of
contractor same shall be retested for
comp. Strength & setting time.
3.2 Coarse Aggregate Moisture content as per IS:2386 B Physical Once for each stack of IS : 456 SR/LB  during monsoon when this has to be done
100 Cu.M. or part there IS : 383/Tech Spec every day before start of concreting
of
ii Specific gravity, water absorption IS:2386 A Physical Once for each source & IS: 2386 Part-III, IS:456, SR/LB/ 
for every change of IS:383/Tech Spec Test
source Report
iii Sieve analysis, flakiness index, IS:2386 B Physical One per 100 cum., or IS: 2386 Part-I, IS:383/Tech SR/LB 
elongation index, part thereof Spec
iv Deleterious materials (coal & lignite, clay IS:2386 A Physical Once per source/ on IS: 2386 Part-II, IS:383/Tech SR/LB/ 
lumps, material finer than 75 micron every change of source Spec Test
sieve, soft fragment, shale) Report
v Soundness IS:2386 A Physical -do- IS: 2386 Part-V, IS:383 SR/LB/ 
Test
Report
vi Crushing value abrasion value and IS:2386 A Physical -do- IS:383, IS-2386 Part IV/Tech Spec SR/LB/ 
impact value Test
Report
3.3 Fine Aggregate
i Moisture content, water absorption balance , oven etc B Physical To be done every day IS: 2386 Part-III IS:383 SR/LB/TR 
before start of work
ii Deleterious materials (coal & lignite, clay IS:2386 B Physical Once per source& for on IS: 2386 Part-II, IS:383 SR/LB/TR 
lumps, material finer than 75 micron every change of source
sieve, soft fragment, shale)
iii All other tests similar to coarse IS-2386, IS-383 SR/LB/TR  except test for flankiness index,elongation
aggregates as mentioned above. index, abrasion value, impact value
3.4 Water
i Complete tests as per IS:456 Buret, conical flask, B Testing One per 3 month for IS:3025 part 22 and 23 (for test procedure SR/LB/TR 
pipette etc each source. ), IS:456(for acceptance criteria )
3.5 CONCRETE
i Crushing strength (works Tests cubes) IS:516 A Physical One set of 6 cubes per IS:516, IS:456, NTPC Tech. Spec. SR/LB/  Min. of 6 cubes for each mix, 3 specimen
50 CuM or part thereof Test shall be tested at 7 days remaining 3 shall
for each grade of Report be for 28 days comp. Strength.
concrete per shift
whichever is earlier.
ii Workability - slump test IS:1199 B Physical At the time of concrete IS:456/NTPC Tech. Spec. SR/LB/TR 
pouring at site every two
hrs
14 of 18
PROJECT:
ITEM : CIVIL WORK
LOGO QP NO. : 1
check Norms Record
1 2 3 4 5 6 7 8 9 D* 10
3.5.1 Admixtures for Concrete Type of admixture As per IS:9103 A For each lot received at Designed mix and IS:9103 Test  Admixture of appd. Brand and tested
EIC Approved source and site Report quality shall be used (each lot of
admixture will included with brochure in
review of MTC/ test reports
which the type of admixture and its
properties shall be clearly indicated)
Suitability As per IS:9103 B Physical For each lot received at Designed mix and IS:9103 SR/LB/T  Relative density, pH and slump retention
site R on each batch / lot of admixture and to
compare these properties with MTC
3.6 Concrete conveying,

placing& compaction
i mixing of concrete shall be done in a To be calibrated at the Review of calibration chart/ Certificate, IS 
approved mixer such as to produce a time of starting and 4926
homogenous mix subsequently once in
three months, and shall
conform to IS:4925
ii Arrangement for transportation & As required C Visual 100% Before clearance for concreting Inspectio 
placement of concrete. n Report
iii Calibration of Batching Plant batcher should comply A Physical To be calibrated at the Review of calibration chart/ Certificate Calibrati  Provision of online printer is manadatory
with reqirement of IS time of starting and on
4926/IS:4925 subsequently once in Certificat
three months, and shall e
conform to IS:4925
iv Handling and Transportation of concrete As required B Physical 100% As per construction/erection methodology SR
(to be approved one week prior to start of
work)
v Placement of concrete Visual B Physical 100% As per construction/erection methodology SR 

and tech.specs / No segregation
vi Compacting As required B Physical At Random IS:456 SR 
vii Curing As required B Physical At Random Period of curing as per IS 456 (use gunny SR 
bags / curing compound)
3.7 TEST/CHECK ON RCC STRUCTURE IN HARDENDED CONDITIONS
i Dimensional check on finished structures As required B Measurement Approved Drawing As per IS:456/ tech. Specification. SR/LB 
& Dimensional tolerances
ii Water Tightness Test of liquid retaining As required A Test 100% IS:3370/ Tech. Specification SR/LB 
structure/ tanks
3.8 REINFORCEMENT STEEL
i Physical and Chemical Properties for As required/ agreed A Each batch of delivery MTC Applicable if steel is procured by
each lot as per relevant IS codes EIC Approved source and IS : 1786, IS:432, IS:1566, Tech Specs Contractor

review of MTC/ test reports and Const. Drawings
15 of 18
PROJECT:
ITEM : CIVIL WORK
LOGO QP NO. : 1
check Norms Record
1 2 3 4 5 6 7 8 9 D* 10
ii Freedom from cracks surface flaws, B Visual Random in each shift SR To be checked at site. Steel collected
Lamination. IS: 1852, IS:432, IS:1786, Tech Specs from source should be free from
As agreed / required
and Const. Drawings excessive rust. To be stored as per
Technical Specs.
3.9 PLACEMENT OF REINFORCEMENT STEEL
i Bar bending schedule with necessary B Visual & Random in each shift Approved Drawings, Tech Specs and SR
lap, Spacers & Chairs As agreed / required Measurement 
Const. Drawings, IS:2502
ii Bending of bars, cutting tolerance B Visual & Random in each shift Approved Drawings, Tech Specs and SR
As agreed / required Measurement 
Const. Drawings, IS:2502
iii Acceptance - Cover, spacing of bars, B Visual & Random in each shift SR
spacers and chairs after the Measurement Approved Drawings, Tech Specs and
reinforcement cage is put inside the As agreed / required 
Const. Drawings
formwork
3.10 STAGING AND FORMS
i Materials and accessories B Visual Once before start of As per relevant IS, Tech Specs and SR
As agreed / required work Const. Drawings
ii Soundness of staging, shuttering and B Visual Once before start of As per manufacturer's spec.and as per SR
scaffolding including application of mould As agreed / required work 3696,4014, 4990, Tech Specs and Const.
oil / release agent Drawings
iii Acceptance of formwork before start of B Physical / visual Before start of each As per provisions and tolerances, Tech SR
concreting concreting 
Specs and Const. Drawings
3.13 PRE-CAST CONCRETE
i Crushing strength compression strength A Physical one sample of six cubes IS:516 & IS: 456 SR/LB A minimum of three specimen shall be
testing machine per 50m m3 or part  tested for 7 and 28 days compressive
thereof strength
ii Workmanship and dimentions Visual B Physical 100% As per IS:456/NTPC Tech. specification. Register
iii Load Test As required B Physical 1% up to 1000 nos. and IS:456/ As decided by NTPC Site Engr. Inspectio
0.5% for more than 1000 Incharge. n Report 
nos. for each type
3.14 JOINTS IN CONCRETE
i Joint material - bitumen impregnated As per manufacturer A Each batch of delivery Tech Specs and Const. Drawings, IS MTC
fibre board, PVC water stops, Sealing Standards EIC Approved source and 1838, IS 1834, IS12200
compound, Expanded polystyrene board, 
Hydrophillic strip, Acrylic polymer etc.
ii Acceptance of installation B Acceptance Each installation

randomly
3.15 DAMP PROOF COURSE Tech Specs and Const. Drawings
Material - Hot bitumen and water EIC Approved source and

i As agreed / required A Each batch of delivery at site Tech Specs and Const. Drawings, IS 702 SR 
proofing materials etc review of MTC/ test reports
ii Acceptance of damp proof course As agreed / required B Acceptance 100% Tech Specs and Const. Drawings SR
3.16 GROUTING
16 of 18
PROJECT:
ITEM : CIVIL WORK
LOGO QP NO. : 1
check Norms Record
1 2 3 4 5 6 7 8 9 D* 10
i Material A Each batch of delivery
EIC Approved source and
As agreed / required Tech Specs and Const. Drawings SR 
Type of mix - fluid mix, plastic mix, stiff B Physical Prior to start of work
mix etc. As agreed / required Tech Specs and Const. Drawings SR 
ii Mixing, placement, application and grout B Physical Random in each shift

pressure As agreed / required Tech Specs and Const. Drawings SR
iii Compressive strength A Physical Random in each shift

As agreed / required Tech Specs and Const. Drawings SR 
iv Acceptance of the grouts As agreed / required B Physical Each grout section Tech Specs and Const. Drawings SR
4.00 BRICK MASONARY

4.1 Test on Bricks
Dimensions , shape, compressive A Measurement/ As per relevant IS Code/ Inspectio Efflorescence shall be checked at each
strength, water absorption, warpage, Physical Test One Sample for 30,000 IS: 1077, IS:13757, IS: 12894 / Tech n Report source.
As agreed / required 
efflorescence. nos. or part thereof Specs and const. Drawings
4.2 Test on Mortar

i Compressive strength B Test At random IS 2250-1981, Tech Specs and Const. LB
Drawings
ii Sand Grading As agreed / required B Test IS:2116 SR/LB
4.3 Masonry construction Workmanship, verticality and alignment B Visual/ Physical 100% IS 2212, IS 1905 , Tech Specs and Const. SR/LB
Drawings
5.00 FINISHING AND ALLIED WORKS .
5.1 PLASTERING- MATERIAL
i Sand Deleterious Material B Physical Once per source IS : 2386 (Part-I &II) & IS :2116, Tech SR
As agreed / required Specs and Const. Drawings
ii Grading B Physical 50 Cum./or part thereof SR

iii Galvanised wire mesh Galvanized hexagonal wire netting for B EIC Approved source and Each batch of delivery SR
lath plastering As agreed / required Tech Specs and Const. Drawings
5.2 PLASTERING - WORKMANSHIP

i Tech specifications, construction
Curing As agreed / required C Physical 100% SR
drawings and agreed methodology
ii Thickness and finishing of plaster, B Visual/ Random in each shift SR/LB
grooves etc Measurement
iii Truness of plastering system As agreed / required B Visual/ Physical Random in each shift Tech Specs and Const. Drawings SR
6.0 RCC Pipes
EIC Approved source and Each lot of delivery as per
i Material RCC pipes As agreed / required A Tech Specs and Const. Drawings /IS 458 SR 
review of MTC/ test reports Specifications
ii Acceptance and leakage As agreed / required B Physical Random Tech Specs and Const. Drawings SR
7.0 FOUNDATION SYSTEM
SHALLOW FOUNDATIONS
17 of 18
PROJECT:
ITEM : CIVIL WORK
LOGO QP NO. : 1
check Norms Record
1 2 3 4 5 6 7 8 9 D* 10
Foundation excavation - Location, As per technical specifications and
i As required / agreed B Physical Each location SR lines and levels to be checked
Layout, size, depth etc construction drawings
Foundation casting - Layout, Shape,
As per technical specifications and lines and levels to be checked. Concrete
ii dimensitions, Reinforcement, concreting, As required / agreed B Physical Each foundation SR
construction drawings Grade to be checked as per Mix Design
curing etc
Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR, TR, MTC, LB

Manufact Main-supplier Categorization Witnessing & Accepting (As per NTPC QA&I System) For NTPC USE
urer/ Sub- Category ‘A’ FQA Engineer in association with Executing Engineer, Category ‘B’ Executing Engineer, Category
supplier ‘C’ Executing Engineer ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate
Signature This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings REVIEWED BY APPROVED BY APPROVAL SEAL
18 of 18
PART- B
INDICATIVE VENDOR LIST

PROJECT :DARLIPALI STPP (2X800MW) INDICATIVE LIST OF ITEMS REQUIRING DOC. No. : CS- 9549-132D-2
PACKAGE: MAKE UP WATER PIPES QUALITY PLAN AND SUB- SUPPLIER Revision No. : 00
PACKAGE APPROVAL DATE:
SUPPLIER : PAGE 1 OF 3
CONT. NO.:CS-9549-132D-2 SUB SYSTEM: MECHANICAL &
ELECTRICAL
SL.NO. ITEM QP/INS QP NO. ACCEPTABLE SUPPLIER AS PER PLACE SUB-SUPPLIER REMARKS
THE PRESENT DATABASE
PN 9549- APPROVAL
CAT 132D-- STATUS/
QVM-Q CATEGORY
1 AIR RELEASE VALVE II H Sarker Kolkata A

Bankin & Company Kolkata A
R & D Multiple Valsad A
KBL Kondhapuri A
2 CI BUTTERFLY VALVE I Weir -BDK Hubli, A
Fouress Bangalore A
( UP TO 1000NB –PN 10)
Tyco Halol A
Intervalve Pune A Up to 1400 N NB, PN-10
Crane Process Satara A UP TO 600 NB, PN -16
Dembla Valve Thane A UP TO 800 NB, PN- 10
R & D Multiples Valsad A
KBL Kondhapuri A
Hawa Enginrres Ahmedabad A
IL Palghat A
LEGENDS:
1. SYSTEM SUPPLIER / SUB-SUPPLIERSTATUS CATEGORY (SHALL BE FILLED BY NTPC).
A – Indicated acceptable sub-suppliers to NTPC along with condition of approval, if any.
2. INSPECTION CATEGORY:
Cat I : For these items the quality plans are approved by NTPC and final acceptance will be after physical inspection witness by NTPC.
CAT II : For these items the quality plans are approved by NTPC. However no physical inspection will be done by NTPC. The final acceptance by NTPC shall be on the basis of review of
documents as per QP.
CAT III: For these items Main Supplier approves quality plans. The final acceptance by NTPC shall be on the basis of certificate of conformance by Main Supplier.
2. GRP / DI PIPES are sub QR Items.
PROJECT :DARLIPALI STPP (2X800MW) INDICATIVE LIST OF ITEMS REQUIRING DOC. No. : CS- 9549-132D-2
PACKAGE: MAKE UP WATER PIPES QUALITY PLAN AND SUB- SUPPLIER Revision No. : 00
PACKAGE APPROVAL DATE:
SUPPLIER : PAGE 2 OF 3
CONT. NO.:CS-9549-132D-2 SUB SYSTEM: MECHANICAL &
ELECTRICAL
SL.NO. ITEM QP/INS QP NO. ACCEPTABLE SUPPLIER AS PER PLACE SUB-SUPPLIER REMARKS
THE PRESENT DATABASE
PN 9549- APPROVAL
CAT 132D-- STATUS/
QVM-Q CATEGORY
NTPC Main Contractor

PROJECT: DARLIPALI STPP –I (2X800MW) LIST OF ITEMS REQUIRING QUALITY PLAN AND SUB- SUPPLIER APPROVAL NTPC DOC
NO
PACKAGE: MAKEUP WATER PIPES REV. NO. 0
CS-9549-132D-2
MAIN SUPPLIER: SUB SYSTEM: CIVIL WORKS DATE
CONTRACT NO.:
SR. NO. ITEM QAP QAP PROPOSED SUB SUPPLIER PLACE OF APPROVAL REMARKS
/ NO. MANUFACTURING STATUS /
INSP. CATEGORY
CAT
1. CEMENT III - CCI - N
GUJARAT AMBUJA - N
JK LAXMI - N
JAYPEE - N
GRASIM - N
BIRLA - N
LAFARGE - N
ACC - N
SHREE - N
INDIA CEMENT - N
PENNA CEMENT - N
MADRAS CEMENT - N
PRISM - N
ULTRATECH - N
ORIENT - N
MANCHERIAL - N
JSW - N
ANDHRA CEMENT - N
PARASHAKTI - N
SAGAR - N
MAIHAR - N
MANIKGARH - N
2. CONSTRUCTION CHEMICALS - III - SIKA INDIA LTD - N
ADMIXTURES, PLASTISIZERS, CICO TECHONOLOGIES LTD - N
Important: See notes at the end of the document Page 1 of 3

NO
CS-9549-132D-2
CONTRACT NO.:
INSP. CATEGORY
CAT
RETARDERS FOSROC CHEMICALS (I) PVT - N
WATER PROOFING COMPOUNDS LTD
GROUTS BASF - N
3. BITUMEN ASPHALT III - ALL GOVERNMENT - N

REFIINARIES
4. RCC PIPES III - BIS APPROVED SOURCES
HAVING VALID BIS LICENCE
- N
LEGENDS:
1. SYSTEM SUPPLIER/SUB-SUPPLIER APPROVAL STATUS CATEGORY (SHALL BE FILLED BY NTPC)
A – For these items proposed vendor is acceptable to NTPC. To be indicated with letter “A” in the list along with the condition of approval, if any.
DR – For these items “Details required” for NTPC review. To be identified with letter “DR” in the list.
'N' NOTED – For these items vendors are approved by Main Supplier and accepted by NTPC without specific vendor approval from NTPC. To be
identified with ‘NOTED.’
2. QP/INSPN CATEGORY:
CAT-I : For these items the Quality Plans are approved by NTPC and the final acceptance will be on physical inspection witness by NTPC.
CAT-II : For these items the Quality Plans approved by NTPC. However no physical inspection shall be done by NTPC. The final acceptance by NTPC
shall be on the basis review of documents as per approved quality plan.
CAT-III : For these items Main Supplier approves the Quality Plans.
UNITS/ WORKS : Place of manufacturing Place of Main Supplier of multi units/works.
NOTE 1: For the items placed in CAT-III for Civil Works, the review and final acceptance shall be done by NTPC-EIC/ FQA on the basis of MTC /
certificate of conformance in line with Indicative FQP / Technical Specifications.
NOTE 2:
i) This list has been compiled based on the names of suppliers / sub vendors proposed by the Bidders / Main Contractors to NTPC for various Corporate
Civil packages awarded in the past based on respective Technical Specifications / Bill of Quantities / Tender Documents. This list is not exhaustive. Listed
sub-suppliers may or may not have supplied the material to NTPC in the past.

NO
CS-9549-132D-2
CONTRACT NO.:
INSP. CATEGORY
CAT
ii) The purpose of this list is not to limit the sub vendors but to provide general guidance to the prospective Bidders / Main Contractors. However this list is
indicative in nature and may undergo revision for future packages based on the performance feedback received from NTPC sites / other agencies about
the supplier / sub vendors / supplied material. Moreover listed suppliers may or may not be able to supply the material as per current Tech Specifications /
Bill of Quantities / Tender Documents for the present package. Bidder is required to enquire before finalizing the suppliers / sub vendors for the present
contract to meet provisions of the current Tech Specs / BOQ / Tender Documents. Moreover some of these listed sub-suppliers might have stopped
manufacturing the identified items. It is also possible that some of the listed manufacturers/suppliers do not exist now. Bidder to make necessary enquiry
before submitting bids. Bidders / Contractors are free to propose names of suppliers / sub vendors for various items as per their procurement policy to
NTPC for considering supplies for the present Contract.

PART- C
GENERAL TECHNICAL
REQUIREMENTS
CLAUSE NO.
GENERAL TECHNICAL REQUIREMENTS
GENERAL TECHNICAL REQUIREMENT
1.00.00 INTRODUCTION
This part covers technical requirements which will form an integral part of the
Contract. The following provisions shall supplement all the detailed technical
requirements brought out in the Technical Specifications and the Technical Data
Sheets.
2.00.00 BRAND NAME
Whenever a material or article is specified or described by the name of a particular

brand, manufacturer or vendor, the specific item mentioned shall be understood to
be indicative of the function and quality desired, and not restrictive; other
manufacturer's products may be considered provided sufficient information is
furnished to enable the Employer to determine that the products proposed are
equivalent to those named.
3.00.00 BASE OFFER & ALTERNATE PROPOSALS
The Bidder's proposal shall be based upon the use of equipment and material
complying fully with the requirements specified herein. It is recognized that the
Contractor may have standardized on the use of certain components, materials,
processes or procedures different than those specified herein. Alternate proposals
offering similar equipment based on the manufacturer's standard practice may also
be considered, provided the base offer is in line with technical specifications and
such proposals meet the specified design standards and performance requirement
and are acceptable to the Employer. Sufficient amount of information for justifying
such proposals shall be furnished to Employer along with the bid to enable the
Employer to determine the acceptability of these proposals.
4.00.00 COMPLETENESS OF FACILITIES
4.01.00 Bidders may note that this is a contract inclusive of the scope as indicated
elsewhere in the specification. Each of the plant shall be engineered and designed in
accordance with the specification requirement. All engineering and associated
services are required to ensure that a completely engineered plant is provided.
4.02.00 All equipments furnished by the Contractor shall be complete in every respect, with
all mountings, fittings, fixtures and standard accessories normally provided with such
equipment and/or those needed for erection, completion and safe operation &
maintenance of the equipment and for the safety of the operating personnel, as
required by applicable codes, though they may not have been specifically detailed in
the respective specifications, unless included in the list of exclusions.
All similar standard components/ parts of similar standard equipment provided shall
be interchangeable with one another.
5.00.00 CODES & STANDARDS
5.01.00 In addition to the codes and standards specifically mentioned in the relevant
technical specifications for the equipment / plant / system, all equipment parts,
systems and works covered under this specification shall comply with all currently
DARLIPALI STPP STAGE-I (2X800 MW) Sub-Section – GTR

MAKE-UP WATER PIPES PACKAGE GENERAL TECHNICAL
SECTION VI –Part – C 1 of 39
BID DOCUMENT NO: CS- 9549-132D-2 REQUIREMENTS
CLAUSE NO.
applicable statutory regulations and safety codes of the Republic of India as well as
of the locality where they will be installed, including the following:
(a) Bureau of Indian Standards (BIS)

(b) Indian electricity act
(c) Indian electricity rules
(d) Indian Explosives Act
(e) Indian Factories Act and State Factories Act
(f) Indian Boiler Regulations (IBR)
(g) Regulations of the Central Pollution Control Board, India
(h) Regulations of the Ministry of Environment & Forest (MoEF), Government of
India
(i) Pollution Control Regulations of Department of Environment, Government of
India
(j) State Pollution Control Board.
(k) Rules for Electrical installation by Tariff Advisory Committee (TAC).
(l) Any other statutory codes / standards / regulations, as may be applicable.
5.02.00 Unless covered otherwise by Indian codes & standards and in case nothing to the
contrary is specifically mentioned elsewhere in the specifications, the latest editions
(as applicable as on date of bid opening), of the codes and standards given below
shall also apply:
(a) Japanese Industrial Standards (JIS)

(b) American National Standards Institute (ANSI)
(c) American Society of Testing and Materials (ASTM)
(d) American Society of Mechanical Engineers (ASME)
(e) American Petroleum Institute (API)
(f) Standards of the Hydraulic Institute, U.S.A.
(g) International Organization for Standardization (ISO)
(h) Tubular Exchanger Manufacturer's Association (TEMA)
(i) American Welding Society (AWS)
(j) National Electrical Manufacturers Association (NEMA)
(k) National Fire Protection Association (NFPA)
(l) International Electro-Technical Commission (IEC)
(m) Expansion Joint Manufacturers Association (EJMA)
(n) Heat Exchange Institute (HEI)
5.03.00 Other International/ National standards such as DIN, VDI, BS, etc. shall also be
accepted for only material codes and manufacturing standards, subject to the
Employer's approval, for which the Bidder shall furnish, along with the offer,
adequate information to justify that these standards are equivalent or superior to the
standards mentioned above. In all such cases the Bidder shall furnish specifically
the variations and deviations from the standards mentioned else where in the
specification together with the complete word to word translation of the standard that
is normally not published in English.
5.04.00 In the event of any conflict between the codes and standards referred to in the
above clauses and the requirement of this specification, the requirement of
Technical Specification shall govern.
5.05.00 NOT USED

CLAUSE NO.
5.06.00 The codes, and/or standards referred to in these specifications shall govern, in all
the cases wherever such references are made for design of various equipments
/system etc. Latest edition shall be followed by the Contractor for all the codes and
/or Standards. In case of a conflict between such codes and/or standards and the
specifications, the latter shall govern. Such codes and/or standard referred to shall
mean the latest revision, amendments/changes adopted and published by the
relevant agencies. In case of any further conflict in this matter the same shall be
referred to the Engineer, whose decision shall be final and binding.
5.07.00 Other internationally acceptable standards which ensure equal or higher

performance than those specified shall also be accepted subject to the Employer's
approval, for which the Bidder shall furnish, adequate information to justify that these
standards are equivalent or superior to the standards referred. In all such cases the
Bidder shall furnish specifically the variations and deviations from the standards
mentioned else where in the specification together with the complete word to word
translation of the standard that is normally not published in English.
5.08.00 In case of any change in codes, standards & regulations between the date of bid
opening and the date when vendors proceed with fabrication, the Employer shall
have the option to incorporate the changed requirements or to retain the original
standard. It shall be the responsibility of the Contractor to bring to the notice of the
Employer such changes and advise Employer of the resulting effect.
6.00.00 EQUIPMENT FUNCTIONAL GUARANTEE
6.01.00 The functional guarantees of the equipment under the scope of the Contract are
given elsewhere in the technical specification. These guarantees shall supplement
the general functional guarantee provisions covered under General Conditions of
Contract.
6.02.00 Liquidated damages for shortfall in meeting functional guarantee(s) during the
performance and guarantee tests shall be assessed and recovered from the
Contractor as specified elsewhere in this specification.
7.00.00 DESIGN OF FACILITIES / MAINTENANCE & AVAILABILITY CONSIDERATIONS
7.01.00 Design of Facilities
All the design procedures, systems and components proposed shall have already
been adequately developed and shall have demonstrated good reliability under
similar conditions elsewhere.
The Contractor shall be responsible for the selection and design of appropriate
equipments to provide the best co-ordinated performance of the entire system. The
basic requirements are detailed out in various clauses of the Technical
Specifications. The design of various components, assemblies and subassemblies
shall be done so that it facilitates easy field assembly and dismantling. All the
rotating components shall be so selected that the natural frequency of the complete
unit is not critical or close to the operating range of the unit.

CLAUSE NO.
7.02.00 Maintenance and Availability Considerations
Equipment/facilities offered shall be designed for high availability, low maintenance

and ease of maintenance. The Bidder shall specifically state the design features
incorporated to achieve high degree of reliability/ availability and ease of
maintenance. The Bidder shall also furnish details of availability records in the
reference plants stated in his experience list.
Bidder shall state in his offer the various maintenance intervals, spare parts and
man-hour requirement during such operation.
Lifting devices i.e. hoists and chain pulley jacks, etc. shall be arranged by the
contractor for handling of any equipment or any of its part having weight in excess of
500 Kgs during erection.
Lifting devices like lifting tackles, slings, etc. to be connected to hook of the hoist /
crane shall be arranged by the contractor for lifting the equipment and accessories
covered under the specification.
8.00.00 DOCUMENTS, DATA AND DRAWINGS TO BE FURNISHED BY CONTRACTOR
8.01.00 Bidders may note that this is a contract inclusive of the scope as indicated
elsewhere in the specification. Each of the plant and equipment shall be fully
integrated, engineered and designed to perform in accordance with the technical
specification. All engineering and technical services required ensuring a completely
engineered plant shall be provided in respect of mechanical, electrical, control &
instrumentation, civil & structural works as per the scope.
The Contractor shall furnish engineering data/drgs. in accordance with the schedule
of information as specified in Technical Specification and data sheet.
8.02.00 The number of copies/prints /CD-ROMs/manuals to be furnished for various types of

documents is given in Annexure-I.
8.03.00 The documentation that shall be provided by the Contractor is indicated in the
various sections of specification. This documentation shall include but not be limited
to the following:
8.03.01 Detailed Engineering Documents
i. General layout plan of the station.
ii. Layouts, general arrangements, elevations and cross-sections drawings for

all the equipment and facilities of the plant.
iii. Flow diagrams, Process & Instrumentation Diagrams along with write-up and
system description.
iv. Piping isometric, composite layout and fabrication drawings.
v. Piping engineering diagrams, pipe and fittings schedules, valve schedules,

hanger and support schedules.

CLAUSE NO.
vi. Technical data sheets for all bought out and manufactured items. Contractor
shall use the NTPC specifications as a base for placement of orders on their
sub-vendors.
vii. Detailed design calculations for components, system/sub-system, piping etc.,

wherever applicable including sizing calculations for all auxiliaries as per
criteria specified elsewhere in specification.
viii. Transient, hydraulic and thermal stress analysis of piping and system
wherever applicable & input and output data along with stress analysis
isometrics showing nodes.
ix. Comprehensive list of all terminal points which interface with Employer's
facilities giving details of location, terminal pressure, temperature, fluid
handled & end connection details, forces, moments etc.
x. Instrument schedule, measuring point list, I/O list, Interconnection & wiring
diagram, functional write-ups, installation drawings for field mounted
instruments, logic diagrams,). Motor list and valve schedule including type of
actuator etc.
xi. Type test reports
xii. Civil & Structural works drawings and documents for all structures, facilities,
foundations, underground and over ground works and super-structural works
as included in the scope of the Bidder.
xiii. Model study reports wherever applicable.
xiv. Functional & guarantee test procedures and test reports.
xv. Documentation in respect of Quality Assurance System as listed out

elsewhere in this specification.
xvi. Documentation in respect of commissioning as listed out elsewhere in this

specification.
xvii. The Contractor while submitting the above documents / drawings for
approval / reference as the case may be, shall mark on each copy of
submission the reference letter along with the date vide which the
submissions are made.
8.03.02 Instruction Manuals
The Contractor shall make first submission of Instruction Manuals for all the
equipments covered under the Contract by the end of one year from the date of his
acceptance of the Letter of Award. The Instruction manuals shall contain full details
required for erection, commissioning, operation and maintenance of each
equipment. The manual shall be specifically compiled for this project. After
finalization and approval of the Employer the Instruction Manuals shall be submitted
as indicated in Annexure-I. The Contract shall not be considered to be completed for
purposes of taking over until the final Instructions manuals have been supplied to the
Employer. The Instruction Manuals shall comprise of the following:

CLAUSE NO.
(a) Erection Manuals
The erection manuals shall be submitted at least three (3) months prior to the
commencement of erection activities of particular equipment/system. The erection
manual should contain the following as a minimum.
(i) Erection strategy.

(ii) Sequence of erection.
(iii) Erection instructions.
(iv) Critical checks and permissible deviation/tolerances.
(v) List of tool, tackles, heavy equipments like cranes, dozers, etc.
(vi) Bill of Materials
(vii) Procedure for erection.
(viii) General safety procedures to be followed during erection/installation.
(ix) Procedure for initial checking after erection.
(x) Procedure for testing and acceptance norms.
(xi) Procedure / Check list for pre-commissioning activities.
(xii) Procedure / Check list for commissioning of the system.
(xiii) Safety precautions to be followed in electrical supply distribution
during erection
(b) Operation & Maintenance Manuals
(i) The operating and maintenance instructions together with drawings

(other than shop drawings) of the equipment, as completed, shall be
in sufficient detail to enable the Employer to operate, maintain,
dismantle, reassemble and adjust all parts of the equipment. They
shall give a step-by-step procedure for all operations likely to be
carried out during the life of the plant / equipment including,
operation, maintenance, dismantling and repair including periodical
activities wherever required. Each manual shall also include a
complete set of drawings together with performance/rating curves of
the equipment and test certificates wherever applicable. The contract
shall not be considered to be completed for purposes for taking over
until these manuals have been supplied to the Employer.
(ii) If after the commissioning and initial operation of the plant, the
manuals require any modification / additions / changes, the same
shall be incorporated and the updated final instruction manuals shall
be submitted to the Employer for records.
(iii) A separate section of the manual shall be for each size/ type of
equipment and shall contain a detailed description of construction and
operation, together with all relevant pamphlets and drawings.
(iv) The manuals shall include the following:
(a) List of spare parts along with their drawing and catalogues
and procedure for ordering spares.
(b) Lubrication Schedule including charts showing lubrication

checking, testing and replacement procedure to be carried

CLAUSE NO.
daily, weekly, monthly & at longer intervals to ensure trouble

free operation.
(c) Where applicable, fault location charts shall be included to

facilitate finding the cause of mal operation or break down.
(v) Detailed specifications for all the consumables including lubricant oils,
greases, and chemicals etc. system/equipment/assembly/sub
assembly - wise required for the complete plant.
(vi) On completion of erection, a complete list of bearings / equipment

giving their location, and identification marks etc. shall also be
furnished to the Employer indicating lubrication method for each type.
8.03.03 Project Completion Report
The Contractor shall submit a Project Completion Report at the time of handing over
the plant.
8.03.04 Drawings
(a) All the plant layouts shall be made in computerized 2D modeling system. The
Employer reserves the right to review the 2D model at different stages during
the progress of engineering. The layout drawings submitted for Employer's
review shall be fully dimensioned and extracted from 2D model after
interference check.
(b) All documents submitted by the Contractor for Employer's review shall be in
electronic form (soft copies) along with the desired number of hard copies as
per Annexure-I. The soft copies shall b unloaded by the vendors in c-folders,
a Web based system of NTPC ERP, for which a username and password will
be allotted to the new vendor by NTPC.
Similarly, the vendor can download the drawings/documents, approved/

commented by NTPC, through above site.
The soft copies of identified drawings/documents shall be in pdf format,

whereas the attachments/reply to the submitted document(s) can b in doc,
xls, pdf, dwg or std formats”.
(c) Final copies of the approved drawings alongwith requisite number of hard
copies shall be submitted as per Annexure-I.
(d) All documents/text information shall be in latest version of MS Office. The tag
numbering system to be adopted for various equipment, instrument signals
etc. shall be based on the KKS codification system, which is in like with DIN
6779.
(e) All drawings submitted by the Contractor including those submitted at the
time of bid shall be in sufficient detail indicating the type, size, arrangement,
weight of each component for packing and shipment, the external
connection, fixing arrangement required, the dimensions required for
installation and interconnections with other equipments and materials,

CLAUSE NO.
clearance and spaces required between various portions of equipment and

any other information specifically requested in the drawing schedules.
(f) Each drawing submitted by the Contractor (including those of sub vendors)
shall bear a title block at the right hand bottom corner with clear mention of
the name of the Employer, the system designation, the specifications title,
the specification number, the name of the Project, drawing number and
revisions. If standard catalogue pages are submitted the applicable items
shall be indicated therein. All titles, notings, markings and writings on the
drawing shall be in English. All the dimensions should be in metric units.
(g) The drawings submitted by the Contractor (or their sub vendors) shall bear
Employer's drawing number in addition to contractor's (their sub-vendor's)
own drawing number. Employer's drawing numbering system shall be made
available to the successful bidder so as to enable him to assign Employer's
drawing numbers to the drawings to be submitted by him during the course of
execution of the Contract.
(h) The Contractor shall also furnish a "Master Drawing List" which shall be a
comprehensive list of all drawings/ documents/ calculations envisaged to be
furnished by him during the detailed engineering to the Employer in line with
engineering information flow schedule (to be tied up with successful bidder).
Such list should clearly indicate the purpose of submission of these drawings
i.e. "FOR APPROVAL" or "FOR INFORMATION ONLY".
(i) Similarly, all the drawings/ documents submitted by the Contractor during
detailed engineering stage shall be marked "FOR APPROVAL" or "FOR
INFORMATION" prior to submission. Further, space shall be identified on
each drawing for Approval stamp and electronic signature.
(j) The furnishing of detailed engineering data and drawings by the Contractor
shall be in accordance with the time schedule for the project. The review of
these documents/ data/ drawings by the Employer will cover only general
conformance of the data/ drawings/ documents to the specifications and
contract, interfaces with the equipments provided by others and external
connections & dimensions which might affect plant layout. The review by the
Employer should not be construed to be a thorough review of all dimensions,
quantities and details of the equipments, materials, any devices or items
indicated or the accuracy of the information submitted. The review and/ or
approval by the Employer / Project Manager shall not relieve the Contractor
of any of his responsibilities and liabilities under this contract.
(k) After the approval of the drawings, further work by the Contractor shall be in
strict accordance with these approved drawings and no deviation shall be
permitted without the written approval of the Employer.
(l) All manufacturing, fabrication and execution of work in connection with the
equipment / system, prior to the approval of the drawings, shall be at the
Contractor's risk. The Contractor is expected not to make any changes in the
design of the equipment /system, once they are approved by the Employer.
However, if some changes are necessitated in the design of the
equipment/system at a later date, the Contractor may do so, but such
changes shall promptly be brought to the notice of the Employer indicating

CLAUSE NO.
the reasons for the change and get the revised drawing approved again in
strict conformance to the provisions of the Technical Specification. While
submitting revised document/drawing/P&ID the Contractor shall also highlight
the revision marks like R1, R2, R3 etc. against those items/areas such as
pipes/valves/equipments/notes/sizes/pressure etc. on the documents/
drawings indicating the major reasons for revisions at the bottom of
documents/drawing.
(m) Drawings shall include all installations and detailed piping layout drawings.
Layout drawings for all piping of 65 mm and larger diameter shall be
submitted for review/ approval of Employer prior to erection. Small diameter
pipes shall however be routed as per site conditions in consultation with site
authority / representative of Employer based on requirements of such piping
indicated in approved / finalized Flow Scheme / Process & Instrumentation
Diagrams and/or the requirements cropping up for draining & venting of
larger diameter piping or otherwise after their erection as per actual physical
condition for the entire scope of work of this package.
(n) Assessing & anticipating the requirement and supply of all piping and
equipment shall be done by the contractor well in advance so as not to
hinder the progress of piping & equipment erection, subsequent system
charging and its effective draining & venting arrangement as per site
suitability.
(o) Any software used by the contractor shall be given to the project manager
and concerned engineer of employer. The contractor shall make the engineer
of the employer aware of the programme. Any computer aided programme
shall be approved subject to giving entire detail to the project manager.
(p) Drawings must be checked by the Contractor in terms of its completeness,

data adequacy and relevance with respect to engineering schedule prior to
submission to the Employer. In case drawings are found to be submitted
without proper endorsement for checking by the Contractor, the same shall
not be reviewed and returned to the Contractor for re-submission. The
contractor shall make a visit to site to see the existing facilities and
understand the layout completely and collect all necessary data / drawings at
site which are needed as an input to the engineering. The contractor shall do
the complete engineering including interfacing and integration of all his
equipment, systems & facilities within his scope of work as well as interface
engineering & integration of systems, facilities, equipment & works under
Employer's scope and submit all necessary drawings/ documents for the
same.
(q) All drawings shall be reviewed and approved by Engineering coordinator,

including the following drawings / data which require specific approval.
1. Data sheets for various equipments / systems.

2. Field testing procedures for various equipment and piping system.
3. Pre commissioning / commissioning procedures including flushing,
Chemical cleaning, steam blowing and hydro test etc. (Wherever
applicable) O&M manual shall also be reviewed and approved by
Employer. The content of O&M manual shall be as specified
elsewhere in the specification.
4. Guarantee test procedures (including model tests, if any).

CLAUSE NO.
5. Any other drawings that may be required by the Engineer from time to
time).
6. Data furnished in the bid shall be binding on the contractor even if
superior to the technical specification requirement and any revision
shall be done with the Employer's agreement.
(r) The Contractor shall submit adequate prints of drawing / data / document for
Employer's review and approval. The Employer shall review the drawings
and return soft copy to the Contractor authorizing either to proceed with
manufacture or fabrication, or marked to show changes desired. When
changes are required, drawings shall be re-submitted promptly, with
revisions clearly marked, for final review. Any delays arising out of the failure
of the Contractor to submit/rectify and resubmit in time shall not be accepted
as a reason for delay in the contract schedule.
(s) Upon review of each drawing, depending on the correctness and

completeness of the drawing, the same will be categorized and approval
accorded in one of the following categories:
CATEGORY I Approved
CATEGORY II Approved subject to incorporation of comments/

modification as noted. Resubmit revised drawing incorporating the comments
CATEGORY III Not approved. Resubmit revised drawings for approval after
incorporating comments/modification as noted.
CATEGORY IV For information and records.
(t) Vendor shall resubmit the drawings approved under Category II and III within
three (3) weeks of receipt of comments on the drawings, incorporating all
comments. Every revision of the drawing shall bear a revision index wherein
such revisions shall be highlighted in the form of description or marked up in
the drawing identifying the same with relevant revision Number enclosed in a
triangle (eg. 1, 2, 3 etc).
In case Vendor does not agree with any specific comment, he shall furnish
the explanation for the same to NTPC 'EC' for consideration. In all such
cases vendor shall necessarily enclose explanations along with the revised
drawing (taking care of balance comments) to avoid any delay and/or
duplication in review work.
It is responsibility of the Vendor to get all the drawings approved in the

Category I & IV (as the case may be) and complete engineering activities
within the agreed schedule. Any delay arising out of submission and
modification of drawings shall not alter the contract completion schedule.
Vendor shall not make any changes in the portions of the drawing other than
those commented. If changes are required to be made in the portions already
approved, the vendor shall resubmit the drawing identifying the changes for
owner's review and approval.

CLAUSE NO.
(u) If Vendor fails to resubmit the drawings as per the schedule, construction
work at site will not be held up and work will be carried out on the basis of
comments furnished on previous issues of the drawing.
These comments will be taken care by the contractor while submitting the
revised drawing.
(v) All engineering data submitted by the Contractor after final process including
review and approval by the Project Manager/ Employer shall form part of the
contract documents and the entire works covered under these specification
shall be performed in strict conformity with technical specifications unless
otherwise expressly requested by the Project Manager in writing.
(w) As Built Drawings
After final acceptance of individual equipment / system by the Employer, the

Contractor will update all original drawings and documents for the equipment
/ system to "as built" conditions and submit no. of copies as per Annexure - I .
(x) Drawings must be checked by the Contractor in terms of its completeness,

data adequacy and relevance with respect to engineering schedule prior to
submission to the Employer. In case drawings are found to be submitted
without proper endorsement for checking by the Contractor, the same shall
not be reviewed and returned to the Contractor for re-submission. The
contractor shall make a visit to site to see the existing facilities and
understand the layout completely and collect all necessary data / drawings at
site which are needed as an input to the engineering. The contractor shall do
the complete engineering including interfacing and integration of all his
equipment, systems & facilities within his scope of work as well as interface
engineering & integration of systems, facilities, equipment & works under
Employer's scope and submit all necessary drawings/ documents for the
same.
(y) The Contractor shall submit adequate prints of drawing / data / document for
Employer's review and approval. The Employer shall review the drawings
and return one (1) copy to the Contractor authorizing either to proceed with
manufacture or fabrication, or marked to show changes desired. When
changes are required, drawings shall be re-submitted promptly, with
revisions clearly marked, for final review. Any delays arising out of the failure
of the Contractor to submit/rectify and resubmit in time shall not be accepted
as a reason for delay in the contract schedule.
(z) All engineering data submitted by the Contractor after final process including
review and approval by the Project Manager/ Employer shall form part of the
contract documents and the entire works covered under these specification
shall be performed in strict conformity with technical specifications unless
otherwise expressly requested by the Project Manager in writing.
8.04.00 Engineering Information Submission Schedule
Prior to the award of Contract, a Detailed Engineering Information Submission

Schedule/Master Drawing list shall be tied up with the Employer. For this, the bidder
shall furnish a detailed list of engineering information along with the proposed

CLAUSE NO.
submission schedule. This list would be a comprehensive one including all

engineering data / drawings / information for all bought out items and manufactured
items. The information shall be categorized into the following parts:
(a) Information that shall be submitted for the approval of the Employer before
proceeding further, and
(b) Information that would be submitted for Employer's information only.
The Master Drawing list (MDL) shall be updated periodically and submitted to the
Employer, highlighting the changes made in the MDL.
The schedule should allow adequate time for proper review and incorporation of
changes/ modifications, if any, to meet the contract without affecting the equipment
delivery schedule and overall project schedule. The early submission of drawings
and data is as important as the manufacture and delivery of equipment and
hardware and this shall be duly considered while determining the overall
performance and progress.
8.05.00 Engineering Coordination Procedure
Identification of Principal Engineering Coordinators
8.05.01 The following principal coordinators will be identified by respective organizations at

time of award of contract
OWNER'S COORDINATORS
NTPC Engineering Coordinators (NTPC EC)
Name :
Designation :
Address :
a) Postal :
b) Telegraphic :
TELEX :
FAX : TELEPHONE :
NTPC Site Co-ordinator (NTPC SC)
Name :
Designation :
Address :
a) Postal :
b) Telegraphic :
TELEX :
FAX : TELEPHONE :
Vendor Engineering Co-ordinator (Vendor EC)
Name :
Designation :
Address :

CLAUSE NO.
a) Postal :
b) Telegraphic :
TELEX :
FAX : TELEPHONE :
8.05.02 All engineering correspondence shall be in the name of above coordinators on

behalf of the respective organizations.
8.05.03 Vendors Drawings
(a) The contractor shall furnish, discuss and finalize with the Employer, the
engineering information flow schedule at the time of award of the contract.
The dates for submission of drawings as finalized in the above engineering
schedule shall be strictly adhered to. This is essential for the timely
completion of the project.
(b) A detailed drive list shall be furnished along with the tender. Further drive list
in the Employer's format shall be submitted to the Engineering coordinator
within 60 days from the date of award of the contract.
(c) In any case, in order to achieve the project completion dates, the contractor
must strictly comply with engineering schedules.
(d) Final distribution copies of all approved drgs. (in Cat. I & IV) shall be
submitted by the contractor to the Engineer within two (2) weeks of the
approval.
(e) Copies of all approved drgs. (in cat. I & IV) shall be submitted incorporating
all site modifications, if any, during construction, erection, commission stages
and performance and guarantee testing (till its continuous operation) as 'As
Built Drgs'.
(f) The contractor shall use a single transmittal for drgs. submission. This shall
include transmittal numbers and date, number of copies being sent, names of
the agencies to whom are all the copies being sent drg numbers and titles,
remarks or special notes if any etc.
(g) All manufacturing and fabrication work in connection with the equipments
prior to the approval of the drg. shall be at contractors risks.
(h) Approval of contractor's drgs. or work by the Engineer shall not relieve the
contractor of any of his responsibilities or liabilities under the contract.
8.05.04 Erection Drawings
(a) Contractor shall furnish erection drawings for the guidance of his/ Employer's
site staff at least 4 weeks before scheduled commencement of erection or
the first shipment, whichever is earlier. These shall generally comprise of
fabrication/assembly drawings, various component/part details drawings,
assembly, clearance, data requirements etc. The drawings shall contain
details of components/ equipment with identification numbers, match marks,
bills of materials, assembly procedures etc.

CLAUSE NO.
(b) For all major equipment apart from above details, assembly sequence and
instructions with check lists shall be furnished in the form of erection manuals
8.06.00 Engineering Progress and Exception Report
8.06.01 Report giving the status of each engineering information including
(a) A list of drawings/engineering information which remains unapproved for

more than four (4) weeks after the date of first submission.
(b) Drawings which were not submitted as per agreed schedule.
8.06.02 The draft format for this report shall be furnished to the Employer within four (4)
weeks of the award of the contract, which shall then be discussed and finalized with
the Employer.
8.07.00 Technical Co-ordination Meeting
8.07.01 The Contractor shall be called upon to organize and attend monthly Design/
Technical Co-ordination Meetings (TCMs) with the Employer/Employer's
representatives and other Contractors of the Employer during the period of contract.
The Contractor shall attend such meetings at his own cost at NEW DELHI / NOIDA
or at mutually agreed venue as and when required and fully co-operate with such
persons and agencies involved during the discussions.
8.07.02 The Contractor should note that "Time" is the essence of the contract. In order to
expedite the early completion of engineering activities, the Contractor shall submit all
drawings as per the agreed Engineering Information Submission Schedule. The
drawings submitted by the Contractor will be reviewed by the Employer as far as
practicable within three (3) weeks from the date of receipt of the drawing. The
comments of the Employer shall then be discussed across the table during the
above Technical Co-ordination Meeting (s) wherein best efforts shall be made by
both sides to ensure the approval of the drawing.
8.07.03 The Contractor shall ensure availability of the concerned experts / consultants/
personnel who are empowered to take necessary decisions during these meetings.
The Contractor shall be equipped with necessary tools and facilities so that the
drawings/documents can be resubmitted after incorporating necessary changes and
approved during the meeting itself.
8.07.04 Should any drawing remain unapproved for more than six (6) weeks after it's first
submission, this shall be brought out in the monthly Engineering Progress and
Exception Report with reasons thereof.
8.07.05 Any delays arising out of failure by the Contractor to incorporate Employer's
comments and resubmit the same during the TCM shall be considered as a default
and in no case shall entitle the Contractor to alter the Contract completion date.
8.08.00 Design Improvements
The Employer or the Contractor may propose changes in the specification of the
equipment or quality thereof and if the parties agree upon any such changes the
specification shall be modified accordingly.

CLAUSE NO.
If any such agreed upon change is such that it affects the price and schedule of
completion, the parties shall agree in writing as to the extent of any changing the
price and/or schedule of completion before the Contractor proceeds with the change.
Following such agreement, the provision thereof, shall be deemed to have been
amended accordingly.
8.09.00 Equipment Bases
A cast iron or welded steel base plate shall be provided for all rotating equipment
which is to be installed on a concrete base, unless otherwise specifically agreed to
by the Employer. Each base plate which supports the unit and its drive assembly,
shall be of a neat design with pads for anchoring the units, shall have a raised lip all
around, and shall have threaded drain connections.
8.10.00 Protective Guards
Suitable guards shall be provided for protection of personnel on all exposed rotating
and/or moving machine parts. All such guards shall be designed for easy installation
and removal for maintenance purpose.
8.11.00 Lubricants, Servo Fluids and Chemicals
8.11.01 The Bidder's scope includes all the first fill and one year's topping, requirements of
consumables such as oils, lubricants including grease, servo fluids, gases and
essential chemicals etc. Consumption of all these consumables during the initial
operation and final filling after the initial operation shall also be included in the scope
of the Bidder. Bidder shall also supply a quantity not less than 10% of the full
charge of each variety of lubricants, servo fluids, gases, chemicals etc. used which
is expected to be utilized during the first year of operation. This additional quantity
shall be supplied in separate Containers.
8.11.02 As far as possible lubricants marketed by the Indian Oil Corporation shall be used.
The variety of lubricants shall be kept to a minimum possible.
Detailed specifications for the lubricating oil, grease, gases, servo fluids, control
fluids, chemicals etc. required for the complete equipments covered herein shall be
furnished. On completion of erection, a complete list of bearings/ equipment giving
their location and identification marks shall be furnished to the Employer along with
lubrication requirements.
8.12.00 Lubrication
8.12.01 Equipment shall be lubricated by systems designed for continuous operation.

Lubricant level indicators shall be furnished and marked to indicate proper levels
under both standstill and operating conditions.
8.13.00 Material of Construction
8.13.01 All materials used for the construction of the equipment shall be new and shall be in
accordance with the requirements of this specification. Materials utilized for various
components shall be those which have established themselves for use in such
applications.

CLAUSE NO.
8.14.00 Rating Plates, Name Plates & Labels
8.14.01 Each main and auxiliary item of equipment including instruments shall have
permanently attached to it in a conspicuous position, a rating plate of non-corrosive
material upon which shall be engraved manufacturer's name, equipment, type or
serial number together with details of the ratings, service conditions under which the
item of equipment in question has been designed to operate, and such diagram
plates as may be required by the Employer.
8.14.02 Such nameplates or labels shall be of white no hygroscopic material with engraved
black lettering or alternately, in the case of indoor circuit breakers, starters, etc. of
transparent plastic material with suitably colored lettering engraved on the back. The
name plates shall be suitably fixed on both front and rear sides.
8.14.03 Items of plant such as valves, which are subject to handling, shall be provided with
engraved chromium plated nameplate or label with engraving filled with enamel. The
name plates for valves shall be marked in accordance with MSS standard SP-25
and ANSI B 16.34 as a minimum.
8.14.04 Hanger/ support numbers shall be marked on all pipe supports, anchors, hangers,
snubbers and restraint assemblies. Each constant and variable spring support shall
also have stamped upon it the designed hot and cold load which it is intended to
support. Suitable scale shall also be provided to indicate load on support/hanger.
8.14.05 Valves and strainers shall be identified by Employer's tag number of a metal tap
permanently attached to non pressure parts such as the yoke by a stainless steel
wire. The direction of flow shall also be marked on the body.
8.14.06 Safety and relief valves shall be provided with the following:
(a) Manufacturer's identification.

(b) Nominal inlet and outlet sizes in mm.
(c) Set pressure in Kg/cm2 (abs).
(d) Blow down and accumulation as percentage of set pressure.
(e) Certified capacity in Kg of saturated steam per hour or in case of liquid
certified capacity in liters of water per minute.
8.14.07 All such plates, instruction plates, etc. shall be bilingual with Hindi inscription first,
followed by English. Alternatively, two separate plates one with Hindi and the other
with English inscriptions may be provided.
8.14.08 All segregated phases of conductors or bus ducts, indoor or outdoor, shall be
provided with colored phase plates to clearly identify the phase of the system
8.15.00 TOOLS AND TACKLES
The Contractor shall supply with the equipment one complete set of all special tools
and tackles and other instruments required for the erection, assembly, disassembly
and proper maintenance of the equipment and piping systems (including software).
These special tools will also include special material handling equipment, jigs and
fixtures for maintenance and calibration/readjustment, checking and measurement

CLAUSE NO.
aids etc. A list of such tools and tackles shall be submitted by the Bidder along with
the offer.
The price of each tool / tackle shall be deemed to have been included in the total bid
price. These tools and tackles shall be separately packed and sent to site. The
Contractor shall also ensure that these tools and tackles are not used by him during
erection, commissioning and initial operation. For this period the Contractor should
bring his own tools and tackles. All the tools and tackles shall be of reputed make
acceptable to the Employer.
8.16.00 Welding
8.16.01 If the manufacturer has special requirements relating to the welding procedures for
welds at the terminals of the equipments to be performed by others the requirements
shall be submitted to the Employer in advance of commencement of erection work.
8.17.00 Colour Code for all Equipments/ Pipings/ Pipe Services
8.17.01 All equipment/ piping/ pipe services are to be painted by the Contractor in
accordance with Employer's standard colour coding scheme, which will be furnished
to the Contractor during detailed engineering stage.
8.18.00 Protection and Preservative Shop Coating
8.19.00 Protection
All coated surfaces shall be protected against abrasion, impact, discoloration and
any other damages. All exposed threaded portions shall be suitably protected with
either metallic or a nonmetallic protection device. All ends of all valves and pipings
and conduit equipment connections shall be properly sealed with suitable devices to
protect them from damage. The parts which are likely to get rusted, due to exposure
to weather, should also be properly treated and protected in a suitable manner. All
primers/paints/coatings shall take into account the hot humid, corrosive & alkaline,
subsoil or over ground environment as the case may be.
8.20.00 Preservative Shop Coating
All exposed metallic surfaces subject to corrosion shall be protected by shop

application of suitable coatings. All surfaces which will not be easily accessible after
the shop assembly, shall be treated beforehand and protected for the life of the
equipment. All surfaces shall be thoroughly cleaned of all mill scales, oxides and
other coatings and prepared in the shop. The surfaces that are to be finish-painted
after installation or require corrosion protection until installation, shall be shop
painted with at least two coats of primer.
Transformers and other electrical equipments if included shall be shop finished with
one or more coats of primer and two coats of high grade resistance enamel. The
finished colors shall be as per manufacturer's standards, to be selected and
specified by the Employer at a later date.
8.20.01 Shop primer for all steel surfaces which will be exposed to operating temperature
below 95 degrees Celsius shall be selected by the Contractor after obtaining specific
approval of the Employer regarding the quality of primer proposed to be applied.

CLAUSE NO.
Special high temperature primer shall be used on surfaces exposed to temperature

higher than 95 degrees Celsius and such primer shall also be subject to the approval
of the Employer.
8.20.02 All other steel surfaces which are not to be painted shall be coated with suitable rust
preventive compound subject to the approval of the Employer.
8.20.03 All piping shall be cleaned after shop assembly by shot blasting or other means
approved by the Employer. Lube oil piping or carbon steel shall be pickled.
8.20.04 Painting for Civil structures shall be done as per relevant part of technical
specification
9.00.00 QUALITY ASSURANCE PROGRAMME
9.01.00 The Contractor shall adopt suitable quality assurance programme to ensure that the
equipment and services under the scope of contract whether manufactured or
performed within the Contractor's works or at his sub-contractor's premises or at the
Employer's site or at any other place of work are in accordance with the
specifications. Such programmes shall be outlined by the Contractor and shall be
finally accepted by the Employer/authorized representative after discussions before
the award of the contract. The QA programme shall be generally in line with IS/ISO-
9001.A quality assurance programme of the contractor shall generally cover the
following:
(a) His organization structure for the management and implementation of the
proposed quality assurance programme
(b) Quality System Manual
(c) Design Control System
(d) Documentation and Data Control System
(e) Qualification data for bidder's key personnel.
(f) The procedure for purchase of materials, parts, components and selection of
sub-contractor's services including vendor analysis, source inspection,
incoming raw-material inspection, verification of materials purchased etc.
(g) System for shop manufacturing and site erection controls including process,
fabrication and assembly.
(h) Control of non-conforming items and system for corrective actions and
resolution of deviations.
(i) Inspection and test procedure both for manufacture and field activities.
(j) Control of calibration and testing of measuring testing equipment.
(k) System for Quality Audits.
(l) System for identification and appraisal of inspection status.
(m) System for authorizing release of manufactured product to the Employer.
(n) System for handling, storage and delivery.
(o) System for maintenance of records, and
(p) Quality plans for manufacturing and field activities detailing out the specific
quality control procedure adopted for controlling the quality characteristics
relevant to each item of equipment/component.
9.02.00 General Requirements - Quality Assurance
9.02.01 All materials, components and equipment covered under this specification shall be
procured, manufactured, erected, commissioned and tested at all the stages, as per
a comprehensive Quality Assurance Programme. An indicative programme of

CLAUSE NO.
inspection/tests to be carried out by the contractor for some of the major items is
given in the respective technical specification. This is, however, not intended to form
a comprehensive programme as it is the contractor’s responsibility to draw up and
implement such programme duly approved by the Employer. The detailed Quality
Plans for manufacturing and field activities shall be drawn up by the Bidder and will
be submitted to Employer for approval. Schedule of finalisation of such quality plans
will be finalised before award. Monthly progress reports on Manufacturing Quality
Plan (MQP)/ Field Quality Plan (FQP) submission/approval shall be furnished on
enclosed format No. QS-01-QAI-P-02/F1.
9.02.02 MQP will detail out for all the components and equipment, various tests/inspection,
to be carried out as per the requirements of this specification and standards
mentioned therein and quality practices and procedures followed by Contractor’s/
Sub-contractor’s/ sub-supplier's Quality Control Organisation, the relevant reference
documents and standards, acceptance norms, inspection documents raised etc.,
during all stages of materials procurement, manufacture, assembly and final
testing/performance testing. The Quality Plan shall be submitted on electronic
media through c-folders, a Web-based system of NTPC ERP in addition to hard
copy, for review and approval. After approval the same shall be submitted in
compiled form on CD-ROM.
9.02.03 FQPs will detail out for all the equipment, the quality practices and procedures etc.
to be followed by the Contractor’s "Site Quality Control Organisation", during various
stages of site activities starting from receipt of materials/equipment at site.
9.02.04 The Bidder shall also furnish copies of the reference documents/plant
standards/acceptance norms/tests and inspection procedure etc., as referred in
Quality Plans along with Quality Plans. These Quality Plans and reference
documents/standards etc. will be subject to Employer’s approval without which
manufacturer shall not proceed. These approved documents shall form a part of the
contract. In these approved Quality Plans, Employer shall identify customer hold
points (CHP), i.e. test/checks which shall be carried out in presence of the
Employer’s Project Manager or his authorised representative and beyond which the
work will not proceed without consent of Employer in writing. All deviations to this
specification, approved quality plans and applicable standards must be documented
and referred to Employer along with technical justification for approval and
dispositioning.
9.02.05 The contractor shall submit to the Employer Field Welding Schedule for field welding
activities in the enclosed format No.: QS-01-QAI-P-02/F2. The field welding
schedule shall be submitted to the Employer along with all supporting documents,
like welding procedures, heat treatment procedures, NDT procedures, etc. at least
ninety days before schedule start of erection work at site.
9.02.06 The contractor shall have suitable Field Quality Organization with adequate
manpower at Employer's site, to effectively implement the Field Quality Plan (FQP)
and Field Quality Management System for site activities. The contractor shall submit
the details of proposed FQA setup (organizational structure and manpower) for
employer's approval. The FQA setup shall be in place at least one month before the
start of site activities.
9.02.07 No material shall be dispatched from the manufacturer’s works before the same is
accepted, subsequent to pre dispatch final inspection including verification of

CLAUSE NO.
records of all previous tests/inspections by Employer’s Project Manager/Authorized

representative and duly authorized for dispatch by issuance of Material Dispatch
Clearance Certificate (MDCC).
9.02.08 All material used for equipment manufacture including casting and forging etc. shall
be of tested quality as per relevant codes/standards. Details of results of the tests
conducted to determine the mechanical properties; chemical analysis and details of
heat treatment procedure recommended and actually followed shall be recorded on
certificates and time temperature chart. Tests shall be carried out as per applicable
material standards and/or agreed details.
9.02.09 All welding and brazing shall be carried out as per procedure drawn and qualified in
accordance with requirements of ASME Section IX/BS-4870 or other International
equivalent standard acceptable to the Employer.
9.02.10 All welding/brazing procedures shall be submitted to the Employer or its authorized
representative for approval prior to carrying out the welding/brazing.
9.02.11 All brazers, welders and welding operators employed on any part of the contract
either in Contractor’s/sub-contractor works or at site or elsewhere shall be qualified
as per ASME Section-IX or BS-4871 or other equivalent International Standards
acceptable to the Employer.
9.02.12 Welding procedure qualification & Welder qualification test results shall be furnished
to the Employer for approval. However, where required by the Employer, tests shall
be conducted in presence of Employer/authorised representative.
9.02.13 For all pressure parts and high pressure piping welding, the latest applicable
requirements of the IBR (Indian Boiler Regulations) shall also be essentially
complied with. Similarly, any other statutory requirements for the equipment/systems
shall also be complied with. On all back-gauged welds MPI/LPI shall be carried
before seal welding.
9.02.14 Unless otherwise proven and specifically agreed with the Employer, welding of
dissimilar materials and high alloy materials shall be carried out at shop only.
9.02.15 No welding shall be carried out on cast iron components for repair.
9.02.16 All the heat treatment results shall be recorded on time temperature charts and
verified with recommended regimes.
9.02.17 All non-destructive examination shall be performed in accordance with written

procedures as per International Standards. The NDT operator shall be qualified as
per SNT-TC-IA (of the American Society of non-destructive examination). NDT shall
be recorded in a report, which includes details of methods and equipment used,
result/evaluation, job data and identification of personnel employed and details of co-
relation of the test report with the job.
All plates of thickness above 40mm & all bar stock/Forging above 40mm dia shall be
ultrasonically tested. For pressure parts, plate of thickness equal to or above 25mm
shall be ultrasonically tested.

CLAUSE NO.
9.02.18 a) The Contractor shall list out all major items/ equipment/ components to be
manufactured in house as well as procured from sub-contractors (BOI). All the sub-
contractor proposed by the Contractor for procurement of major bought out items
including castings, forging, semi-finished and finished components/equipment etc.,
list of which shall be drawn up by the Contractor and finalised with the Employer,
shall be subject to Employer's approval on enclosed format No. QS-01-QAI-P-01/F3.
The sub-vendors name which are not in NTPC provided list shall be deemed to be
considered in DR category.
b) NTPC follows a well defined sub-contractor’s/sub-vendor assessment and approval

process, the broad contours of which are also defined at NTPC website
www.ntpctender.com alongwith a FAQ which answers most of the queries on the
subject.
c) An indicative list of sub-vendors which has been accepted by NTPC in the past for
Corporate Awarded similar packages based on the respective Technical
Specifications are enclosed in the tender specification for reference purpose only.
The purpose of this list is to provide general guidance to the prospective Bidders /
Main Contractors for this package only. Further, this list is indicative in nature and
may undergo revision for future packages based on the performance feedback
received from NTPC sites / other agencies about the supplier / sub vendors /
supplied material. However, it is not the intention to limit the sub-vendor to only such
names appearing in the above list and Main contractor is free to propose additional
sub-vendors in his bid offer which will be subject to NTPC sub-vendor assessment
system upon receipt of requisite details in a time bound mutually agreed schedule. .
Moreover listed suppliers may or may not be able to supply the material as per
current Tech Specifications for the present package. Bidder is required to enquire
before finalizing the suppliers / sub vendors for the present contract to meet
provisions of the current Tech Specs.
d) The contractor’s proposal shall include vendor’s facilities established at the
respective works, the process capability, process stabilization, QC systems followed,
experience list, etc. along with his own technical evaluation for identified sub-
contractors and shall be submitted to the Employer for approval within a time bound
schedule drawn during detailed engineering process. Such sub-vendor proposed in
his bid offer shall be deemed to be identified in DR category and upon final
acceptance by NTPC in writing, contractor can place order on such accepted sub-
vendor only.
e) Monthly progress reports on sub-contractor detail submission / approval shall be
furnished as per Engineering Co-ordination Procedure. Such vendor approval shall
not relieve the contractor from any obligation, duty or responsibility under the
contract. Sub-vendor whose details are not submitted within the agreed cut-off date,
shall be deemed to be withdrawn by the contractor.
9.02.19 For components/equipment procured by the contractors for the purpose of the
contract, after obtaining the written approval of the Employer, the contractor’s
purchase specifications and inquiries shall call for quality plans to be submitted by
the suppliers. The quality plans called for from the sub-contractor shall set out,
during the various stages of manufacture and installation, the quality practices and
procedures followed by the vendor’s quality control organisation, the relevant
reference documents/standards used, acceptance level, inspection of
documentation raised, etc. Such quality plans of the successful vendors shall be

CLAUSE NO.
finalised with the Employer and such approved Quality Plans shall form a part of the
purchase order/contract between the Contractor and sub-contractor. With in three
weeks of the release of the purchase orders /contracts for such bought out items
/components, a copy of the same without price details but together with the detailed
purchase specifications, quality plans and delivery conditions shall be furnished to
the Employer on the monthly basis by the Contractor along with a report of the
Purchase Order placed so far for the contract.
9.02.20 Employer reserves the right to carry out quality audit and quality surveillance of the
systems and procedures of the Contractor’s or their sub-contractor’s quality
management and control activities. The contractor shall provide all necessary
assistance to enable the Employer carry out such audit and surveillance.
9.02.21 The contractor shall carry out an inspection and testing programme during
manufacture in his work and that of his sub-contractor’s and at site to ensure the
mechanical accuracy of components, compliance with drawings, conformance to
functional and performance requirements, identity and acceptability of all materials
parts and equipment. Contractor shall carry out all tests/inspection required to
establish that the items/equipment conform to requirements of the specification and
the relevant codes/standards specified in the specification, in addition to carrying out
tests as per the approved quality plan.
9.02.22 Quality audit/surveillance/approval of the results of the tests and inspection will not,
however, prejudice the right of the Employer to reject the equipment if it does not
comply with the specification when erected or does not give complete satisfaction in
service and the above shall in no way limit the liabilities and responsibilities of the
Contractor in ensuring complete conformance of the materials/equipment supplied to
relevant specification, standard, data sheets, drawings, etc.
9.02.23 For all spares and replacement items, the quality requirements as agreed for the
main equipment supply shall be applicable.
9.02.24 Repair/rectification procedures to be adopted to make the job acceptable shall be

subject to the approval of the Employer/ authorized representative.
9.02.25 Environmental Stress Screening
All solid state electronic system / equipment / sub assembly shall be free from infant
mortile components. For establishing the compliance to this requirement, the
contractor / sub – contractor should meet the following:
The Contractor / Sub – contractor shall furnish the established procedure being
followed for eliminating infant mortile components. The procedure followed by the
Contractor / Sub – contractor should be substantiated along with the statistical
figures to validate the procedure being followed. The necessary details as required
under this clause shall be furnished at the stage of QP finalization.
Or
In case the Contractor / Sub – contractor do not have any established procedure to
eliminate infant mortile components then two or 10% which ever is less, most
densely populated Panels shall be tested for Elevated Temperature Cycle Test as
per the following procedure.

CLAUSE NO.
1) Elevated Temperature Test Cycle
During the elevated temperature test which shall be for 48 hours, the ambient
temperature shall be maintained at 50° C. The equipment shall be interconnected
with devices and kept under energized conditions so as to repeatedly perform all
operations it is expected to perform in actual service with load on various
components being equal to those which will be experienced in actual service.
During the elevated temperature test the cubicle doors shall be closed (or shall be in
the position same as they are supposed to be in the field) and inside temperature in
the zone of highest heat dissipating components / modules shall be monitored. The
temperature rise inside the cubicle should not exceed 10° C above the ambient
temperature at 50° C.
In case of any failure during the test cycle, the further course of action should be
mutually discussed for demonstrating the intent of the above requirement.
2) Burn in Test Cycle
The test shall be conducted on all the panels fully assembled and wired including the
panels having undergone the above mentioned elevated temperature test.
The period of Burn in Test Cycle shall be 120 hrs and process shall be similar to the
elevated temperature test as above except that the temperature shall be reduced to
the ambient temperature prevalent at that time.
During the above tests, the process I/O and other load on the system shall be
simulated by simulated inputs and in the case of control systems; the process which
is to be controlled shall also be simulated. Testing of individual components or
modules shall not be acceptable.
During the Burn in Test the cubicle doors shall be closed (or shall be in the position
same as they are supposed to be in the field) and inside temperature in the zone of
highest heat dissipating components / modules shall be monitored. The temperature
rise inside the cubicle should not exceed 10° C above the ambient temperature.
The Contractor / Sub-contractor shall carry out routine test on 100% item at
contractor / sub-contractor's works. The quantum of check / test for routine &
acceptance test by employer shall be generally as per criteria / sampling plan
defined in referred standards. Wherever standards have not been mentioned
quantum of check / test for routine / acceptance test shall be as agreed during
detailed engineering stage.
9.03.00 QA Documentation Package
The Contractor shall be required to submit the QA Documentation in two hard copies
and two CD ROMs, as identified in respective quality plan with tick (?) mark.
9.03.01 Each QA Documentation shall have a project specific Cover Sheet bearing name &
identification number of equipment and including an index of its contents with page
control on each document.

CLAUSE NO.
The QA Documentation file shall be progressively completed by the Supplier's sub-

supplier to allow regular reviews by all parties during the manufacturing.
The final quality document will be compiled and issued at the final assembly place of
equipment before dispatch. However CD-Rom may be issued not later than three
weeks.
9.03.02 Typical contents of QA documentation is as below:-
(a) Quality Plan

(b) Material mill test reports on components as specified by the specification and
approved Quality Plans.
(c) Manufacturer / works test reports/results for testing required as per
applicable codes and standard referred in the specification and approved
Quality Plans.
(d) Non-destructive examination results /reports including radiography
interpretation reports. Sketches/drawings used for indicating the method of
traceability of the radiographs to the location on the equipment.
(e) Heat Treatment Certificate/Record (Time- temperature Chart)
(f) All the accepted Non-conformance Reports (Major/Minor) / deviation,
including complete technical details / repair procedure).
(g) CHP / Inspection reports duly signed by the Inspector of the Employer and
Contractor for the agreed Customer Hold Points.
(h) Certificate of Conformance (COC) wherever applicable.
(i) MDCC
9.03.03 Similarly, the contractor shall be required to submit two sets (two hard copies and
two CD ROMs), containing QA Documentation pertaining to field activities as per
Approved Field Quality Plans and other agreed manuals/ procedures, prior to
commissioning of individual system.
9.03.04 Before dispatch / commissioning of any equipment, the Supplier shall make sure that
the corresponding quality document or in the case of protracted phased deliveries,
the applicable section of the quality document file is completed. The supplier will
then notify the Inspector regarding the readiness of the quality document (or
applicable section) for review.
(a) If the result of the review carried out by the Inspector is satisfactory, the
Inspector shall stamp the quality document (or applicable section) for
release.
(b) If the quality document is unsatisfactory, the Supplier shall endeavor to

correct the incompleteness, thus allowing to finalize the quality document (or
applicable section) by time compatible with the requirements as per contract
documents. When it is done, the quality document (or applicable section) is
stamped by the Inspector.
(c) If a decision is made for dispatch, whereas all outstanding actions cannot be
readily cleared for the release of the quality document by that time, The
supplier shall immediately, upon shipment of the equipment, send a copy of
the quality document Review Status signed by the Supplier Representative to
the Inspector and notify of the committed date for the completion of all
outstanding actions & submission. The Inspector shall stamp the quality

CLAUSE NO.
document for applicable section when it is effectively completed. The

submission of QA documentation package shall not be later than 3 weeks
after the dispatch of equipment.
9.03.05 Transmission of QA Documentation
On release of QA Documentation by Inspector, one set of quality document shall be

forwarded to Corporate Quality Assurance Department and other set to respective
Project Site of Employer.
For the particular case of phased deliveries, the complete quality document to the
Employer shall be issued not later than 3 weeks after the date of the last delivery of
equipment.
9.04.00 Project Manager's Supervision
9.04.01 To eliminate delays and avoid disputes and litigation, it is agreed between the
parties to the Contract that all matters and questions shall be referred to the Project
Manager and without prejudice to the provisions of 'Arbitration' clause in Section
GCC of Vol.I, the Contractor shall proceed to comply with the Project Manager's
decision.
9.04.02 The work shall be performed under the supervision of the Project Manager. The
scope of the duties of the Project Manager pursuant to the Contract will include but
not be limited to the following:
(a) Interpretation of all the terms and conditions of these documents and
specifications:
(b) Review and interpretation of all the Contractor's drawing, engineering data,
etc.
(c) Witness or his authorized representative to witness tests and trials either at
the manufacturer's works or at site, or at any place where work is performed
under the contract:
(d) Inspect, accept or reject any equipment, material and work under the
contract:
(e) Issue certificate of acceptance and/or progressive payment and final
payment certificates.
(f) Review and suggest modifications and improvement in completion schedules
from time to time, and
(g) Supervise Quality Assurance Programme implementation at all stages of the
works.
9.05.00 Inspection, Testing and Inspection Certificates
9.05.01 The word 'Inspector' shall mean the Project Manager and/or his authorized
representative and/or an outside inspection agency acting on behalf of the Employer
to inspect and examine the materials and workmanship of the works during its
manufacture or erection.
9.05.02 The Project Manager or his duly authorized representative and/or an outside
inspection agency acting on behalf of the Employer shall have access at all
reasonable times to inspect and examine the materials and workmanship of the
works during its manufacture or erection and if part of the works is being

CLAUSE NO.
manufactured or assembled on other premises or works, the Contractor shall obtain

for the Project Manager and for his duly authorized representative permission to
inspect as if the works were manufactured or assembled on the Contractor's own
premises or works.
9.05.03 The Contractor shall give the Project Manager/Inspector fifteen (15) days written
notice of any material being ready for testing. Such tests shall be to the Contractor's
account except for the expenses of the Inspector's. The Project Manager/Inspector,
unless the witnessing of the tests is virtually waived and confirmed in writing, will
attend such tests within fifteen (15) days of the date on which the equipment is
noticed as being ready for test/inspection failing which the contractor may proceed
with test which shall be deemed to have been made in the inspector's presence and
he shall forthwith forward to the inspector duly certified copies of test reports in two
(2) copies.
9.05.04 The Project Manager or Inspector shall within fifteen (15) days from the date of
inspection as defined herein give notice in writing to the Contractor, or any objection
to any drawings and all or any equipment and workmanship which is in his opinion
not in accordance with the contract. The Contractor shall give due consideration to
such objections and shall either make modifications that may be necessary to meet
the said objections or shall inform in writing to the Project Manager/Inspector giving
reasons therein, that no modifications are necessary to comply with the contract.
9.05.05 When the factory tests have been completed at the Contractor's or sub-contractor's
works, the Project Manager /Inspector shall issue a certificate to this effect fifteen
(15) days after completion of tests but if the tests are not witnessed by the Project
Manager /Inspectors, the certificate shall be issued within fifteen (15) days of the
receipt of the Contractor's test certificate by the Project Manager /Inspector. Project
Manager /Inspector to issue such a certificate shall not prevent the Contractor from
proceeding with the works. The completion of these tests or the issue of the
certificates shall not bind the Employer to accept the equipment should it, on further
tests after erection be found not to comply with the contract.
9.05.06 In all cases where the contract provides for tests whether at the premises or works
of the Contractor or any sub-contractor, the Contractor, except where otherwise
specified shall provide free of charge such items as labour, material, electricity, fuel,
water, stores, apparatus and instruments as may be reasonably demanded by the
Project Manager /Inspector or his authorized representatives to carry out effectively
such tests on the equipment in accordance with the Contractor and shall give
facilities to the Project Manager/Inspector or to his authorized representative to
accomplish testing.
9.05.07 The inspection by Project Manager / Inspector and issue of Inspection Certificate
thereon shall in no way limit the liabilities and responsibilities of the Contractor in
respect of the agreed Quality Assurance Programme forming a part of the contract.
9.05.08 To facilitate advance planning of inspection in addition to giving inspection notice as
specified at clause no 9.05.03 of this chapter, the Contractor shall furnish quarterly
inspection programme indicating schedule dates of inspection at Customer Hold
Point and final inspection stages. Updated quarterly inspection plans will be made
for each three consecutive months and shall be furnished before beginning of each
calendar month.

CLAUSE NO.
9.05.09 All inspection, measuring and test equipment used by contractor shall be calibrated
periodically depending on its use and criticality of the test/measurement to be done.
The Contractor shall maintain all the relevant records of periodic calibration and
instrument identification, and shall produce the same for inspection by NTPC.
Wherever asked specifically, the contractor shall re-calibrate the measuring/test
equipment in the presence of Project Manager / Inspector.
9.06.00 Associated Document for Quality Assurance Programme
9.06.01 List of items requiring quality plan and sub supplier approval. Format No.: QS-01-
QAI-P-01/F3-R0 (Annexure-II).
9.06.02 Status of items requiring Quality Plan and sub supplier approval. Format No.: QS-
01-QAI-P-02/F1-R0 (Annexure-III).
9.06.03 Field Welding Schedule Format No.: QS-01-QAI-P-02/F2 (Annexure-IV).
9.06.04 Manufacturing Quality Plan Format No.: QS-01-QAI-P-09/F1-R0 (Annexure-V).
9.06.05 Field Quality Plan Format No.: QS-01-QAI-P-09/F2-R0 (Annexure-VI).
The above formats are enclosed Annexure-III to VII.
10.00.00 PRE-COMMISSIONING AND COMMISSIONING FACILITIES
(a) As soon as the facilities or part thereof has been completed operationally and
structurally and before start-up, each item of the equipment and systems
forming part of facilities shall be thoroughly cleaned and then inspected
jointly by the Employer and the Contractor for correctness of and
completeness of facility or part thereof and acceptability for initial pre-
commissioning tests, commissioning and start-up at Site. The list of pre-
commissioning tests to be performed shall be as mutually agreed and
included in the Contractor's quality assurance programme as well as those
included elsewhere in the Technical Specifications.
(b) The Contractor's pre-commissioning/ commissioning/start-up engineers,

specially identified as far as possible, shall be responsible for carrying out all
the pre-commissioning tests at Site. On completion of inspection, checking
and after the pre-commissioning tests are satisfactorily over, the
commissioning of the complete facilities shall be commenced during which
period the complete facilities, equipments shall be operated integral with sub-
systems and supporting equipment as a complete plant.
(c) All piping system shall be flushed; air blown as required and cleanliness
demonstrated using acceptable industry standards. Procedures to
accomplish this work shall be submitted for approval to the Employer six
months prior to the respective implementations. The Employer will approve
final verification of cleanliness.
(d) The time consumed in the inspection and checking of the units shall be
considered as a part of the erection and installation period.

CLAUSE NO.
(e) The check outs during the pre - commissioning period should be
programmed to follow the construction completion schedule. Each
equipment/system, as it is completed in construction and turned over to
Employer's commissioning (start-up) Engineer(s), should be checked out and
cleaned. The checking and inspection of individual systems should then
follow a prescribed commissioning documentation [SLs (Standard Check
List) / TS (Testing Schedule) / CS (Commissioning Schedule)] approved by
the Employer.
(f) Contractor shall furnish the commissioning organization chart for review &
acceptance of employer at least eighteen months prior to the schedule date
of synchronization of 1st unit. The chart should contain:
(1) Bio data including experience of the Commissioning Engineers.

(2) Role and responsibilities of the Commissioning Organization
members.
(3) Expected duration of posting of the above Commissioning Engineers
at site.
10.01.00 Initial Operation
(a) On completion of all pre-commissioning activities / tests and as a part of

commissioning the complete facilities shall be put on 'Initial Operation' during
which period all necessary adjustments shall be made while operating over
the full load range enabling the facilities to be made ready for the Guarantee
Tests.
(b) The Initial Operation shall be considered successful, provided that each item/
part of the facility can operate continuously at the specified operating
characteristics, for the period of Initial Operation with all operating
parameters within the specified limits and at or near the predicted
performance of the equipment/ facility.
(c) The Contractor shall intimate the Employer about the commencement of
initial operation and shall furnish adequate notice to the Employer in this
respect.
(d) An Initial Operation report comprising of observations and recordings of

various parameters to be measured in respect of the above Initial Operation
shall be prepared by the Contractor. This report, besides recording the
details of the various observations during initial operation shall also include
the dates of start and finish of the Initial Operation and shall be signed by the
representatives of both the parties. The report shall have sheets, recording
all the details of interruptions occurred, adjustments made and any minor
repairs done during the Initial Operation. Based on the observations,
necessary modifications/repairs to the piping system/equipment shall be
carried out by the Contractor to the full satisfaction of the Employer to enable
the latter to accord permission to carry out the Guarantee tests on the
facilities. However, minor defects which do not endanger the safe operation
of the equipment, shall not be considered as reasons for with holding the
aforesaid permission.
10.02.00 Guarantee Tests

CLAUSE NO.
(a) The final test as to prove the Functional Guarantees shall be conducted at
Site by the Contractor in presence of the Employer. The contractor's
Commissioning, Start-up Engineer shall make the unit ready to conduct such
test. Such test will be commenced, within a period of three (3) months after
the successful completion of Initial Operations. Any extension of time beyond
the above three (3) months shall be subject to Employer's approval.
(b) These tests shall be binding on both the parties of the Contract to determine
compliance of the equipment with the functional guarantee.
(c) For performance/ demonstration tests instrumentations, of accuracy class, to

the approval of the Employer shall be used. The numbers and location of the
instruments shall be as per the specified test codes.
(d) Any special equipment, tools and tackles required for the successful
completion of the Guarantee Tests shall be provided by the Contractor, free
of cost.
(e) The Guarantee tests and specific tests to be conducted on equipments have
been brought out in detail elsewhere in the specification.
11.00.00 TAKING OVER
Upon successful completion of Initial Operations and all the tests conducted to the
Employer's satisfaction, the Employer shall issue to the Contractor a Taking over
Certificate as a proof of the final acceptance of the equipment. Such certificate shall
not unreasonably be with held nor will the Employer delay the issuance thereof, on
account of minor omissions or defects which do not affect the commercial operation
and/or cause any serious risk to the equipment. Such certificate shall not relieve the
Contractor of any of his obligations which otherwise survive, by the terms and
conditions of the Contract after issuance of such certificate.
12.00.00 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION
In addition to the requirements given in Erection Conditions of Contract (ECC) the

following shall also cover:
(a) Working platforms should be fenced and shall have means of access.
(b) Ladders in accordance with Employer's safety rules for construction and
erection shall be used. Rungs shall not be welded on columns. All the stairs
shall be provided with handrails immediately after its erection.
13.00.00 NOISE LEVEL
The equivalent 'A' weighted sound pressure level measured at a height of 1.5 m
above floor level in elevation and at a distance of one (1) metre horizontally from the
nearest surface of any equipment / machine, furnished and installed under these
specifications, expressed in decibels to a reference of 0.0002 microbar, shall not
exceed 85 dBA except for

CLAUSE NO.
(a) Safety valves and associated vent pipes for which it shall not exceed 105
dBA.
(b) Regulating drain valves in which case it shall be limited to 90 dBA.
14.00.00 PACKAGING AND TRANSPORTATION
All the equipments shall be suitably protected, coated, covered or boxed and crated
to prevent damage or deterioration during transit, handling and storage at Site till the
time of erection. While packing all the materials, the limitation from the point of view
of the sizes of railway wagons available in India should be taken account of. The
Contractor shall be responsible for any loss or damage during transportation,
handling and storage due to improper packing. The Contractor shall ascertain the
availability of Railway wagon sizes from the Indian Railways or any other agency
concerned in India well before effecting dispatch of equipment. Before dispatch it
shall be ensured that complete processing and manufacturing of the components is
carried out at shop, only restricted by transport limitation, in order to ensure that site
works like grinding, welding, cutting & preassembly to bare minimum. The
Employer's Inspector shall have right to insist for completion of works in shops
before dispatch of materials for transportation.
15.00.00 ELECTRICAL ENCLOSURE
All electrical equipments and devices, including insulation, heating and ventilation
devices shall be designed for ambient temperature and a maximum relative humidity
as specified elsewhere in the specification.
16.00.00 INSTRUMENTATION AND CONTROL
All instrumentation and control systems/ equipment/ devices/ components, furnished

under this contract shall be in accordance with the requirements stated herein,
unless otherwise specified in the detailed specifications.
16.01.00 All instrument scales and charts shall be calibrated and printed in metric units and
shall have linear graduation. The ranges shall be selected to have the normal
reading at 75% of full scale.
All scales and charts shall be calibrated and printed in Metric Units as follows:
(a) Temperature - Degree centigrade (deg C)
(b) Pressure - Kilograms per square centimeter (Kg/cm2)
Pressure instrument shall have the unit suffixed with 'a' to indicate absolute
pressure. If nothing is there, that will mean that the indicated pressure is gauge
pressure.
(c) Draught - Millimeters of water column (mm wc).

(d) Vacuum - Millimeters of mercury column (mm Hg) or
water column (mm Wcl).
(e) Flow (Gas) - Tonnes/ hour
(f) Flow (Steam) - Tonnes/ hour

CLAUSE NO.
(g) Flow (Liquid) - Tonnes / hour

(h) Flow base - 760 mm Hg. 15 deg.C
(i) Density Grams per cubic centimeter.
16.02.00 All instruments and control devices provided on panels shall be of miniaturized
design, suitable for modular flush mounting on panels with front draw out facility and
flexible plug-in connection at rear.
16.03.00 All electronic modules shall have gold plated connector fingers and further all input
and output modules shall be short circuit proof. These shall also be tropicalised &
components shall be of industrial grade or better.
17.00.00 ELECTRICAL NOISE CONTROL
The equipment furnished by the Contractor shall incorporate necessary techniques

to eliminate measurement and control problems caused by electrical noise. Areas in
Contractor’s equipment which are vulnerable to electrical noise shall be hardened to
eliminate possible problems. Any additional equipment, services required for
effectively eliminating the noise problems shall be included in the proposal. The
equipment shall be protected against ESD as per IEC-801- 2. Radio Frequency
interference (RFI) and Electro Magnetic Interference (EMI) protection against
hardware damage and control system mal-operations/errors shall be provided for all
systems.
18.00.00 INSTRUMENT AIR SYSTEM
The instrument air supply system as supplied by the Contractor for various
pneumatic control & instrumentation devices like pneumatic actuators, power
cylinders, E/P converters, piping / tubing etc. shall be as per the details furnished
elsewhere.
Each pneumatic instrument shall have an individual air shut - off valve. The pressure
regulating valve shall be equipped with an internal filter, a 50 mm pressure gauge
and a built-in filter housing blow down valve.
19.00.00 TAPPING POINTS FOR MEASUREMENTS
Tapping points shall include probes, wherever applicable, for analytical

measurements and sampling.
For direct temperature measurement of all working media, one stub with internal
threading of approved pattern shall be provided along with suitable plug and washer.
The Contractor will be intimated about thread standard to be adopted.
The following shall be provided on equipment by the Contractor. The standard which
is to be adopted will be intimated to the Contractor.
(a) Temperature test pockets with stub and thermo well
(b) Pressure test pockets
20.00.00 ELECTRONIC MODULE/COMPONENT DETAILS

CLAUSE NO.
The Bidder shall have to furnish all technical details including circuit diagrams,
specifications of components, etc., in respect of each and every electronic
card/module as employed on the various solid state as well as microprocessor
based systems and equipment including conventional instruments, peripherals etc.
It is mandatory for the Bidder to identify clearly the custom built ICs used in the
package. The Bidder shall also furnish the details of any equivalents of the same.
21.00.00 JUNCTION BOXES
The junction boxes shall be made of minimum 2 mm thick sheet steel. Gland plates
shall be removable type and made of 3 mm thick sheet steel. The boxes shall be
provided with detachable cover or hinged door with captive screws. Top of the box
shall be arranged to slope towards the rear of the box. The box shall be hot dip
galvanized and shall be provided with suitable neoprene gaskets to achieve degree
of protection of IP-55 as per IS: 2147. Adequate spacing shall be provided to
terminate the external cables. The boxes shall be suitable for mounting on various
types of steel structures. The terminal blocks provided shall be of 650 V grade, rated
for 10 A for control cables. Suitable numbering for terminal blocks shall be done. In
case of junction box for power cable, the box shall be rated for maximum current
carrying capacity. Terminal blocks shall be of one piece, klippon RSF-1 or ELMEX
CSLT-1 type with insulating barriers.
22.00.00 SPECIFIC REQUIREMENT FOR DC PANELS
22.01.00 DC starter shall essentially consist of following:-
(a) One (1) - Double pole 220 V D.C. air break switch and HRC fuses.
(b) One (1) - Double pole 220 V D.C. contactor with 2 NO and 2 NC contacts.
(c) Contactors and timers as required for the control scheme.
(d) Overload relay (for alarm only).
(e) Shunt and ammeter for motors rated 15 KW an above.
(f) One (1) - Red indicating lamp to give motor 'ON' indication.
(g) One (1) - Green indicating lamp to give motor 'OFF' indication.
(h) Starting resistor.
The resistance shall be air cooled, stainless steel grid type, suitable for 220 V DC
and continuously rated. The resistance shall be provided with sheet steel covers with
louvers and canopy type top cover.

CLAUSE NO.
ANNEXURE-I
-------------------------------------------------------------------------------------------------------
S. NO. DESCRIPTION OF DOCUMENTS NO OF NO. OF
PRINTS CD-ROMs
-------------------------------------------------------------------------------------------------------
1. Drawings "FOR APPROVAL"
i) Layout drawings / P&IDs 6 2 CD-ROMs

ii) Other drawings 2 2 CD-ROMs
2. Drawings "FOR INFORMATION" 2 2 CD-ROMs
3. Drawings "FINAL DRAWING" 15 4 CD-ROMs
4. Drawings "AS BUILT” 15 4 CD-ROMs
5. Datasheets, Design Calculations,

Purchase Specifications etc.
and other type of Documents
i) For Approval 2 2 CD-ROMs
ii) FINAL 15 4 CD-ROMs
iii) Analysis reports of equipments/ 2 2 CD-ROMs

Piping/ structures components/
Systems employing software
Packages as detailed in the
Specifications including
input / output data
6. Erection manual
“1ST SUBMISSION” 4 sets 2 CD-ROMs
7. Erection manual "FINAL" 4 sets 4 CD ROMS
8. Operation & Maintenance 4 sets 2 CD-ROMs

Manual "1ST SUBMISSION”
9. Operation & Maintenance manual 4 sets 4 CD ROMS

"FINAL"
10. Commissioning and Performance 4 sets 2 CD-ROMs

Procedure manual
"1 ST SUBMISSION"
11. Commissioning and Performance 4 sets 4CD-ROMs

Procedure manual "FINAL"
12. Performance and Functional 4 sets 4CD-ROMs

GURANTEES
TEST REPORT

CLAUSE NO.
ANNEXURE-I
-------------------------------------------------------------------------------------------------------
S. NO. DESCRIPTION OF DOCUMENTS NO OF NO. OF
PRINTS CD-ROMs
-------------------------------------------------------------------------------------------------------
13. Project completion report 15 4 CD ROMS
14. QA programme including 1 1 CD ROM

Organization for implementation
and QA system manual
(with revision-servicing)
15. Vendor details in respect of 1 1 CD ROM

proposed vendors including
contractor's evaluation report.
16. Manufacturing QPs, Field QPs,

Field welding schedules and their
reference documents like test
procedures, WPS, POR etc.
i) For review/comment 2 2 CD-ROMs
(ii) For final approval 2 2 CD-ROMs
17. Welding Manual, Heat Treatment

Manuals, Storage & preservation
manuals
1st SUBMISSION 4 sets 2 CD-ROMs
Final 4 sets 4 CD-ROMs
18. QA Documentation Package for

Items/equipment manufactured
and dispatched to site 2 4 CD ROMS
19. QA Documentation Package for

field activities on equipment /
systems at site 2 4 CD ROMS
-------------------------------------------------------------------------------------------------------

ANNEXURE-II
LIST OF ITEMS REQUIRING QUALITY PLAN AND SUB SUPPLIER APPROVAL
Project
ANNEXURE- I
Package Doc No :CS
MAIN CONTRACTOR Rev No : 0

Date :
Contract No
SL Item QP / QP No Proposed Subvendor Place of SC Appl Remarks
No Insp.Cat Manufacturer Status / Comm
4
5
6
7
9
10
11
12
13
DARLIPALI STPP STAGE-I (2X800 MW) TECHNICAL SPECIFICATIONS Sub-Section – GTR Page 35 of 39
MAKE-UP WATER PIPES PACKAGE SECTION-VI - PART-C GENERAL TECHNICAL REQUIREMENTS
ANNEXURE-III
Project : Stage STATUS OF ITEM REQUIRING QP & DOC. NO. :
Package : SUB-SUPPLIER APPROVAL REV. NO. :
Contractor : DATE :
Contractor No. : PAGE : OF
S.No. ITEM/SERVICE QP/Insp. QP Sub. Date of Date of Status Proposed Place of Approval Sub- Remarks
Cat. Schedule Sub- commt. Code Sub-suppliers manufacturing status supplier
Approval mission Appl. C/II/I works detail
Schedule submission
schedule
FORMAT NO. : QS-01-QAI-P-02/F1-R0 1/1 Engg.Div./QA&I
ANNEXURE-IV
Project : Stage FIELD WELDING SCHEDULE DOC. NO. :
Contractor : (To be raised by the Contractor) REV. NO. :
Contractor No. : Welding Code …………………………………. DATE :
System : PAGE : OF
Sl. DRG. No. for Description Matl. Dimensions Process of Type Electrode WPS. Min. Heat treatment NDT REF Remarks
No. Weld Location of parts to Spec. welding of filler No. pre- method/
Temp. Holding Spec. ACC
and welded weld spec. heat Quantum
time No. Norm
Identification
Ref.
mark
NOTES:
SIGNATURE
FORMAT NO.: QS-01-QAI-P-02/F2-R0 1/1 Engg. Div./QA&I
ANNEXURE-V
MFGR’S MANUFACTURER’S NAME MANUFACTURING QUALITY PLAN PROJECT :
LOGO & ADDRESS ITEM QP NO. PACKAGE :
REV.NO.: CONTRACT NO. :
DATE :
MAIN-SUPPLIER :
SUB-SYSTEM PAGE: ………. OF ……..
SL. COMPONENT & CHARACTERISTICS CLASS TYPE OF QUANTUM REFERERNCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO. OPERATIONS CHECK OF CHECK DOCUMENT NORMS RECORD
M C N
1 2 3 4 5 6 7 8 9 D ** 10 11
LEGEND : * RECORDS, IDENTIFIED WITH "TICK" () SHALL BE ESSENTIALLY DOC. NO. : REV. …………. CAT ………….
INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
MANUFACTURER/ MAIN-SUPPLIER
SUB-SUPPLIER ** M : MANUFACTURER / SUB-SUPPLIER
C: SUPPLIER/NOMINATED INSPECTION AGENCY, N : NTPC/EMPLOYEER

SIGNATURE FOR NTPC
P: PERFORM W : WITNESS AND V : VERIFICATION, AS
USE
APPROPRIATE
REVIEWED APPROVED APPROVAL
CHP : NTPC/EMPLOYEER SHALL IDENTIFIED IN COLUM "N" BY BY SEAL
FORMAT NO.: - QS-01-QAI-P-09/F1-R0 1/1 ENGINEERING DIV. / QA&I
ANNEXURE-VI
SUPPLIER’S SUPPLIER’S NAME FIELD QUALITY PLAN DOC. NO. :
LOGO & ADDRESS ITEM QP NO. PACKAGE :
REV.NO.: CONTRACT NO. :
DATE :
MAIN-SUPPLIER :
SUB-SYSTEM PAGE: ………. OF ……..
SL. ACTIVITY AND CHARACTERISTICS/INSTRUMENTS CLASS# TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF REMARKS
NO. OPERATION OF CHECK OF CHECK DOCUMENT NORMS RECORD
CHECK
1 2 3 4 5 6 7 8 9 D* 10
LEGEND : * RECORDS, IDENTIFIED WITH "TICK" () SHALL BE DOC. NO. : REV. …………. CAT
ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION ………….
MANUFACTURER/ MAIN-SUPPLIER LEGEND TO BE USED : CLASS # : A - CRITICAL, B = MAJOR, C =

SUB-SUPPLIER MINOR; "A' SHALL BE WITNESSED BY NTPC/EMPLOYEER FQA,
'B' SHALL BE WITNESSED BY NTPC/EMPLOYEER ERECTION /
SIGNATURE CONSTRUCTION DEPTT. AND 'C' SHALL BE WITNESSED BY FOR NTPC
ERECTION SUPPLIER (A & B CHECK SHALL BE USE
NTPC/EMPLOYEER CHP STAGE) REVIEWED APPROVED APPROVAL
BY BY SEAL
FORMAT NO.: - QS-01-QAI-P-09/F2-R0 1/1 ENGINEERING DIV. / QA&I
PART- D
ERECTION CONDITIONS OF
CONTRACT
CLAUSE NO. ERECTION CONDITIONS OF CONTRACT
ERECTION CONDITIONS OF CONTRACT
1.00.00 GENERAL
1.01.00 The following provisions shall supplement the conditions already contained in the
other parts of these specifications and documents and shall govern that portion of
the work of this contract which is to be performed at site. The erection requirements
and procedures not specified in these documents shall be in accordance with the
recommendations of the equipment manufacturer, or as mutually agreed to between
the Employer and the Contractor prior to commencement of erection work.
1.02.00 The Contractor upon signing of the Contract shall, in addition to a Project Co-
ordinator, nominate another responsible officer as his representative at Site suitably
designated for the purpose of overall responsibility and co-ordination of the Works to
be performed at Site. Such a person shall function from the Site office of the
Contractor during the pendency of Contract.
2.00.00 REGULATION OF LOCAL AUTHORITIES AND STATUTES
2.01.00 In addition to the local laws and regulations, the Contractor shall also comply with the
Minimum Wages Act and the Payment of Wages Act (both of the Government of
India) and the rules made there under in respect of its labour and the labour of its
sub-contractors currently employed on or connected with the contract.
2.02.00 All registration and statutory inspection fees, if any, in respect of his work pursuant to
this Contract shall be to the account of the Contractor. However, any registration,
statutory inspection fees lawfully payable under the provisions of the Indian Boiler
Regulations and any other statutory laws and its amendments from time to time
during erection in respect of the plant equipment ultimately to be owned by the
Employer, shall be to the account of the Employer. Should any such inspection or
registration need to be re-arranged due to the fault of the Contractor or his Sub-
Contractor, the additional fees for such inspection and/or registration shall be borne
by the Contractor.
3.00.00 WELDING OF PRESSURE PARTS AND HIGH PRESSURE PIPING
The welding of all pressure parts and high-pressure piping shall be in accordance
with the following requirements:
3.01.00 Qualification of Weld Procedures
Only qualified welding procedures as per ASME Section IX shall be used by

contractor at site. Procedure qualification records along with WPS shall be
submitted to Employer for review. Welding procedure shall indicate all essential and
non-essential parameters as per ASME Section IX. Makes of welding consumables
shall be subject to employer’s approval.
DARLIPALI STPP STAGE-I (2X800 MW) TECHNICAL SPECIFICATION ERECTION

MAKE-UP WATER PIPES PACKAGE SECTION-VI CONDITIONS OF PAGE 1 OF 50
BID DOCUMENT NO: CS- 9549-132D-2 PART-D CONTRACT
3.02.00 Welder's Qualification
Only welders who are qualified in accordance with the latest applicable requirements
of the Indian Boiler Regulations, shall be permitted to perform any welding work on
the pressure parts and its attachment welding. In addition to such statutory
qualification requirements, the welders shall also undergo a satisfactory pre-
production qualification test to be conducted by the Contractor at site as per ASME
Sec IX in presence of employer’s representative(s), prior to performing work under
these specifications. The services of an independent testing laboratory shall be
retained by the Contractor to perform welder qualification tests for welders.
All the welders carrying out welding at site shall carry an identification badge, which
shall indicate the category and the grade of welding for which they have been tested
and authorised to carry out welding. All such badges shall be countersigned by the
Employer.
3.03.00 Records
Welders performance shall be monitored regularly and record of their performance

shall be maintained by contractor in a manner acceptable to the employer.
Contractor shall maintain such records including record of procedure qualification &
welder qualification and hand-over to the employer at the end of work.
3.04.00 MARKING
On completion of each welded joint, the welder shall mark his regularly assigned
identification mark near the joint. The welder's identification numbers, inspection
stamps or code symbol stamps and any other information shall not be directly
stamped on any alloy steel piping. In alloy steel piping, all such information shall be
stamped on separate marking plate which shall be tack welded on pipe near the
weld.
4.00.00 HEAT TREATMENT
4.01.00 Pre-heating, post-heating and post-weld stress relief operations of all welds, shall be
performed in accordance with the requirements of applicable code. Local post weld
stress relieving heat - treatments shall be adopted only in cases where it is normally
impracticable to subject the entire assembly as such for stress relieving operations.
Heating may be by means of electric induction coils or electric resistance coils. Oxy-
acetylene flame heating or exothermic chemical heating methods will not be
permitted. Complete recording of the temperatures through out the stress relieving
cycle of the material and the weld subjected to heat treatment shall be made by
means of a potentiometric recorder. Recorders other than those of potentiometric
type shall not be used for such temperature recording during stress relieving
operations.

The contractor & employer’s representative, at start and at the end of HT Cycle shall
sign the time and temperature charts for heat-treatment.
4.02.00 After setting up the weld joint for heat treatment operation, the Employer's signature
shall be obtained on the strips chart of the recorder prior to starting of heat treatment
cycle. The right hand corner of the strip chart at the starting point of the heat
treatment cycle shall contain details like the weld number, material, diameter and
thickness, method of heating adopted, prescribed ranges of heat treatment
temperatures, date of heat treatment, reference to item number of the Field welding
Schedule (as specified at clause no 7.00.00- of this chapter) etc.
5.00.00 WELD EDGE PREPARATION
Preparation at site of weld joint shall be in accordance with details acceptable to the
Employer. Wherever possible, machining or automatic flame cutting shall be used for
edge preparation. Hand flame cutting will be permitted only where edge preparation
otherwise is impractical. All slag shall be removed from cuts and all the hand cuts
shall be ground smooth to the satisfaction of the Employer. Flame cutting of alloy
steel pipe shall be avoided. Wherever such cutting is done, a 200mm length at the
cut face shall be removed by machining. Pneumatic hand tools such as edge
preparation, tube cutting machine can be used.
6.00.00 CLEANING AND SERVICING
6.01.00 The inside of all tubes, pipes, valves and fittings shall be free from dirt, and loose
scales before being erected. All the pipelines shall be thoroughly blown and/or
flushed. Each steam and water tubes shall be blown with compressed air and shall
be subjected to 'ball test' before erection to ensure that no obstructions exist. A
system for recording of all such operations shall be developed and maintained in a
manner to ensure that no obstructions are left inside the tubes and no tubes are left
uncleaned and untested.
6.02.00 All valves and valve actuators, and dampers and damper actuators, if any, shall be
thoroughly cleaned and serviced prior to pre-commissioning tests and/or Initial
Operations of the plant. A system for recording of such servicing operation shall be
developed and maintained in a manner acceptable to the Employer and to ensure
that no valves or dampers including their actuators are left unserviced.
6.03.00 All interior surfaces of the turbine shall be thoroughly cleaned prior to boxing - up to
remove all traces of oil preservations.
7.00.00 FIELD WELDING SCHEDULE
The Contractor shall submit to the Employer, a certified and complete field welding
schedule for all the field welding activities to be carried out in respect of the pressure
parts involved in the equipment furnished and erected by him, at least 90 days prior
to the scheduled start of erection work at site. Such schedule will be strictly followed
by the Contractor during the process of erection. The above field-welding schedule to
be issued by the Contractor shall contain the following:

(a.) Drawing No (s)
(a.) Location of the weld
(a.) Size of the weld (outside diameter and thickness)
(a.) Type of joints
(a.) Material specifications
(a.) Size of fillet on backing ring, when the type of joint is with backing ring
(a.) Electrode/ filler metal specifications
(a.) Number of welds per unit
(a.) Quantity of filler metal per weld
(a.) Indication of required Non-destructive Examination (NDE) for each weld
(a.) Pre-heat temperatures for welding
(a.) Process of welding
(a.) Post-welding heat treatment temperature ranges, duration, under as specified

at clause no 4.00.00- of this chapter entitled "Heat Treatment".
(a.) Qualification details of weld procedures to be adopted as specified under as

specified at clause no 3.01.00- of this chapter entitled 'Qualification of Weld
Procedures'.
8.00.00 SITE RUN MISCELLANEOUS PIPING
Sketches or diagrams of the proposed routings of all piping, not already indicated
and routed on the shop drawings which were reviewed by the Employer, shall be
submitted to the Employer for review, Employer's acceptance of such site routings
shall be obtained before the piping is erected. All these site run piping shall be
installed in such a manner as to present an orderly and neat installation. They shall
be located as to avoid obstruction of access and passages. Valves, instruments or
any other special items shall be located convenient for operation by the operating
personnel. Pipe runs shall be plumb or level except where pitch for drainage is
required. Pipe runs that are not parallel to the building structure, walls or column
rows shall be avoided so that deflection of pipes between hangers does not exceed 6
mm. No miscellaneous pipe shall be routed and installed above or adjacent to
electrical equipment.
9.00.00 THERMAL EXPANSIONS
All piping installation shall be such that no excessive or destructive expansion forces
exist either in the cold condition or under condition of maximum temperature. All

bends, expansion joints and any other special fittings, necessary to provide proper
expansion, shall be incorporated. During installation of expansion joints and anchors,
care must be taken to make sure that full design movement is available at all times
for maximum to minimum temperature and vice-versa.
10.00.00 PIPING SUPPORTS
10.01.00 Hangers, supports and anchors shall be installed as required to obtain a safe,
reliable and complete pipe installation. All supports shall be properly levelled and
anchored when installed. The anchors shall be so placed that thermal expansion will
be absorbed by bends without subjecting the valves or equipment to excessive
strains.
10.02.00 The hanger assemblies shall not be used for the attachment of rigging to hoist the
pipe into place. Other means shall be used to securely hold the pipe in place till the
pipe support is completely assembled and attached to the pipe and building
structures and spring support is set to accommodate the pipe way. All temporary
rigging shall be removed in such a way that the pipe support is not subjected to any
sudden load. All piping, having variable spring type supports, shall be held securely
in place by temporary means during the hydraulic test of pipe system. Constant
support type spring hangers used during hydraulic test shall be pinned or blocked
solid during the test. After complete installation and insulation of the piping and filling
of the piping with its normal operating medium, the pipe support springs shall be
adjusted to the cold positions. If necessary, the spring support shall be re-adjusted to
the hot positions after the line has been placed for service at its normal maximum
operating temperature conditions. Electric arc welding only shall be used to weld all
pipe supports to structural steel members that form part of the building supporting
structure. The structural beams shall not be heated more than necessary during
welding of supports and such welds shall run parallel to the axis of the span. All lugs
or any other attachments welded to the piping shall be of the same material as the
pipe.
11.00.00 PRESSURE TESTING
11.01.00 On completion of erection of pressure parts, a hydraulic test in accordance with the
requirements of the Indian Boiler Regulations shall be performed by the Contractor.
11.02.00 All the valves, high pressure pipes and inter-connected pipes connecting the
pressure parts shall be tested along with pressure parts. All blank flanges or any
removable plugs required for openings not closed by the valves, and piping provided,
shall be furnished by the Contractor. The pressurization equipment including water
piping from the supply, needed for the above test shall also be furnished by the
Contractor. Any defects noticed during the testing are to be rectified and the unit re-
tested. If any welding is done on the pressure parts after the Hydraulic test, the
Hydraulic test for that portion of pressure parts shall be repeated.

11.03.00 Thy hydraulic test shall be considered successful only on certification to that effect by
the concerned inspecting Authority as per the provisions of the Indian Boiler
Regulations and the Employer.
12.00.00 THERMOWELLS AND FLOW NOZZLES
12.01.00 All the thermowells and flow nozzles in the equipment furnished under the technical
specifications shall be installed as a part of this work.
12.02.00 All thermowell connections incorporated in the steam service shall be plugged during
the pressure testing and the blow out of steam piping systems. Upon completion of
the blow out operation, all thermowells shall be installed and seam welded. Similarly,
all flow nozzles in the steam lines shall also be installed only on completion of steam
blowing operations unless otherwise agreed to by the Employer, depending upon the
sequence of cleaning and purging operations to be adopted by the Contractor at the
field.
13.00.00 INSULATION, LAGGING AND CLADDING
The provision of insulation, lagging and cladding of the various equipments and
portion of the equipment covered under the Contract, shall be furnished by the
Contractor as specified elsewhere or agree to separately in writing. Welds required
for holding insulation on pressure parts shall be carried out by IBR qualified welder.
13.01.00 In case of equipment other than steam turbine, Lugs made out of MS rods of 5 mm
dia conforming to IS280 or equivalent shall be welded on the surface at intervals of
250 mm pitch zigzag to support insulation. Mineral wool mats with wire netting on
both sides shall be applied against the surface with lugs piercing through. The edges
of mattress shall be laced together with galvanised MS 0.71 mm dia (22 SWG) IS
280 or equivalent (soft) lacing wire. Galvanized binding wire of 1.63 mm dia (16
SWG) IS 280 or equivalent (soft) will be used criss-cross between lugs to hold it. The
lugs will then be bent over the netting.
13.02.00 Unless otherwise specified, all equipment insulation shall be covered with aluminium
cladding/ jacketing. The thickness of aluminium sheet shall not be less than 0.63
mm. Galvanic corrosion shall be prevented by carefully avoiding permanent contact
of aluminium cladding with copper, copper alloys, tin, lead nickel or nickel alloys
including monel metal. Where cladding is attached to carbon steel or low alloy steels,
the steel shall first be prime painted with zinc chromate and then painted with
aluminium paint. The use of lead base paints for this purpose shall be avoided.
13.03.00 Prior to application of cladding, all surface imperfections such as ducts, cracks and
voids shall be filled with insulation cement so as to form a smooth base for the final
shall be machine rolled and formed. All overlaps at longitudinal joints shall face
downwards. The fixing of cladding shall be by means of screws and they shall be
adequate in number and be so place is such location as to produce tight joints
eliminating ' bellying'. The screws, as far as possible, shall be uniformly placed and
on centres not exceeding 150 mm except where insulated outside diameters are
smaller than 230 mm in which case spacing shall be on centres not exceeding

100mm. Self tapping type screws, of 12 mm size of stainless steel/aluminium alloy

as per the requirements shall be used. All joints wherever possible shall be lapped a
minimum of 50 mm. The overlaps of longitudinal joints shall be a 10 mm turnback
edge. Butt joints such as those at piping tees, shall be made using a rolled seam.
Suitable provisions for expansion movement shall be provided in joints. Hinged or
sliding doors for convenience shall be provided in the cladding at all access
openings, non-projecting connections, important codes stampings etc.
13.04.00 Piping, Pipe Fittings & Valves
All piping insulation and metal cladding furnished with the equipment to be erected
shall be applied as specified herein.
13.04.01 Piping
The insulation on piping shall be applied using wire loops on 150mm centres. These
wire loops shall be thoroughly embedded into the outer insulation surface and all
cracks, voids and depressions shall be filled with insulating cement suitable for the
piping temperature so as to form a smooth base for application of cladding. The
wires used for piping insulation shall be of 16 SWG. The surface shall be smooth and
uniform before applying the outer covering . All piping insulation ends shall be
terminated at a sufficient distance from flanges to facilitate removal of bolts.
13.04.02 Flanges
Insulation on flanges shall be by means of blocks of insulating material securely

bound to the flange by wire loops. Such blocks of insulation shall be long enough to
overlap the adjacent pipe insulation by an amount equal to the thickness of adjacent
pipe insulation. Smooth finish shall be obtained by the application of insulating
cement. Alternatively, sectional pipe insulation of proper diameter may be used.
Insulation on flanges shall not be done until the pipe and equipment have been in
service during the initial operation and till all the flange bolts have been re-tightened.
13.04.03 Bends and Elbows
Insulation on bends and elbows shall be cut into sections sufficiently short to form a
reasonable smooth external surface. After the application of insulation material in
place, it shall be smoothly coated with insulating cement. Elbows may be insulated
as above or alternatively by means of specially moulded insulation enclosures.
13.04.04 Cladding
Cladding shall be of aluminium sheet of thickness as per details given in detail

Technical Specification or will be provided during detail engineering shall be machine
rolled and formed to accurately fit insulation curvatures. Cladding shall be secured
using self-tapping screws. Screws shall be adequate number and so located as to

produce tight joints. The spacing of screws shall be as far as possible uniform and on
centres not exceeding 150 mm. For outside diameters less than 230 mm, spacing of
screws shall be on centres not exceeding 100 mm. adequate number of screws shall
be provided for fixing the cladding and be so placed in such locations, as to produce
a smooth cladding finish without bellying'. Insulated elbows having insulated
diameters less than 330 mm shall be provided with preformed smooth aluminium
elbow jackets. Wherever possible, all joints should be lapped a minimum of 50 mm
with joints facing downwards and so placed that they are obscured from normal
points of vision. All the joints in the cladding shall be made with suitable provisions
for expansions. All butt joints such as those at piping tees shall be made using rolled
seams. In addition, to prevent galvanic corrosion, suitable action, as stipulated as
specified at clause no 13.02.00- of this chapter, shall be taken.
13.04.05 Valves and Fittings
All valves and fittings installed in the pipelines shall also be applied with insulation
and furnished with suitably shaped boxes so as to facilitate easy dismantling of the
fittings. The insulation thickness for valves, valve fittings etc., shall be same as that
used on the line on which they are installed. All voids shall be properly filled up with
insulating material and as per the directions of the Employer.
13.05.00 Protection of Equipment during Insulation Applications
All equipment and structures shall be suitably protected from damage while applying
insulation after completion of insulation. All equipment and structures shall be
thoroughly cleaned and remove insulating materials which might have fallen on
them.
14.00.00 CODE REQUIREMENTS
The erection requirements and procedures to be followed during the installation of

the equipment shall be in accordance with the relevant Indian Electricity Rules &
Codes, Indian Boiler Regulations, ASME codes and accepted good practices, the
Employer's Drawings and other applicable Indian recognized codes and laws and
regulations of the Government of India.
15.00.00 REMOVAL OF MATERIAL
No material brought to the Site shall be removed from the Site by the Contractor
and/or his Sub-Contractors without the prior written approval of the Employer.
16.00.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES
The provisions of the clause entitled Inspection, Testing and Inspection Certificates
given in Part - C of the Technical Specification, shall also be applicable to the
erection portion of the Works. The Employer shall have the right to re-inspect any
equipment though previously inspected and approved by him at the Contractor’s
works, before and after the same are erected at Site. If by the above inspection, the
Employer rejects any equipment, the Contractor shall make good for such rejections

either by replacement or modification/ repairs as may be necessary to the

satisfaction of the Employer. Such replacements will also include the replacements
or re-execution of such of those works of other Contractors and/or agencies, which
might have got damaged or affected by the replacements or re-work done to the
Contractor’s work.
17.00.00 ACCESS TO SITE AND WORKS ON SITE
17.01.00 Suitable access to site and permission to work at the Site shall be accorded to the
Contractor by the Employer in reasonable time.
17.02.00 In the execution of the Works, no person other than the Contractor or his duly
appointed representative, Sub-Contractor and workmen, shall be allowed to do work
on the Site, except by the special permission, in writing by the Employer or his
representative.
18.00.00 CONTRACTOR’S SITE OFFICE ESTABLISHMENT
The Contractor shall establish a Office at the Site and keep posted an authorised
representative for the purpose of the Contract. Any written order or instruction of the
Employer or his duly authorised representative, shall be communicated to the said
authorised resident representative of the Contractor and the same shall be deemed
to have been communicated to the Contractor at his legal address.
19.00.00 CO-OPERATION WITH OTHER CONTRACTORS
19.01.00 The Contractor shall co-operate with all other Contractors or tradesmen of the
Employer, who may be performing other works on behalf of the Employer and the
workmen who may be employed by the Employer and doing work in the vicinity of
the works under the Contract. The Contractor shall also arrange to perform his work
as to minimise to the maximum extent possible, interference with the work of other
Contracts and their workmen. Any injury or damage that may be sustained by the
employees of the other Contractors and the Employer, due to the Contractor’s work
shall promptly be made good at his own expense. The Employer shall determine the
resolution of any difference or conflict that may arise between the Contractor and
other Contractors or between the Contractor and the workmen of the Employer in
regard to their work. If the work of the Contractor is delayed because of the any acts
of omission of another Contractor, the Contractor shall have no claim against the
Employer on that account other than an extension of time for completing his works.
Employer shall have full access to visit the contractor’s site at any time for inspection
and surveillance checks.
19.02.00 The Employer shall be notified promptly by the Contractor of any defects in the other
Contractor’s works that could affect the Contractor’s Works. The Employer shall
determine the corrective measures if any, required to rectify this situation after
inspection of the works and such decisions by the Employer shall be binding on the
Contractor.

20.00.00 DISCIPLINE OF WORKMEN
The Contractor shall adhere to the disciplinary procedure set by the Employer in
respect of his employees and workmen at Site. The Employer shall be at liberty to
object to the presence of any representative or employee of the Contractor at the
Site, if in the opinion of the Employer such employee has mis-conducted himself or is
incompetent, negligent or otherwise undesirable then the Contractor shall remove
such a person objected to and provide in his place a competent replacement.
21.00.00 CONTRACTOR’S FIELD OPERATION
21.01.00 The Contractor shall keep the Employer informed in advance regarding his field
activity plans and schedules for carrying out each part of the works. Any review of
such plan or schedule or method of work by the Employer shall not relieve the
Contractor of any of his responsibilities towards the field activities. Such reviews
shall also not be considered as an assumption of any risk or liability by the Employer
or any of his representatives and no claim of the Contractor will be entertained
because of the failure or inefficiency of any such plan or schedule or method of work
reviewed. The Contractor shall be solely responsible for the safety, adequacy and
efficiency of plant and equipment and his erection methods.
21.02.00 The Contractor shall have the complete responsibility for the conditions of the Work-
Site including the safety of all persons employed by him or his Sub-Contractor and all
the properties under his custody during the performance of the work. This
requirement shall apply continuously till the completion of the Contract and shall not
be limited to normal working hours. The construction review by the Employer is not
intended to include review of Contractor’s safety measures in, on or near the Work-
Site, and their adequacy or otherwise.
22.00.00 PHOTOGRAPHS AND PROGRESS REPORT
22.01.00 The Contractor shall furnish three (3) prints each to the Employer of progress
photographs of the work done at Site. Photographs shall be taken as and when indi-
cated by the Employer or his representative. Photographs shall be adequate in size
and number to indicate various stages of erection. Each photograph shall contain
the date, the name of the Contractor and the title of the photograph.
22.02.00 The above photographs shall accompany the monthly progress report detailing out
the progress achieved on all erection activities as compared to the schedules. The
report shall also indicate the reasons for the variance between the scheduled and
actual progress and the action proposed for corrective measures, wherever
necessary.
22.03.00 The Contractor shall submit the progress of work in VCD/ DVD/ Pendrive (2 copies)
quarterly highlighting the progress and constraints at site.
23.00.00 MAN-POWER REPORT

23.01.00 The Contractor shall submit to the Employer, on the first day of every month, a man
hour schedule for the month, detailing the man hours scheduled for the month, skill-
wise and area-wise.
23.02.00 The Contractor shall also submit to the Employer on the first day of every month, a
man power report of the previous month detailing the number of persons scheduled
to have been employed and actually employed, skill- wise and the areas of
employment of such labour.
24.00.00 PROTECTION OF WORK
The Contractor shall have total responsibility for protecting his works till it is finally
taken over by the Employer. No claim will be entertained by the Employer or the
representative of the Employer for any damage or loss to the Contractor’s works and
the Contractor shall be responsible for complete restoration of the damaged works to
original conditions to comply with the specification and drawings. Should any such
damage to the Contractor’s Works occur because of other party not being under his
supervision or control, the Contractor shall make his claim directly with the party
concerned. If disagreement or conflict or dispute develops between the Contractor
and the other party or parties concerned regarding the responsibility for damage to
the Contractor’s Works the same shall be resolved as per the provisions of the as
specified at clause no 19.00.00- of this chapter entitled “Co-operation with other
Contractors.” The Contractor shall not cause any delay in the repair of such
damaged Works because of any delay in the resolution of such disputes. The
Contractor shall proceed to repair the Work immediately and no cause thereof will be
assigned pending resolution of such disputes.
25.00.00 EMPLOYMENT OF LABOUR
25.01.00 In addition to all local laws and regulations pertaining to the employment of labour to
be complied with by the Contractor pursuant to GCC, the Contractor will be expected
to employ on the work only his regular skilled employees with experience of the
particular work. No female labour shall be employed after darkness. No person
below the age of eighteen years shall be employed.
25.02.00 All travelling expenses including provisions of all necessary transport to and from
Site, lodging allowances and other payments to the Contractor’s employees shall be
the sole responsibility of the Contractor.
25.03.00 The hours of work on the Site shall be decided by the Employer and the Contractor
shall adhere to it. Working hours will normally be eight (8) hours per day - Monday
through Saturday.
25.04.00 Contractor’s employees shall wear identification badges while on work at Site.
25.05.00 In case the Employer becomes liable to pay any wages or dues to the labour or any
Government agency under any of the provisions of the Minimum Wages Act,
Workmen Compensation Act, Contact Labour Regulation Abolition Act or any other

law due to act of omission of the Contractor, the Employer may make such payments
and shall recover the same from the Contractor’s Bills.
26.00.00 FACILITIES TO BE PROVIDED BY THE EMPLOYER
26.01.00 Space
The Contractor shall advise the Employer within thirty (30) days from the date of
acceptance of the Notification of Award about his exact requirement of space for his
office, storage area, pre-assembly & fabrication areas and toilet etc. The above
requirement shall be reviewed by the Employer and space as decided by Employer will
be allotted to the Contractor for construction of his temporary structures/ facilities like
office, storage sheds, pre-assembly and fabrication areas and toilets etc. for
Contractor's as well as his Sub-Contractor’s use.
The space requirement indicated above is for works within the Main Plant boundary.
However, for the works outside Main Plant boundary, it is within the scope of contractor
to arrange space for such facilities.
Land for staff and labor colony shall not be provided by the owner and contractor has to
make his own arrangement for the same at his own cost.
26.02.00 Electricity
The Contractor shall submit to the Employer within thirty (30) days from the date of
acceptance of the Notification of Award, his electrical power requirements, if any to
allow the planning of the same by the Employer. The Contractor shall be provided with
free supply of electricity for the purposes of the Contract, only at maximum three (3)
locations in the Employer's Site, at 415V voltage level. The Contractor shall make his
own further distribution arrangement and shall maintain a minimum drawl power factor
of 0.8, and all such devices for maintaining power factor of 0.8 or better shall be under
the scope of contractor. All temporary wiring must comply with local regulations and will
be subject to Employer's inspection and approval before connection to supply. The
supply of power will not be provided for the use in the labour and staff colony.
The power supply requirement indicated above is for works within the Main Plant
boundary. However, for the works outside Main Plant boundary, it is within the scope
of contractor to arrange power etc. for such facilities
26.03.00 Water
Contractor shall make all arrangements himself for the supply of construction water as
well as potable water.
26.04.00 Communication
The Employer will extend the Intercom telephone facilities at one point in site office, if
available at Site, for purposes of Contract.

26.05.00 Clause not used.
27.00.00 FACILITIES TO BE PROVIDED BY THE CONTRACTOR
27.01.00 Contractor's site office Establishment
The Contractor shall establish a site office at the site and keep posted an authorized
representative for the purpose of the contract, pursuant to GCC.
27.02.00 Tools, tackles and scaffoldings
The Contractor shall provide all the construction equipments, tools, tackles and
scaffoldings required for pre-assembly, installation, testing, commissioning and
conducting Guarantee tests of the equipments covered under the Contract. He shall
submit a list of all such materials to the Employer before the commencement of pre-
assembly at Site. These tools and tackles shall not be removed from the Site without
the written permission of the Employer. The Contractor shall arrange Dozer, Hydra,
Cranes, Trailer, etc. for the purpose of fabrication, erection and commissioning.
27.03.00 Testing Equipment and Facilities:
The contractor shall provide the necessary testing, equipment and facilities.
27.04.00 Site laboratory for civil works:
Contractor shall provide and maintain a site laboratory for the testing of construction
material under the direction and general supervision of employer.
27.05.00 First-aid
27.05.01 The Contractor shall provide necessary first-aid facilities for all his employees,
representatives and workmen working at the Site. Enough number of Contractor’s
personnel shall be trained in administering first-aid.
27.05.02 The Employer will provide the Contractor, in case of any emergency, the services of
an ambulance for transportation to the nearest hospital.
27.06.00 Cleanliness
27.06.01 The Contractor shall be responsible for keeping the entire area allotted to him clean
and free from rubbish, debris etc. during the period of Contract. The Contractor shall
employ enough number of special personnel to thoroughly clean his work-area at
least once in a day. All such rubbish and scrap material shall be stacked or disposed
in a place to be identified by the Employer. Materials and stores shall be so arranged
to permit easy cleaning of the area. In areas where equipment might drip oil and
cause damage to the floor surface, a suitable protective cover of a flame resistant, oil
proof sheet shall be provided to protect the floor from such damage.

27.06.02 Similarly, the shall be kept clean and neat to the entire satisfaction of the Employer.
Proper sanitary arrangements shall be provided by the Contractor, in the work-areas
and office of the Contractor.
28.00.00 LINES AND GRADES
All the Works shall be performed to the lines, grades and elevations indicated on the
drawings. The Contractor shall be responsible to locate and layout the Works.
Basic horizontal and vertical control points will be established and marked by the
Employer at Site at suitable points. These points shall be used as datum for the
works under the Contract. The Contractor shall inform the Employer well in advance
of the times and places at which he wishes to do work in the area allotted to him so
that suitable datum points may be established and checked by the Employer to
enable the Contractor to proceed with his works. Any work done without being
properly located may be removed and/or dismantled by the Employer at Contractor’s
expense.
29.00.00 FIRE PROTECTION
Required Fire Protection Measures are described under Clause titled “WORK
&SAFETY REGULATIONS” of this Sub-section.
30.00.00 SECURITY
The Contractor shall have total responsibility for all equipment and materials in his
custody stores, loose, semi-assembled and/or erected by him at Site. The Contractor
shall make suitable security arrangements including employment of security
personnel to ensure the protection of all materials, equipment and works from theft,
fire, pilferage and any other damages and loss. All materials of the Contractor shall
enter and leave the Employer Site only with the written permission of the Employer in
the prescribed manner.
31.00.00 CONTRACTOR’S AREA LIMITS
The Employer will mark-out the boundary limits of access roads, parking spaces,
storage and construction areas for the Contractor and the Contractor shall not
trespass the areas not so marked out for him. The Contractor shall be responsible to
ensure that none of his personnel move out of the areas marked out for his
operations. In case of such a need for the Contactor’s personnel to work out of the
areas marked out for him the same shall be done only with the written permission of
the Employer.
32.00.00 CONTRACTOR’S CO-OPERATION WITH THE EMPLOYER
In case where the performance of the erection work by the Contractor affects the
operation of the system facilities of the Employer, such erection work of the
Contractor shall be scheduled to be performed only in the manner stipulated by the
Employer and the same shall be acceptable at all times to the Contractor. The
Employer may impose such restrictions on the facilities provided to the Contractor

such as electricity, etc. as he may think fit in the interest of the Employer and the
Contractor shall strictly adhere to such restrictions and co-operate with the Employer.
It will be the responsibility of the Contractor to provide all necessary temporary
instrumentation and other measuring devices required during start-up and operation
of the equipment systems which are erected by him. The Contractor shall also be
responsible for flushing and initial filling of all the oil and lubricants required for the
equipment furnished and installed by him, so as to make such equipment ready for
operation. The Contractor shall be responsible for supplying such flushing oil and
other lubricants unless otherwise specified elsewhere in documents and
specifications.
33.00.00 PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES
33.01.00 GENERAL
33.01.01 The Contractor upon completion of installation of equipments and systems, shall
conduct pre-commissioning and commissioning activities, to make the
equipment/systems ready for safe, reliable and efficient operation on sustained
basis. All pre-commissioning/commissioning activities considered essential for such
readiness of the equipment/systems including those mutually agreed and included in
the Contractor’s quality assurance programme as well as those indicated in clauses
elsewhere in the technical specifications shall be performed by the contractor.
33.01.02 The pre-commissioning and commissioning activities including Guarantee tests,

checks and trial operations of the equipment/systems furnished and installed by the
contractor shall be the responsibility of the Contractor as detailed in relevant clauses
in Technical Specification. The Contractor shall provide, in addition, test instruments,
calibrating devices etc. and labour required for successful performance of these
operations. If it is anticipated that the above test may prolong for a long time, the
Contractor’s workmen required for the above test shall always be present at site
during such operations.
33.01.03 The following activities shall be carried out by the contractor, 18 month prior to
schedule date of commissioning of the equipment/systems installed by him.
(a.) The contractor shall furnish the organization chart of his operation and
commissioning engineers for the acceptance of employer. Adequate number
of operation and commissioning engineers shall be deployed by the
contractor to effectively meet the requirement of round the clock operation in
shifts also, till the plant is taken over by the employer.
(a.) The contractor shall submit the bio-data containing the details of experience
of his operation and commissioning engineers for the acceptance of
employer.
(a.) The contractor shall furnish the deployment schedule of his operation and
commissioning engineers for the acceptance of the employer.

(a.) Apart from above, contractor shall ensure deployment of sufficient

skilled/semi-skilled/unskilled manpower during pre-commissioning and
commissioning activities.
33.01.04 It shall be the responsibility of the Contractor to provide all necessary temporary
instrumentation and other measuring devices required during start-up and initial
operation of the equipment/systems, which are installed by him.
33.01.05 The Contractor shall also be responsible for flushing and initial filling of all oils and
lubricants required for the equipment furnished and installed by him so as to make
such equipment ready for operation. The Contractor shall be responsible for
supplying such flushing oil and other lubricants unless otherwise specified elsewhere
in these specifications and documents.
33.02.00 COMMISSIONING DOCUMENTATION
33.02.01 The contractor shall submit the commissioning documentation, comprising of

Standard checklists, pre-commissioning procedures, testing schedules,
commissioning schedules and commissioning networks for various
equipment/systems covered under the contract, for the approval of employer.
33.02.02 Standard checklist, as the name suggests, shall be a fairly general documents,
containing the list of all checks required to be carried out for similar and repetitive
type of equipment to ensure consistent and thorough checking. An indicative list of
such equipment is enclosed as Annexure I.
33.02.03 The testing schedule is a document, designed for safe and systematic
commissioning of individual equipment/sub-system (for example Boiler Feed Pump,
condensate pump, compressor etc) Commissioning schedule is a document
envisaged for commissioning of a system (for example feed system, Condensate
system, Compressed Air system, Fire water system, Unit commissioning etc). The
testing/Commissioning schedule shall have a standard format in order to maintain
consistency of presentation, content and reporting. A brief write up on the contents
of the Testing Schedule/Commissioning Schedule is enclosed as Annexure-II.
33.02.04 The contractor shall submit the list of commissioning documentation to be submitted
by him, along with their submission schedule for various equipment/systems covered
under the contract, with in 6(six) month from the date of award of contract, for the
acceptance of employer.
33.02.05 The Contractor shall submit the commissioning documentation, for various
equipment/covered under the contract, for the approval of employer, at least 18
months before the scheduled date of commissioning of the equipment/systems.
33.03.00 COMMISSIONING ACTIVITIES
33.03.01 Upon completion of pre-commissioning activities/tests, the contractor shall initiate

commissioning of facilities. During commissioning the Contractor shall carry out
system checking and reliability trials on various parts of the facilities.

33.03.02 Contractor shall carry out the checks/tests at site to prove to the Employer that each
equipment of the supply complies with requirements stipulated and is installed in
accordance with requirements specified.
33.03.03 Before the plant is put into initial operation the Contractor shall be required to
conduct test to demonstrate to the Employer that each item of the plant is capable of
correctly performing the functions for which it was specified and its performance,
parameters etc. are as per the specified/approved values. These tests may be
conducted concurrently with those required under commissioning sequence.
33.03.04 The Contractor shall also demonstrate the performance of all C&I equipment, the
tests on main equipment of prior to that as the case may be.
33.03.05 Other tests shall be conducted, if required by the Employer, to establish that the
plant equipment are in accordance with requirements of the specifications.
33.03.06 The Contractor shall conduct all the commissioning tests and undertake
commissioning activities pertaining to all other auxiliaries and equipments including
all electrical and C&I equipment/systems not specifically brought out above but are
within the scope of work and facilities being supplied and installed by the Contractor
and follow the guidelines indicated above or elsewhere in these technical
specifications (Section-VI).
33.04.00 Initial Operation
Upon completion of system checking/Tests as above and as a part of commissioning

of facilities, complete plant/facilities shall be put on initial operation as stipulated in
General Technical Requirements.
34.00.00 MATERIALS HANDLING AND STORAGE
34.01.00 All the equipments furnished under the Contract and arriving at Site shall be promptly
received, unloaded and transported and stored in the storage spaces by the
Contractor.
34.02.00 Contractor shall be responsible for examining all the shipment and notify the
Employer immediately of any damage, shortage, discrepancy etc. for the purpose of
Employer's information only. The Contractor shall submit to the Employer every
week a report detailing all the receipts during the week. However, the Contractor
shall be solely responsible for any shortages or damage in transit, handling and / or
in storage and erection of the equipment at Site. Any demurrage, wharf age and
other such charges claimed by the transporters, railways etc. shall be to the account
of the Contractor.
34.03.00 The Contractor shall maintain an accurate and exhaustive record detailing out the list
of all equipment received by him for the purpose of erection and keep such record
open for the inspection of the Employer.

34.04.00 All equipment shall be handled very carefully to prevent any damage or loss. No bare
wire ropes, slings, etc. shall be used for unloading and/or handling of the equipment
without the specific written permission of the Employer. The equipment stored shall
be properly protected to prevent damage either to the equipment or to the floor
where they are stored. The equipment from the store shall be moved to the actual
location at the appropriate time so as to avoid damage of such equipment at Site.
34.05.00 All electrical panels, controls gear, motors and such other devices shall be properly
dried by heating before they are installed and energised. Motor bearings, slip rings,
commutators and other exposed parts shall be protected against moisture ingress
and corrosion during storage and periodically inspected. Heavy rotating parts in
assembled conditions shall be periodically rotated to prevent corrosion due to
prolonged storage.
34.06.00 All the electrical equipment such as motors, generators, etc. shall be tested for
insulation resistance at least once in three months from the date of receipt till the
date of commissioning and a record of such measured insulation values maintained
by the Contractor. Such records shall be open for inspection by the Employer.
34.07.00 The Contractor shall ensure that all the packing materials and protection devices
used for the various equipments during transit and storage are removed before the
equipment are installed.
34.08.00 The consumables and other supplies likely to deteriorate due to storage must be
thoroughly protected and stored in a suitable manner to prevent damage or dete-
rioration in quality by storage.
34.09.00 All the materials stored in the open or dusty location must be covered with suitable
weatherproof and flameproof covering material wherever applicable.
34.10.00 If the materials belonging to the Contractor are stored in areas other than those
earmarked for him, the Employer will have the right to get it moved to the area
earmarked for the Contractor at the Contractor’s cost.
34.11.00 The Contractor shall be responsible for making suitable indoor storage facilities to
store all equipment which require indoor storage. Normally, all the electrical
equipments such as motors, control gear, generators, exciters and consumables like
electrodes, lubricants etc. shall be stored in the closed storage space. The Employer,
in addition, may direct the Contractor to move certain other materials, which in his
opinion will require indoor storage, to indoor storage areas which the Contractor shall
strictly comply with.
35.00.00 CONSTRUCTION MANAGEMENT
35.01.00 The field activities of the Contractors working at Site, will be coordinated by the
Employer and the Employer decision shall be final in resolving any disputes or
conflicts between the Contractor and other Contractors and tradesmen of the
Employer regarding scheduling and coordination of work. Such decision by the

Employer shall not be a cause for extra compensation or extension of time for the
Contractor.
35.02.00 The Employer shall hold weekly meetings of all the Contractors working at Site, at a
time and place to be designated by the Employer. The Contractor shall attend such
meetings and take notes of discussions during the meeting and the decisions of the
Employer and shall strictly adhere to those decisions in performing his Works. In
addition to the above weekly meeting, the Employer may call for other meeting either
with individual Contractors or with selected number of Contractors and in such a
case the Contractor if called, will also attend such meetings.
35.03.00 Time is the essence of the Contract and the Contractor shall be responsible for
performance of his works in accordance with the specified construction schedule. If
at any time, the Contractor is falling behind the schedule, he shall take necessary
action to make good for such delays by increasing his work force or by working
overtime or otherwise accelerate the progress of the work to comply with the
schedule and shall communicate such actions in writing to the Employer, satisfying
that his action will compensate for the delay. The Contractor shall not be allowed any
extra compensation for such action.
35.04.00 The Employer shall however not be responsible for provision of additional labour
and/or materials or supply or any other services to the Contractor except for the co-
ordination work between various Contractors as set out earlier.
36.00.00 FIELD OFFICE RECORDS
The Contractor shall maintain at his Site Office up-to- date copies of all drawings,
specifications and other Contract Documents and any other supplementary data
complete with all the latest revisions thereto. The Contractor shall also maintain in
addition the continuous record of all changes to the above Contract Documents,
drawings, specifications, supplementary data, etc. effected at the field and on
completion of his total assignment under the Contract shall incorporate all such
changes on the drawings and other Engineering data to indicate as installed
conditions of the equipment furnished and erected under the Contract. Such
drawings and Engineering data shall be submitted to the Employer in required
number of copies.
37.00.00 CONTRACTOR’S MATERIALS BROUGHT ON TO SITE
37.01.00 The Contractor shall bring to Site all equipment, components, parts, materials,
including construction equipment, tools and tackles for the purpose of the Works
under intimation to the Employer. All such goods shall, from the time of their being
brought vest in the Employer, but may be used for the purpose of the Works only and
shall not on any account be removed or taken away by the Contractor without the
written permission of the Employer. The Contractor shall nevertheless be solely
liable and responsible for any loss or destruction thereof and damage thereto.
37.02.00 The Employer shall have a lien on such goods for any sum or sums which may at
any time be due or owing to him by the Contractor, under, in respect of or by reasons

of the Contract. After giving a fifteen (15) days notice in writing of his intention to do
so, the Employer shall be at liberty to sell and dispose off any such goods, in such
manner as he shall think fit including public auction or private treaty and to apply the
proceeds in or towards the satisfaction of such sum or sums due as aforesaid.
37.03.00 After the completion of the Works, the Contractor shall remove from the Site under
the direction of the Employer the materials such as construction equipment, erection
tools and tackles, scaffolding etc. with the written permission of the Employer. If the
Contractor fails to remove such materials, within fifteen (15) days of issue of a notice
by the Employer to do so then the Employer shall have the liberty to dispose off such
materials as detailed under as specified at clause no 38.02.00- of this chapter and
credit the proceeds thereto to the account of the Contractor.
38.00.00 PROTECTION OF PROPERTY AND CONTRACTOR’S LIABILITY
38.01.00 The Contractor shall be responsible for any damage resulting from his operations.
He shall also be responsible for protection of all persons including members of public
and employees of the Employer and the employees of other Contractors and Sub-
Contractors and all public and private property including structures, building, other
plants and equipments and utilities either above or below the ground.
38.02.00 The Contractor will ensure provision of necessary safety equipment such as barriers,
sign - boards, warning lights and alarms, etc. to provide adequate protection to
persons and property. The Contractor shall be responsible to give reasonable notice
to the Employer and the Employers of public or private property and utilities when
such property and utilities are likely to get damaged or injured during the
performance of his Works and shall make all necessary arrangements with such
Employers, related to removal and/or replacement or protection of such property and
utilities.
39.00.00 PAINTING
Unless otherwise mentioned in other sub-sections. all exposed metal parts of the
equipment including pipings, structure railings, etc. wherever applicable, after
installation unless otherwise surface protected, shall be first painted with at least two
coats of suitable primer which matches the shop primer paint used, after throughly
cleaning all such parts of all dirt, rust, scales, greases, oils and other foreign
materials by wire brushing, scraping or sand blasting and the same being inspected
and approved by the Employer for painting. Afterwards, the above parts shall be fin-
ished painted with three coats of allowed resin machinery enamel paints. The
minimum thickness of paint film shall not be less than 100 microns. The quality of the
finish paint shall be as per the standards of Bureau of Indian Standards (BIS) or
equivalent and to be of the colour as approved by the Employer.
40.00.00 INSURANCE
40.01.00 In addition to the conditions covered under the Clause entitled “Insurance” in Section
General Conditions of Contract (GCC), the following provisions will also apply to the

portion of works to be done beyond the Contractor’s own or his Sub-Contractor’s

manufacturing Works.
40.02.00 Workmen’s Compensation Insurance
This insurance shall protect the Contractor against all claims applicable under the
Workmen’s Compensation Act, 1948 (Government of India). This policy shall also
cover the Contractor against claims for injury, disability disease or death of his or his
Sub-Contractor’s employees, which for any reason are not covered under the
Workmen’s Compensation Act, 1948. The liabilities shall not be less than the
following:
Workmen's Compensation - As per Statutory Provisions
Employee's Liability - As per Statutory Provisions
40.03.00 Comprehensive Automobile Insurance
This insurance shall be in such a form to protect the Contractor against all claims for
injuries, disability, disease and death to members of public including the Employer’s
men and damage to the property of other arising from the use of motor vehicles
during on or off the Site operations, irrespective of the Employership of such
vehicles. The liability covered shall be as herein indicated :
Fatal Injury : Rs.100,000 each person
: Rs.200,000 each occurrence
Property Damage : Rs.100,000 each occurrence
40.04.00 Comprehensive General Liability Insurance
40.04.01 The insurance shall protect the Contractor against all claims arising from injuries,
disabilities, disease or death of members of public or damage to property of others,
due to any act or omission on the part of the Contractor, his agents, his employees,
his representatives and Sub-Contractors or from riots, strikes and civil commotion.
This insurance shall also cover all the liabilities of the Contractor arising out of the
Clause entitled “Defence of Suits” in Section General Conditions of Contract (GCC).
40.04.02 The hazards to be covered will pertain to all the Works and areas where the
Contractor, his Sub-Contractors, his agents and his employees have to perform work
pursuant to the Contract.
40.05.00 The above are only illustrative list of insurance covers normally required and it will be
the responsibility of the Contractor to maintain all necessary insurance coverage to
the extent both in time and amount to take care of all his liabilities either direct or
indirect, in pursuance of the Contract.
41.00.00 UNFAVOURABLE WORKING CONDITIONS

The Contractor shall confine all his field operations to those works which can be
performed without subjecting the equipment and materials to adverse effects during
inclement weather conditions, like monsoon, storms, etc. and during other
unfavorable construction conditions. No field activities shall be performed by the
Contractor under conditions which might adversely affect the quality and efficiency
thereof, unless special precautions or measures are taken by the Contractor in a
proper and satisfactory manner in the performance of such Works and with the
concurrence of the Employer. Such unfavorable construction conditions will in no
way relieve the Contractor of his responsibility to perform the Works as per the
schedule.
42.00.00 PROTECTION OF MONUMENTS AND REFERENCE POINTS
The Contractor shall ensure that any finds such as relic, antiquity, coins, fossils, etc.
which he may come across during the course of performance of his Works either
during excavation or elsewhere, are properly protected and handed over to the
Employer. Similarly the Contractor shall ensure that the bench marks, reference
points, etc., which are marked either with the help of Employer or by the Employer
shall not be disturbed in any way during the performance of his Works. If, any work is
to be preformed which disturb such reference, the same shall be done only after
these are transferred to other suitable locations under the direction of the Employer.
The Contractor shall provide all necessary materials and assistance for such
relocation of reference points etc.
43.00.00 WORK & SAFETY REGULATIONS
43.01.00 General:
i) The contractor shall comply with all the requirements of "The Building and
Other Construction Workers (Regulation of Employment & Conditions of
Service) Act," 1996 and its Central Rule 1998 / State Rules and any other
statutory requirements as applicable.
ii) The Contractor shall follow Employer Safety Rules as issued from time to
time with respect to safety in construction & erection.
iii) The contractor shall have the approved Safety; Health and Environment
(SHE) Policy in respect of Safety and health of Building Workers and it shall
be circulated widely and displayed at conspicuous place in Hindi and local
language understood by the majority of the workers. A copy of the safety
policy should be submitted to Engineer-in-charge.
iv) The contractor shall prepare the safety plan comprising of methods to
implement the Safety Policy/ Rules, Risk assessment and ensuring Safety at
work areas. Safety audits, inspections and its compliance, Supervision and
responsibility to ensure Safety at various levels, Safety training to employees,
review of Safety and accident analysis, ensure Health and Safety Procedures
to prevent accidents and submit to Engineer-in-charge for approval as per the
format of Safety plan as per the Table below:

SAFETY PLAN
1) Safety policy of the contractor to be enclosed

2) When was the safety policy last reviewed
3) Details of implementation procedure/methods to implement Safety

Policy/Safety Rules
4) Name, qualification, experience of Safety Officer
5) Review of Accident, Analysis Method, Methods to ensure Safety

and Health
6) Unit executive responsible to ensure Safety at various levels in

work area
7) List of employees trained in safety employed before execution of

the job. Give the details of training.
8) Safety training Targets, Schedules, Methods adopting to provide

safety training to all employees
9) Details of checklist for different jobs/ work and responsible person

to ensure compliance (copy of checklist to be enclosed.)
10) Regular Safety Inspection Methods and Periodicity and list of

members to be enclosed
11) Risk Assessment, Safety Audit by Professional Agencies,

Periodicity
12) Implementation of Recommendations of Audit / Inspections.

Procedures for implementation and follow up.
13) Provision for treatment of injured persons at work site

14) Review of overall safety by top Management and Periodicity
15) System for Implementation of Statutory legislations
16) Issue of PPEs to employees, Periodicity / stock on hand etc.
Head of the Organisation
With date & stamp
v) The Contractors shall ensure proper safety of all the workmen, materials,
plant and equipment belonging to him or to the Employer or to others,
working at the Site.

vi) All equipments used in construction and erection by the contractor shall meet
BIS / International Standards and where such standards do not exist, the
Contractor shall ensure these to be absolutely safe. All equipments shall be
strictly operated and maintained by the contractor in accordance with
manufacturer’s operation manual. The contractor should also follow
Guidelines / Rules of the Employer in this regard.
vii) The Contractors shall provide suitable latest Personal Protective Equipments
of prescribed standard to all their employees and workmen according to the
need. The Engineer In charge shall have the right to examine these safety
equipments to determine their suitability, reliability, acceptability and
adaptability. The contractor should also ensure these before their use at
worksite.
viii) The Contractor shall provide safe working conditions to all workmen and
employees at his workplace including safe means of access, railings, stairs,
and ladders, scaffolding, work platforms, toe boards etc. The scaffoldings
shall be erected under the control and supervision of an experienced and
competent person. For erection of scaffolds, access, work platforms etc. shall
be good and the contractor shall use standard quality of material.
ix) The Contractor shall follow and comply with all the Safety Rules, standards,
code of practices of Employer and relevant provisions of applicable laws
pertaining to the safety of workmen, employees, plant and equipment as may
be prescribed from time to time without any protest or contest or reservation.
In case of any’ unconformity between statutory requirement and the Safety
Rules of the Employer referred above, the latter shall be binding on the
Contractor unless the statutory provisions are more stringent. As and when
required he can refer / obtain copy of Employer safety documents as stated
above.
x) The contractor shall have his own arrangements with nearby hospitals for
shifting and treatment of sick and injured. The medical examination of the
workers employed in hazardous areas shall be conducted as per Rule 223 of
The Building and Other Construction Worker (Regulation of Employment and
Condition of Service) Central Rule 1998. Their health records shall be
maintained accordingly and to be submitted to Engineer In-charge when
asked for. If any worker found suffering from occupational health hazard, the
worker should be shifted to suitable place of working and properly treated
under intimation to Engineer In-charge. The medical fitness certificate to be
submitted to Engineer In-charge.
xi) First Aid boxes equipped with requisite articles as specified in the Rule 231 of
The Building and Other Construction Worker (Regulation of Employment and
Condition of Service) Central Rule 1998 shall be provided at construction
sites for the use of workers. Training has to be provided on first aid to
workmen & office bearers working at site.
43.02.00 Emergency Action Plan.

The contractor shall prepare an emergency action plan approved by his competent
authority to handle any emergency occurred during construction work. Regular mock
drills shall be organized to practice this emergency plan. The Emergency Action Plan
should be widely circulated to all the employees and suitable infrastructure shall be
provided to handle the emergencies.
43.03.00 Scaffolding.
The contractor shall take all precautions to prevent any accidental collapse of
scaffolding or fall of persons from scaffolding. The contractor should ensure that
scaffolding are designed by a competent person and it erection and repairs should
be done under the expert supervision- The scaffolding shall meet the required
strength and other requirements for the purpose for which the scaffold is erected.
The material used for scaffold should conform to the BIS / International standards.
43.04.00 Opening.
The contractor shall ensure that there is no opening in any working platform/any floor
of the building, which may cause fall of workers or material. When ever an opening
on a platform/any floor of the building is unavoidable, the opening should be suitably
fenced and necessary measures for protection against falling objects or building
workers from such platform are taken by providing suitable safety nets, safety belts
or other similar means.
43.05.00 Explosives.
The contractor shall take all precautions while handling, using, storing or transporting
of all explosives. Before usage of any explosive necessary warning / danger signals
be erected at conspicuous places to warn the workers and general public. The
contractor should strictly ensure that all measures and precautions required to be
complied for use, handling, storing or transportation of explosives under the rules
framed under the Explosives Act, 1884.
43.06.00 Coffer Dam and Caissons
The Contractor shall ensure that the cofferdam and caissons are of good
construction and adequate strength. The cofferdam and caissons should be provided
with adequate means for workers to reach safely at the top of such dams in the even
of an in-rush of water. The workers should be allowed to work in a cofferdam or
caisson only after inspection and found safe by Engineer-in –charge. Such
inspection is to be maintained in a Register. Where the workers are employed to
work in a compressed air environment at the work site of cofferdam or caissons a
Construction Medical Officer assisted by a Nurse or trained first aid attendant should
be available at all the times during such work.
43.07.00 Fencing of Machinery.
The contractor shall provide suitable fencing or guard to all dangerous and moving
parts of machinery.

The contractor shall not allow any of the employees to clean, lubricate, repair, adjust
or examine during machinery in motion, which may cause injury to the person.
Working Platforms should be fenced and shall have means of access
43.08.00 Carrying of Excessive Weight by a Worker.
The worker shall not be allowed to lift by hand or carry over his head, back or
shoulder more than the maximum limit set by the prescribed rules for the
construction Workers.
43.09.00 Dangerous and Harmful Gases/Equipment.
The contractor shall ensure that the workers are not exposed to any harmful gases
during any construction activity including excavation, tunneling, confined spaces etc.
The contractor should not allow any worker to go into the confined space unless it is
certified by Engineer in-charge to be safe and fit for the entry to such work place.
Proper record and work permits should be followed to carry out such works.
43.10.00 Overhead Protection.
The contractor shall ensure that any area exposed to risk of falling materials, articles
or objects is roped off or cordoned off or otherwise suitably guarded from inadvertent
entry of any person.
Wherever there is a possibility of falling of any material, equipment or construction

workers while working at heights, a suitable and adequate safety net should be
provided. The safety net should be in accordance with BIS Standards.
43.11.00 Working at Heights.
a) All working platforms, ways and other places of construction work shall be
free from accumulations of debris or any other material causing obstructions
and tripping.
b) Wherever workers are exposed to the hazard of falling into water, the
contractor shall provide adequate equipment for saving the employees from
drowning and rescuing from such hazards. The contractor shall provide boat
or launch equipped with sufficient number of life buoys, life jackets etc.
manned with trained personnel at the site of such work.
c) Every opening at elevation from ground level through which a building

worker, vehicle, material equipment etc. may fall at a construction work shall
be covered and/or guarded suitably by the contractor to prevent such falls.
d) Wherever the workers are exposed to the hazards of falling from height, the
contractor shall provide full harness safety belts fitted with fall arresting
systems to all the employees working at higher elevations and life line of 8
mm diameter wire rope with turn buckles for anchoring the safety belts while

working or moving at higher elevations. Safety nets shall also be provided for
saving them from fall from heights and such equipment should be in
accordance with BIS standards.
e) Wherever there is a possibility of falling of any material, equipment or

construction workers while working at heights, a suitable and adequate safety
net should be provided. The safety net should be in accordance with BIS
Standards.
f) The contractor shall provide standard prefabricated ladders on the columns

where the workers are required to use them as an access for higher
elevations till permanent staircase is provided. The workers shall be provided
with safety belts fitted with suitable fall arresting system (Fall arresters) for
climbing/getting down through ladders to prevent fail from height.
g) Rungs shall not be welded on columns. All the Stairs shall be provided with
handrails immediately after its erection.
43.12.00 Handling of Hazardous Chemicals.
a) The Contractor will notify well in advance to the Engineer-in-charge of his

intention to bring to the Site any container filled with liquid or gaseous fuel or
explosive or petroleum substance or such chemicals which may involve
hazards. Employer shall have the right to prescribe the conditions, under
which such container is to be stored, handled and used during the
performance of the works and the Contract shall strictly adhere to and comply
with such instructions. The Engineer-in-charge shall have the right at his sole
discretion to inspect any such container or such construction plant /
equipment for which material in the container is required to be used and if in
his opinion, its use is not safe; he may forbid its use. N Employer o claim due
to such prohibition shall be entertained by Employer and NTPC shall not
entertain any claim of the Contractor towards additional safety provisions /
conditions to be provided for / constructed.
b) Further, any such decision of the Engineer-in-charge shall not, in any way,
absolve the Contractor of his responsibilities and in case, use of such a
container or entry thereof into the Site area is forbidden by Employer, the
Contractor shall use alternative methods with the approval of the Employer
without any cost implication to the Employer or extension of work schedule.
c) Where it is necessary to provide and / or store petroleum products or

petroleum mixtures and explosives, the Contractor shall be responsible for
carrying-out such provision and / or storage in accordance with the rules and
regulations laid down in Petroleum Act 1934, Explosives Act 1948, and
Petroleum and Carbide of Calcium Manual published by the Chief Inspector
of Explosives of India. All such storage shall have prior approval of the
Engineer In-charge In case any approvals are necessary from the Chief
Inspector (Explosives) or any statutory authorities; the Contractor shall be
responsible for obtaining the same.

d) The Contractor shall be fully responsible for the safe storage of his and his
Sub-contractor's radio-active sources in accordance with BARC/DAE
(Bhabha Atomic Research Centre/ Department of Atomic Energy, Govt. of
India) Rules and other applicable provisions- AU precautionary measures
stipulated by BARC/DAE in connection with use, the contractor would take
storage and handling of such material.
e) The contractor shall provide suitable personal protective equipments to the

workers who are handling the hazardous and corrosive substances including
alkalis and acids.
f) As a precautionary measure the contractor should keep the bottles filled with
distilled water in cupboard / Boxes near work place for emergency eye wash
by worker exposed to such hazardous chemicals.
43.13.00 Eye Protection.
The contractor shall provide suitable personal protective equipment to his workmen
depending upon the nature of hazards and ensure their usage by the workers
engaged in operations like welding, cutting, chipping, grinding or similar operations
which may cause injuries to his eyes.
43.14.00 Excavation.
43.15.00 The contractor shall take all necessary measures during excavation to prevent the
hazards of falling or sliding material or article from any bank or side of such
excavation which is more than one and a half meter above his footing by providing
adequate piling, shoring, bracing etc. against such bank or sides.
Adequate and suitable warning signs shall be put up at conspicuous places at the
excavation work to prevent any persons or vehicles falling into the excavation trench.
No worker should be allowed to work where he may be stuck or endangered by
excavation machinery or collapse of excavations or trenches.
43.16.00 Electrical Hazards.
a) The contractor should ensure that all electrical installations at the

construction work comply with the requirements of latest electricity acts /
rules.
b) The contractor shall take all adequate measures to prevent any worker from
coming into physical contact with any electrical equipment or apparatus,
machines or live electrical circuits which may cause electrical hazards during
the construction work. The contractor shall provide the sufficient ELCBs /
RCCBs for all the portable equipments, electrical switchboards, distribution
panels etc. to prevent electrical shocks.
c) The contractor should ensure use of single / double insulated hand tools or
low voltage i.e., 110 volts hand tools.

d) The contractor should also ensure that all temporary electrical installations at
the construction works are provided with earth leakage circuit breakers.
e) No electric cable in use by the Contractor /Employer will be disturbed without

prior permission. No weight of any description will be imposed on any cable
and no ladder or similar equipment will rest against or attached to it.
f) The Contractor shall employ necessary number of qualified, full time

Electricians/electrical supervisors to maintain his temporary electrical
installations.
43.17.00 Vehicular Traffic.
The contractor should employ vehicle drivers who hold a valid driving license under
the Motor Vehicles Act, 1988.
43.18.00 Lifting Appliances, Tools & Tackles. Lifting Gear And Pressure Plant &
Equipment etc.
The contractor shall ensure alt the lifting appliances, tools & tackles including cranes
etc., lifting gear including fixed or movable and any plant or gear, hoists, Pressure
Plant and equipment etc. are in good condition and shall be examined by competent
person and only certified shall be used at sites. Periodical Examination and the tests
for all lifting / hoisting equipment & tackles shall be carried out. A register of such
examinations and tests shall be properly maintained by the Contractor and will be
promptly produced as and when desired by the Engineer I/c or by the person
authorized by him.
43.19.00 Excessive Noise, Vibration.
The contractor shall take adequate measures to protect the workers against the
harmful effect of excessive noise or vibration. The noise should not exceed the limits
prescribed under the concerned rules. Noise Pollution (Regulation and Control)
Rules, 2000.
43.20.00 Electrical Installations.
a) The Contractor shall not interfere or disturb electric fuses, wiring and other
electrical equipment belonging to the Employer or other contractors under
any circumstances, whatsoever, unless expressly permitted in writing by the
Engineer I/c to handle such fuses, wiring or electrical equipment.
b) Before the Contractor connects any electrical appliances to any plug or

socket belonging to the other contractor or the Employer, he shall :-
 Satisfy the Engineer I/C that the appliance is in good working

condition;

 Inform the Engineer I/C of the maximum current rating, voltage and
phases of the appliances;
 Obtain permission of the Engineer-in-Charge detailing the sockets to

which the appliances may be connected.
c) The Engineer in-charge will not grant permission to connect until he is

satisfied that :-
 The appliance is in good condition and is fitted with suitable plug;

having earth connection with the body.
 Wherever armored / metallic sheathed multi core cable is used, the

same armored / sheathed should be connected to earth.
d) No repair work shall be carried out on any live equipment. The Engineer-in-
Charge must declare the equipment safe and a permit to work shall be issued
by the Employer / contractor as the case may be to carry out any repair /
maintenance work. While working on electric lines / equipments whether live
or dead, suitable type and sufficient quantity of tools will have to be provided
by the contractor to electricians / workmen / Officers.
e) The contractor shall employ necessary number of qualified, full time

Electricians / Electrical Supervisors to maintain his temporary electrical
installation.
f) The installations are provided with suitable ELCBs and RCCBs wherever
required.
43.21.00 Safety Organisation.
a) The contractor employing more than 250 workmen whether temporary,

casual, probationary, regular or permanent shall employ at least one full time
safety officer exclusively to supervise safety aspects of the equipments and
workmen, who will coordinate with the Employer Safety Officer. Further
requirement of safety officers, if any, shall be guided by Rule 209 of The
Building and Other Construction Worker (Regulation of Employment and
Conditions of Service) Central Rule 1998. In case the work is being carried
out through subcontractor, the employees / workmen of the sub contractor
shall also be considered as the contractor's employees/workmen for the
above purpose.
b) In case of contractor deploying less than 250 workmen he should designate

one of his Engineer / supervisor or the contractor himself (if he is directly
supervising the work) as safety officer in addition to his existing
responsibilities. The Engineer./ supervisor should get at least 2 days safety
training from any reputed organization or from Employer before resuming the
work. If already trained in past the declaration along with training. Certificate
to be furnished to Employer safety officer.

c) The name and address of such Safety Officer of the Contractor will be
promptly informed in writing to the EIC with a copy to the Project Safety
Officer before he starts work or immediately after any change of the
incumbent is made during currency of the Contract.
43.22.00 Reporting of Accident and Investigation.
In case any accident occurs during the construction / erection or other associated
activities undertaken by the Contractor thereby causing any near miss, minor or
major or fatal injury to his employees due to any reason, whatsoever, it shall be the
responsibility of the Contractor to promptly inform the same to the Engineer in-
charge, Employer Safety Officer with a copy to Employer Head of Project in the
prescribed form and also to all the authorities envisaged under the applicable laws.
43.23.00 Right to stop Work.
a) The Engineer I/C shall have the right at his sole discretion to stop the work, if
in his opinion the work is being carried out in such a -way that it may cause
accidents and endanger the safety of the persons and / or property, and / or
equipments. In such cases, the contractor shall be informed in writing about
the nature of hazards and possible injury / accident and he shall comply to
remove shortcomings promptly. The Contractor after stopping the specific
work can, if felt necessary appeal against the order of stoppage of work to the
Project Manager within 3 days of such stoppage of work and decision of the
Project Manager in this respect shall be conclusive and binding on the
Contractor.
b) The Contractor shall not be entitled for any damages / compensation for
stoppage of work due to safety reasons and the period of such stoppage of
work shall not be taken as an extension of time for Completion of the
Facilities and will not be the ground for waiver of levy of liquidated damages.
43.24.00 Fire Protection.
a) The contractor shall provide sufficient fire extinguishers at place /s of work.

The fire extinguishers shall be properly maintained as per relevant BIS
Standards. The employees shall be trained to operate the fire extinguishers /
equipment.
b) The Contractor shall provide enough fire protection equipment of the types
and number for the warehouses, office, temporary structures, labour colony
area etc. Access to such fire protection equipment, shall be easy and kept
open at all time.
c) The work procedures that are to be used during the erection shall be those
which minimise fire hazards to the extent practicable. Combustible materials,
combustible waste and rubbish shall be collected and removed from the Site

at least once each day. Fuels, oils and volatile or flammable materials shall
be stored away from the construction and equipment and materials storage
areas in safe containers. Untreated canvas, paper, plastic or other flammable
flexible materials shall not at all be used at Site for any other purpose unless
otherwise specified. If any such materials are received with the equipment at
the Site, the same shall be removed and replaced with acceptable material
before moving into the construction or storage area.
d) Similarly corrugated paper fabricated cartons etc. will not be permitted in the
construction area either for storage or for handling of materials. All such
materials used shall be of water proof and flame resistant type. All the other
materials such as working drawings, plans etc. which are combustible but are
essential for the works to be executed shall be protected against combustion
resulting from welding sparks, cutting flames and other similar fire sources.
e) All the Contractor’s supervisory personnel and sufficient number of workers

shall be trained for fire-fighting and shall be assigned specific fire protection
duties. Enough of such trained personnel must be available at the Site during
the entire period of the Contract.
43.25.00 Penalties.
a) If the Contractor fails in providing safe working environment as per the Safety
Rules of Employer or continues the work even after being instructed to stop
the work by the Engineer –in- Charge as provided above, the Contractor shall
be penalized at the rate of Rs. 25,000/-- per day or part thereof till the
instructions are complied with and so certified by the Engineer I/C- However,
in case of accident, the provisions contained below shall also apply in
addition to the penalties mentioned in this sub-clause.
b) If the Contractor does not take all safety precautions and / or fails to comply
with the Safety Rules as prescribed by the Employer or under the applicable
law for the safety of the plant and equipment and for the safety of personnel
and the contractor does not prevent hazardous conditions which cause injury
to this own employees or employees of other contractors, or Employer
employees or any other person who are at the Site or adjacent thereto, the
Contractor shall be responsible for payment of penalty to Employer as per the
following schedule; -
a) Fatal injury or accident Penalty @10% of contract value

causing death: death or Rs. 5,00,000/- per
person, which ever is less.
b) Major injuries or accident Penalty @2.5 % of contract value

causing 25% or more or Rs.1,00,000/- per person, which
permanent disablement to ever is less.
workmen or employees.

Permanent disablement shall have the same meaning as indicated in The

Workmen's Compensation Act' 1923. The penalty mentioned above shall be
in addition to the compensation payable to the workmen / employees under
the relevant provisions of the Workmen's Compensation Act' 1923 and rules
framed there under or any other applicable laws as applicable from time to
time.
c) If any contractor worker found working without using the safety equipment
like safety helmet, safety shoes, safety belts, etc. or without anchoring the
safety belts while working at height the Engineer in-charge / Safety Officer of
Employer shall have the right to penalize the contractor for Rs. 200/- per
person per day and such worker shall be sent out of the workplace
immediately and shall not be allowed to work on that day. Engineer in-charge
/ Safety Officer of Employer will also issue a notice in this regard to the
contractor.
d) If two or more fatal accidents occur at same Employer site under the control
of contractor during the period of contract and he has :-
(1) not complied with keeping adequate PPEs in stock,
(2) defaulted in providing PPR's to his workmen
(3) not followed statutory requirements / Employer safety rules
(4) been issued warning notice/s by Employer head of the project on non
observance of safety norms
(5) not provided safety training to all his workmen,
the contractor can be debarred from getting tender documents in Employer

for two years from the date of last accident.
e) The safety performance will also be one of the overriding criteria for
evaluation of overall performance of the contractors by Employer. The
contractor shall submit the accident data including fatal / non-fatal accidents
for the last 3 years where he has undertaken the construction activities
Projects-wise along with the tender documents. This will also be considered
for evolution of tender documents. If the information given by the contractor
found incorrect, his contract will be liable to be terminated.
43.26.00 Award.
If the Contractor's performance on safety front is found satisfactory i.e. without any
fatal/reportable accident in the year of consideration; he may be considered for
suitable award "ACCIDENT FREE SAFETY MERITORIOUS AWARD" as per
scheme of the employer.
44.00.00 FOREIGN PERSONNEL

44.01.00 The Contractor shall submit to the Employer data on all personnel he proposes to
bring into India from abroad for the performance of the Works under the Contract, at
least sixty (60) days prior to their departure to India. Such data will include for each
person the name, his present address, his assignment and responsibility in
connection with the works, and a short resume of his qualification, experience etc. in
relation to the work to be performed by him.
44.02.00 Any person unsuitable and unacceptable to the Employer shall not be brought to
India. Any person brought to India, if found unsuitable or unacceptable by the
Employer, the Contractor shall within a reasonable time make alternate
arrangements for providing a suitable replacement and repatriation of such
unsuitable personnel.
44.03.00 No person brought to India for the purposes of the works shall be repatriated without
the consent of the Employer in writing, based on a written request from the
Contractor for such repatriation giving reasons for such an action to the Employer.
The Employer may give permission for such repatriation provided he is satisfied that
the progress of work will not suffer due to such repatriation.
44.04.00 The cost of passports, visas and all other travel expenses to and from India,
incurred by the Contractor shall be to his account. The Employer will not provide any
residential accommodation and/or furniture for any of the Contractor’s personnel
including foreign personnel and Contractor shall make his own arrangements for
such facilities in the area allotted at Site, to him by the Employer for that purpose.
44.05.00 The Contractor and his expatriate personnel shall respect all Indian Acts, Laws, rules
and regulations and shall not in any way interfere with Indian political and religious
affairs and shall conform to any other rules and regulations which the Government of
India and the Employer may establish from time to time, on them. The Contractor’s
expatriate personnel shall work and live in close co-operation and coordination with
their co-workers and the community and shall not engage themselves in any other
employment neither part-time or full-time nor shall they take part in any local politics.
44.06.00 The Employer shall assist the Contractor, to the extent possible, in obtaining
necessary permits to travel to India and back, by issue of necessary certificates and
other information needed by the Government agencies.
45.00.00 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/ EQUIPMENT

BASES
45.01.00 The surfaces of foundations shall be dressed to bring the top surface of the
foundations to the required level, prior to placement of equipment/equipment bases
on the foundations.
45.02.00 All the equipment/ equipment bases, shall be grouted and finished as per these
specifications unless otherwise recommended by the equipment manufacturer.

45.03.00 The concrete foundation surfaces shall be properly prepared by chipping, grinding as
required to bring the top of such foundation to the required level, to provide the
necessary roughness for bondage and to assure enough bearing strength.
45.04.00 Grout
The grout shall be high strength grout having a minimum characteristic compressive
strength of 60 N/mm2 at 28 days. The grout shall be chloride - free, cement based,
free flowing, non-metallic grout.
The Grout shall have good flow ability even at very low water/ grout powder ratio.
The Grout shall have characteristics of controlled expansion to be able to occupy its
original volume to fill the voids and to compensate for shrinkage. Grout shall be of
pre-mix variety so that only water needs to be added before use.
The mixing of the Grout shall conform to the recommendations of the manufacturer
of the Grout.
45.05.00 Placing of Grout
45.05.01 After the base has been prepared, its alignment and level has been checked and
approved and before actually placing the grout, a low dam shall be set around the
base at a distance that will permit pouring and manipulation of the grout. The height
of such dam shall be at least 25mm above the bottom of the base. Suitable size and
number of chains shall be introduced under the base before placing the grout, so that
such chains can be moved back & forth to push the grout into every part of the space
under the base.
45.05.02 The grout shall be poured either through grout holes if provided or shall be poured at
one side or at two adjacent sides to make the grout move in a solid mass under the
base and out in the opposite side. Pouring shall be continued until the entire space
below the base is thoroughly filled and the grout stands at least 25 mm higher all
around than the bottom of the base. Enough care should be taken to avoid any air
or water pockets beneath the bases.
45.05.03 In addition to the above, recommendations of Grout manufacturer shall also be

followed.
45.06.00 Finishing of the Edges of the Grout
The poured grout should be allowed to stand undisturbed until it is well set.
Immediately thereafter, the dam shall be removed and grout which extends beyond
the edges of the structural or equipment base plates shall be cut off, flushed and
removed. The edges of the grout shall then be pointed and finished with 1:2 cement
mortar pressed firmly to bond with the body of the grout and smoothened with a tool
to present a smooth vertical surface. The work shall be done in a clean and scientific
manner and the adjacent floor spaces, exposed edges of the foundations, and

structural steel and equipment base plates shall be thoroughly cleaned of any
spillage of the grout.
45.07.00 Checking of Equipment After Grouting
After the grout is set and cured, the Contractor shall check and verify the alignment
of equipments, alignment of shafts of rotating machinery, the slopes of all bearing
pedestals, centering of rotors with respect to their sealing bores, couplings, etc. as
applicable and the like items to ensure that no displacement had taken place during
grouting. The values recorded prior to grouting shall be used during such post
grouting check- up and verifications. Such pre and post grout records of alignment
details shall be maintained by the Contractor in a manner acceptable to the
Employer.
46.00.00 SHAFT ALIGNMENTS
All the shafts of rotating equipment shall be properly aligned to those of the matching
equipments to as perfect accuracy as practicable. The equipment shall be free from
excessive vibration so as to avoid overheating of bearings or other conditions which
may tend to shorten the life of the equipment. The vibration level of rotating
equipments measured at bearing housing shall not exceed forty (40) microns and
shall conform to VDI 2056.All bearings, shafts and other rotating parts shall be thor-
oughly cleaned and suitably lubricated before starting.
47.00.00 DOWELLING
All the motors and other equipment shall be suitably doweled after alignment of
shafts with tapered machined dowels as per the direction of the Employer.
48.00.00 CHECK OUT OF CONTROL SYSTEMS
After completion of wiring, cabling furnished under separate specification and laid
and terminated by the Employer, the Contractor shall check out the operation of all
control systems for the equipment furnished and installed under these specifications
and documents.
49.00.00 COMMISSIONING SPARES
49.01.00 It will be the responsibility of the Contractor to provide all commissioning spares
including consumable spares required for initial operation till the Completion of
Facilities. The Contractor shall furnish a list of all commissioning spares within 60
days from the date of Notification of Award and such list shall be reviewed by the
Employer and mutually agreed to. However. such review and agreement will not
absolve the Contractor of his responsibilities to supply all commissioning spares so
that initial operation do not suffer for want of commissioning spares. All
commissioning spares shall be deemed to be included in the scope of the Contract at
no extra cost to the Employer.

49.02.00 These spare will be received and stored by the Contractor atleast 3 months prior to
the schedule date of commencement of initial operation of the respective equipment
and utilised as and when required. The unutilised spares and replaced parts, if any,
at the end of successful completion of guarantee tests shall be the property of the
Contractor and he will be allowed to take these parts back at his own cost with the
permission of Employer.
50.00.00 CABLING
50.01.00 All cables shall be supported by conduits or cable tray run in air or in cable channels.
These shall be installed in exposed runs parallel or perpendicular to dominant
surfaces with right angle turn made of symmetrical bends or fittings. When cables
are run on cable trays, they shall be clamped at minimum intervals of 2000mm or
otherwise as directed by the Employer.
50.02.00 Each cable, whether power or control, shall be provided with a metallic or plastic tag
of an approved type, bearing a cable reference number indicated in the cable and
conduit list (prepared by the Contractor), at every 5 meter run or part thereof and at
both ends of the cable adjacent to the terminations. Cable routing is to be done in
such a way that cables are accessible for any maintenance and for easy
identification.
50.03.00 Sharp bending and kinking of cables shall be avoided. The minimum radii for PVC
insulted cables 1100 V grade shall be 15 D where D is the overall diameter of the
cable. Installation of other cables like high voltage, coaxial, screened,
compensating, mineral insulated shall be in accordance with the cable
manufacturer’s recommendations. Wherever cables cross roads and water, oil,
sewage or gaslines, special care should be taken for the protection of the cables in
designing the cable channels.
50.04.00 In each cable run some extra length shall be kept at a suitable point to enable one or
two straight through joints to be made, should the cable develop fault at a later date.
50.05.00 Control cable terminations shall be made in accordance with wiring diagrams, using
identifying codes subject to the Employer’s approval. Multicore control cable jackets
shall be removed as required to train and terminate the conductors. The cable jacket
shall be left on the cable, as far as possible, to the point of the first conductor branch.
The insulated conductors from which the jacket is removed shall be neatly twined in
bundles and terminated. The bundles shall be firmly but not tightly tied utilising
plastic or nylon ties or specifically treated fungus protected cord made for this
purpose. Control cable conductor insulation shall be securely and evenly cut.
50.06.00 The connectors for control cables shall be covered with a transparent insulating
sleeve so as to prevent accidental contact with ground or adjacent terminals and
shall preferably terminate in Elmex terminals and washers. The insulating sleeve
shall be fire resistant and shall be long enough to over pass the conductor insulation.
All control cables shall be fanned out and connection made to terminal blocks and
test equipment for proper operation before cables are corded together.

51.00.00 EQUIPMENT DELIVERY AND ERECTION
(a.) This part covers Contractor's responsibilities for packing, shipping, ware-
housing and the installation of all equipment and materials furnished and
installed under this specification.
(a.) The Contractor shall submit for Employer's approval draft manual for
Equipment Delivery and Erection (EDE Manual) covering detailed
instructions, write up, technical data, drawings, check-lists, documentation
formats for all activities after equipment manufacture upto installation of
equipment. This manual shall cover general instructions for all equipment
and specific instructions for individual equipment wherever required and shall
include at least the following :
(1.) Instructions for packing, shipping, receiving handling, ware-housing

and storage.
(2.) Instructions for location and installation of equipment furnished by this

specification.
(3.) Installation drawings for field mounted equipment, panels, cubicles

and other equipment covered under this specification.
(4.) Instruction relating installation of piping/ tubing, support and routing

drawings of impulse pipes/signal tubes and tube/cable trays.
(5.) Check lists and quality assurance hold points.
(6.) Format for all related documentation.
(a.) The EDE Manual shall conform to the requirements of this specification, all
applicable codes and standards, recommendations of equipment
manufacturers and accepted good engineering practices and shall be subject
to Employer approval during detailed engineering.
(a.) The Contractor shall ensure that all work under this part shall be performed
as per the requirements of this specification, Employer approved EDE
Manual and drawing/documents approved by the Employer during detailed
engg.
51.02.00 Crating
(a.) All equipment and materials shall be suitably coated, wrapped, or covered
and boxed or crated for moist humid tropical shipment and to prevent
damage or deterioration during handling and storage at the site.

(a.) Equipment shall be packed with suitable desiccants, sealed in water proof
vapour-proof wrapping and packed in lumber of plywood enclosures, suitably
braced, tied and skidded. Lumber enclosures shall be solid, not slatted.
(a.) Desiccants shall be either silica gel or calcium sulphate, sufficiently ground to
provide the required surface area and activated prior to placing in the
packaging. Calcium sulphate desiccants shall be of a chemical nature to
absorb moisture. In any case, the desiccant shall not be of a type that will
absorb enough moisture to go into solution. Desiccants shall be packed in
porous containers, strong enough to withstand handling encountered during
normal shipment. Enough desiccant shall be used for the volumes enclosed
in wrapping.
(a.) Review by the Employer of the Contractor's proposed packaging methods

shall not relieve the Contractor of responsibility for damage or deterioration to
the equipment and materials specified.
(a.) All accessory items shall be shipped with the equipment. ; Boxes and crates
containing accessory items shall be marked so that they are identified with
the main equipment. The contents of each box and crates shall be indicated
by markings on the exterior.
(a.) All boxes, crates, cases bundles, loose pieces, etc. shall be marked
consecutively from No.1 upward throughout all shipments from a given port to
completion of the order without repeating the same number.
(a.) An itemized list of contents shall be enclosed inside each case and one other
copy securely fastened to the outside of the case in a tin or light weight sheet
metal envelope or pocket. The lists shall be plainly marked and placed in
accessible locations to facilitate receipt and inspection. The packing list shall
indicate whether shipment is partial or complete and shall incorporate the
following information on each container, etc., according to its individual
shipping number :
(1.) Export case markings
(2.) Case number
(3.) Gross weight and net weight in Kilograms
(4.) Dimensions in centimeters
(5.) Complete description of material
(a.) Packaging or shipping units shall be designed within the limitations of

unloading facilities and the equipment which will be used for transport.
Complications involved with ocean shipment and the limitations of ports,
railways and roads shall be considered. It shall be the Contractor's

responsibility to investigate these limitations and to provide suitable

packaging to permit safe handling during transit and at the job site.
(a.) Electrical equipment, control and instrumentation shall be protected against

moisture and water damage. All external gasket surfaces and flange faces,
couplings, motor pump shafts, bearing and like items shall be thoroughly
cleaned and coated with rust preventive compound as specified above and
protected with suitable wood, metal or other substantial type covering to
ensure their full protection.
(a.) Equipment having antifriction or sleeve bearings shall be protected by

weather tight enclosures.
(a.) Coated surfaces shall be protected against impact, abrasion, discolouration

and other damage. Surfaces which are damaged shall be repaired.
(a.) All exposed threaded parts shall be greased and protected with metallic or
other substantial type protectors. All female threaded openings shall be
closed with forged steel plugs. All pipings, tubing, and conduit equipment and
other equipment openings shall be sealed with metallic or other rough usage
covers and tapped to seal the interior of the equipment piping, tubing, or
conduit.
(a.) Provisions shall be made to ensure that water does not enter any equipment
during shipment or in storage at the plant site.
(a.) Returnable containers and special shipping devices shall be returned by the
manufacturer's field representative at the Contractor's expense.
(a.) While packaging the material, care shall be taken for the limitation from the
point of view of availability of railway wagon sizes in India.
51.03.00 Factory Assembly
(a.) Instrument enclosures shall be supplied and erected completely in the factory
with instrument, air supply and blow down piping with necessary valves,
fittings, etc. and also all electrical wiring between the instruments and the
enclosure terminal blocks. Control panel and cubicles shall also be fully wired
in the factory. Control panel mounted equipments are to be dismounted from
the panels before shipment and individually packed for shipment. Electronic
control modules of the plug-in type are to be removed from equipment racks
after factory checkout are individually packed for shipment. Other equipment
shall be fully assembled at the factory, except for necessary shipping splits in
panels.
(a.) All separately packaged accessories items and parts shall be shipped with
the equipment. Containers for separately packaged items shall be marked so
that they are identified with the main equipment. An itemized packing slip,

indicating what is in that carton only, shall be attached to the outside and
inside of each container used for packing.
A master packing slip covering all accessories items for a given piece of equipment
which are shipped in separate containers, shall be attached to one container.
51.04.00 Equipment Installation
(a.) General Requirements
(1.) The Contractor shall furnish all construction materials, tools and
equipment and shall perform all work required for complete installation
of all control and instrument equipment furnished under this
specification.
(2.) Contractor shall prepare detailed installation drawings for each

equipment furnished under this specification for Employer’s approval.
Installation of all equipment/systems furnished by this specification
shall be as per Employer's approval.
(3.) Erection procedures not specified herein shall be in accordance with

the recommendations of the equipment manufacturers. The
procedures shall be acceptable to the Employer.
(4.) The Contractor shall coordinate his work with other suppliers where
their instruments and devices are to be installed under specifications.
(a.) Installation Materials
All materials required for installation, testing and commissioning of the

equipment shall be furnished by the Contractor.
(a.) Regulatory Requirements
All installation procedures shall confirm with the accepted good engineering
practice and with all applicable governmental laws, regulations and codes.
(a.) Cleaning
All equipment shall be cleaned of all sand, dirt and other foreign materials
immediately after removal from storage and before the equipment is brought
inside the power plant building or to other installation sites. All piping and
tubes shall be air blown.
(a.) Equipment Assembly

Equipment installed under these specifications shall be assembled if shipped

unassembled. The equipment shall be dismantled and reassembled as
required to perform the installation and commissioning work described in
these specifications.
(a.) Equipment Setting
Field mounted instruments and accessories shall be bracket or sub panel

mounted on the nearest suitable firm steel work or masonry. The brackets,
stands, supports and other miscellaneous hardware required for mounting
instruments and accessories such as receiver gauge, air set, valve manifold,
purge-meter etc. shall be furnished and installed. No field mounted
instruments shall be installed such that it depends for support or rigidity on
the impulse piping or on electrical connection to it.
Indicating type field mounted instruments shall be installed in such a way that
centre of indicating dial shall be about 1600-1800mm from operating floor
level. Non-indicating type field instruments shall be installed such that
operating handle of manifold block / isolating cock comes within 1600 mm
from operating floor level.
All free standing instrumentation cabinets and panels shall be located within
the construction tolerances of +/- 3 mm of the location dimensions indicated
on the Employer's plant arrangement drawings.
(a.) Free-Standing Equipment
Free-standing Cabinets shall be attached to the floor, concrete equipment

bases or supporting steel as indicated on the manufacturer's drawings and
the Employer's Plant Arrangement Drawings. The cabinets shall be shimmed
for proper alignment before bolting them to the floor. Adjacent enclosures
shall be shimmed to maintain mutually level appearance before they are
attached to floor. Vibration dampening mounts shall be installed between
supporting structures and panels when specified.
(a.) Non-free Standing Equipment
(1.) Non-free standing local enclosures and cabinets shall be mounted in

accessible locations on columns, walls, or stands in locations as
indicated on the Employer's Plant Arrangement Drawings. Bracket
and stands shall be fabricated as required to install the local
enclosures and cabinets in a workman like manner.
(2.) Rough edges and welds on all fabricated supports shall be ground
smooth. The supports shall be finished with two coats of primer and
two coats of paint as specified in this part.

(a.) Equipment Location
(1.) All individual items of equipment not located in cabinets or on panels

and racks are located approximately according to the floor elevation
and the nearest building column designated by the Employer.
(2.) Solenoid valves not located in enclosures or mounted on valves shall

be mounted in easily accessible protected locations near the
components with which they are associated.
(3.) All brackets, stands, supports and other miscellaneous hardware

required for mounting devices shall be furnished and installed.
(4.) Thermometers shall be installed in the process lines and ducts as

required and adjusted for ease in reading.
(5.) Permanent temperature wells on the main steam, hot reheat and cold
reheat piping shall not be installed until steam blowing has been
completed. Temporary temperature wells shall be installed in the main
and reheat steam piping during steam blow and discarded after
completion.
(6.) Any required adapting hardware such as pipe bushings, nipples,

drilled caps and the like shall be provided for complete installation of
control devices into process connections.
For location of C&I related equipment/devices, the requirement specified

elsewhere in the technical specification may be referred.
(a.) Installation of Field Mounted Instruments and Devices
The Contractor shall submit installation drawings for all field mounted
equipment furnished under this specification for Employer's approval. These
drawings shall meet the requirements of this specification, installation
drawings, applicable codes and standards and recommendations of
manufacturers of instruments/devices. All installation work under this
specification shall be strictly as per installation drawings approved by the
Employer during detailed engineering stage.
In addition to above relevant Portion as specified elsewhere in technical

specification may be referred.
(a.) Piping Connections
(1.) All equipment having piping connections shall be levelled, aligned and
wedged in place but shall not be grouted or bolted prior to the initial
fitting and alignment of connecting piping. All equipment shall,

however, be grouted or bolted to its foundation prior to final bolting or

welding of the connection piping.
(2.) All flanged joints shall be checked and retightened after approximately
10 days of operation at normal operating temperature.
(a.) Equipment Checkout
(1.) All equipment shall be cleaned after installation. Equipment subject to

pressure differentials shall be checked for leakage.
(2.) After erection, all equipment having moving parts, having electrical
apparatus, or subject to pressure differentials shall be trial-operated.
(a.) Defects
(1.) All defects in erection shall be corrected to the satisfaction of the

Employer and the Project Manager. The dismantling and reassembly
of Contractor furnished equipment to remove defective parts, replace
parts, or make adjustments shall be included as a part of the work
under these specifications.
(2.) The removal of control and instrument equipment in order to allow

bench calibration, if required, and the re-installation of the said
equipment after calibration shall also be included as a part of the work
under these specifications.
(a.) Equipment Protection
(1.) All equipment to be erected under these specifications shall be

protected from damage of any kind from the time of contract award
until commissioning of each unit.
(2.) The equipment shall be protected during storage as described herein.
(3.) Equipment shall be protected from weld spatter during construction.
(4.) Suitable guards shall be provided for protection of personnel on all

exposed rotating or moving machine parts. All such guards with
necessary spares and accessories shall be designed for easy removal
and maintenance.
(5.) Equipment having glass components such as gauges, or equipment

having other easily breakable components, shall be protected during
the construction period with plywood enclosures or other suitable
means. Broken, stolen, or lost components shall be replaced by the
Contractor.

(6.) Machine finished surfaces, polished surfaces, or other bare metal

surfaces which are not to be painted, such as machinery shafts and
couplings shall be provided temporary protection during storage and
constructional periods by a coating of a suitable non- drying, oily type,
rust preventive compound.
52.00.00 WELDING - SPECIAL REQUIREMENTS
If the manufacturer has special requirements relating to the welding procedures for
welds at the terminals of the equipments to be performed under separate
specifications, the requirements shall be submitted to the Project Manager in
advance of commencement of erection work.
53.00.00 DEVIATIONS DISPOSITIONING:
Any deviation to the contract and employer approved documents shall be properly
recorded in the format prescribed by Employer. Al the deviations shall be bought to
the knowledge of employer’s representative for suitable dispositioning.
54.00.00 NON-DESTRUCTIVE TESTING ( NDT):
The contractor shall record results of NDTs carried out at site in the format
acceptable to employer. All the radiographs & its report duly signed & correlated to
the job shall be handed over to the employer. Sensitivity of all the test equipment
shall be compatible to the job & acceptance norms agreed.
55.00.00 TESTING EQUIPMENT & FACILITIES:
Contractor shall provide the testing equipment and facilities necessary to carry out
tests & inspections.

ANNEXURE-I
STANDARD CHECKLIST - COMMISSIONING/TESTING ESSENTIAL

PRE-REQUISITE
(a.) Mechanical
Sl. No. DESCRIPTION
(1.) Valves- All Types as applicable
(2.) Tanks And Pressure Vessels as Applicable
(3.) Pumps as applicable
(4.) Pipe Work System as applicable
(5.) Strainer And Filter as applicable
(6.) Heat Exchangers/ Cooling Towers as applicable
(7.) Fans And Compressors as applicable
(8.) Dampers & Gates as applicable
(9.) Duct Work as applicable
(10.) Cranes. Hoists And Elevators as applicable
(11.) Power Transmission (Gear Box, Bearings & Couplings) as applicable
(a.) Electrical
(1.) D.C. Motor
(2.) Hv Squirrel Cage Induction Motor
(3.) 415 V Squirrel Cage Induction Motor
(4.) Motor Operated Actuators
(5.) HT Switchgears
(6.) LT Switchgears/MCC
(i.) Standard Checklists for all types of relays used in Switchgears
Protection System
(ii.) PT Carriage and Cubicles
(iii.) Cable/Bus Duct/Bus Bars
(iv.) Contractor Module
(v.) Switch Fuse Module
(vi.) Master Panel of Lube Oil Panel
(vii.) Feeder Panel Of Lube Oil Panel
(viii.) Space Heater And Cable Module
(ix.) HT Circuit Breaker

(x.) 415 V Circuit Breaker

(7.) Power Cable
(8.) Auxiliary Cable
(9.) D.C. Cable
(10.) Explosion Proof Electrical Equipment
(11.) Junction Box
(12.) Control Transformer Module
(13.) Soot Blower Sequence Panel
(14.) Brush Gear Assembly
(15.) Aux. Control And Relay Panel Desk
(16.) Indicating Instrument
(17.) Recording Instrument
(18.) Integrating Instrument
(a.) Control & Instrumentation
(1.) Conductivity Analysing Equipment including Test procedures
(2.) pH analyser including test procedure
(3.) Silica analyser
(4.) Level switch (float actuated)
(5.) Level Switch (Electrode Type)
(6.) Level Switch Displaced actuated
(7.) Transmitter (Float Operated Pneumatic Output)including testing
procedure
(8.) Level Indicator (Float/Pulley Type)
(9.) Local Temperature Indicators Including Test Procedure
(10.) Resistance Thermometer Element including Test Procedure
(11.) Thermocouple Element And Connecting Cable
(12.) Thermocouple and Resistance Thermometer Convertor/Transmitter
including Test Procedures.
(13.) Temperature Switch/Thermostat including test procedures
(14.) Cold Junction Boxes
(15.) Zener Barrier
(16.) O2 Analyser
(17.) O2 In Hydrogen Including Test Procedures
(18.) Pressure and Vacuum Gauge

(19.) Pressure And Vacuum Switch Including Test Procedure

(20.) Differential Pressure Transmitter including test procedure
(21.) Differential Pressure switch including test procedure.
(22.) Flow Indicator(variable area)
(23.) Orifice Plate
(24.) Turbine Flow Transmitter
(i.) Flow Switch
(ii.) Weir
(iii.) Nozzle
(iv.) Flow Indicator (Pneumatic input) including test procedure
(v.) Flow integrator (Pneumatic input) including test procedure
(vi.) Flow indicator (float operated) including test procedure
(vii.) Venturi (Fluid)
(viii.) Flow switch (Magnetic Type)
(ix.) Averaging Inlet
(x.) Limit Switches
(25.) Turbine Supervisory Measuring System
(26.) Position Measurement and indication including Test Procedures
(i.) Tachometer
(ii.) Vibration Measurement
(iii.) Digital Indicator
(iv.) Moving Coil Indicator Including Test Procedure
(v.) Recorder Including Test Procedure
(vi.) Flame Scanner
(vii.) Electrical Auto Manual Control Station
(viii.) Push Button Module
(ix.) Alarm Annunciator Equipment Including Test Procedure
(x.) Test procedure for electronic Modules of DDCMIS
(xi.) Thermo Control Valve
(xii.) Test Procedure for adjustment of modulating Controller –PID
Terms
(xiii.) Test Procedure indicating Controller-Electrical Input and
Pneumatic Output

Note: The items which are not part of this specification may be considered as not
applicable.

ANNEXURE-II
BRIEF WRITE UP ON THE CONTENTS OF TESTING SCHEDULE /
COMMISSIONING SCEHDUELE
Testing Schedules should be designed to ensure that the plant area, equipment or
apparatus are tested and commissioned and will operate as per the employer’s
specifications and good engineering practices.
Testing Schedule/Commissioning Schedule is required to be of a standard format in
order to maintain consistency of presentation, content and reporting.
Testing Schedule/Commissioning Schedule should contain the following sections to
make the document a self contained one:
(a.) Plant Details/Design data
(b.) Testing Objective/Proposals
(c.) State of the Plant
1) Erection Status with respect to Mech. Elect and C&I
2) Availability of the services required
3) Safety requirements as per manufacturer’s data
(a.) Test method including completion/acceptance criteria
(a.) Results
(a.) Appendix
(1.) Testing Programme
(2.) Mech/Elect/C&I –Plant item completing list
(3.) List of Drawing/documents required for carrying out the testing.

PART- E
LIST OF TENDER DRAWINGS

PART- F
LIST OF MANDATORY SPARES

CLAUSE NO.
MANDATORY SPARES
1.00.00 AIR RELEASE VALVES
Sl. Item Description (as applicable) Quantity

No.
1) 1 number or 10% of total
Air release valves
population of valve of each
type/ size /rating,
whichever is more.

TECHNICAL SPECIFICATIONS PART – F
SECTION VI –Part – F MANDATORY SPARES

Technical Specification GRP Pipes

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Technical Specification GRP Pipes

Загружено:

Авторское право:

Доступные форматы

PART- B

SUB-SECTION – III A-01

GRP PIPES, FITTINGS & SPECIALS

SPECIFICATION FOR GLASS FIBRE REINFORCED PLASTICS (GRP) PIPES,

This specification covers the specific requirement of design, material, manufacture /

2.00.00 CODE AND STANDARDS

S.No. Code No. Code Title

DARLIPALI STPP STAGE-I (2X800 MW) Sub-Section – IIIA-01

16. ASTM D 2105 Standard Test Method for Longitudinal Tensile

DARLIPALI STPP STAGE-I (2X800 MW) Sub-Section – IIIA-01

3.00.00 DESIGN REQUIREMENTS

3.01.00 Nominal Diameter

Pipes shall be supplied in nominal lengths of 6m/9m/12m as per requirements. The

3.03.00 Wall Thickness

3.04.00 Pressure Class

3.05.00 Stiffness Class

3.06.00 Hoop and Longitudinal tensile strength

4.00.00 MATERIAL REQUIREMENTS

DARLIPALI STPP STAGE-I (2X800 MW) Sub-Section – IIIA-01

4.02.00 Glass Fiber Reinforcement: Glass fiber reinforcement shall be of commercial

4.03.00 Other Materials

5.00.00 MANUFACTURING REQUIREMENTS

The pipe shall be manufactured through Filament winding process (Continuous

5.01.00 Wall composition

DARLIPALI STPP STAGE-I (2X800 MW) Sub-Section – IIIA-01

7.00.00 GRP FITTINGS & SPECIALS

Generally, all GRP fittings are to be manufactured in factory. Dimensions of the

Only in exceptional circumstances, specific required fittings may be permitted

7.02.00 Fittings made from straight pipe

7.03.00 Fittings made by Moulding

8.00.00 TYPE TESTS

DARLIPALI STPP STAGE-I (2X800 MW) Sub-Section – IIIA-01

to be supplied under this contract, at an independent laboratory or duly approved by

8.04.00 Not Used.

8.05.00 The following type tests shall be carried out:

a) Long term hydrostatic strength / Long term hydrostatic pressure

b) Chemical resistance of pipe in a deflected condition

d) Long term Stiffness – Material creep

DARLIPALI STPP STAGE-I (2X800 MW) Sub-Section – IIIA-01

e) Long term Ring bending strain test

The marking on pipe shall include the following:

a) Standard mark for the pipes conforming to IS / AWWA / ASTM standards to

b) The manufacturer's name or trademark

c) The nominal pipe diameter

d) Class of pipe (Pressure & Stiffness)

e) Batch no. or date of manufacture

f) Colour bands for over ground piping

10.00.00 TRANSPORTATION AND DELIVERY OF PIPES

DARLIPALI STPP STAGE-I (2X800 MW) Sub-Section – IIIA-01

DARLIPALI STPP STAGE-I (2X800 MW) Sub-Section – IIIA-01

Pipes over 3% deflection shall be replaced completely. No attempt to jack or wedge

DARLIPALI STPP STAGE-I (2X800 MW) Sub-Section – IIIA-01

11.16.00 Field Hydrostatic Tests

12.00.00 ANNUAL MAINTENANCE CONTRACT (AMC) TERMS & CONDITIONS

DARLIPALI STPP STAGE-I (2X800 MW) Sub-Section – IIIA-01

DATA SHEET FOR GRP PIPES, FITTINGS AND SPECIALS

S.no. Description Units Parameters

DARLIPALI STPP STAGE-I (2X800 MW) Sub-Section – IIIA-01

SUB-SECTION – III A-02

DI PIPES, FITTINGS & SPECIALS

SPECIFICATION FOR DUCTILE IRON (DI) PIPES, FITTINGS & SPECIALS

This specification covers the specific requirement of design, material, manufacture /

2.00.00 CODE AND STANDARDS

The material, design, manufacture, dimensions, tolerances, mechanical properties,