TENDER SPECIFICATION

BHEL:PSSR:SCT: 1308

FOR

Handling at Site Stores / Storage yard,

Transportation to site of work, Erection, Testing and
Commissioning of Electrical Package for Unit 10 of
120 MW at Nalco CPP

At

National Aluminium Company Limited

CPP Expansion Phase II
Angul District, Orissa state
PART - I TECHNICAL BID
BOOK NO :

BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking)
Power Sector - Southern Region
690, Anna Salai, Nandanam, Chennai - 600 035.
 INDEX SCT : 1308 - NALCO CPP ELECTRICAL PACKAGE

[Link] Description Page

1 Covering Letter 1-2

2 Special instructions to Bidders 3-4

3 Procedure for submission of sealed bids 5

4 Tender Notice 6-7

5 Certificate for No Deviation 8

6 Offer of Contractor 9-10

7 Project Information 11

8 Section III - Common Conditions of Contract 12-29

9 Section VI - Special Conditions of the Contract 30-98

10 Section –VII 99-139

General Technical Requirements and Guidelines for Installation,

Testing, Commissioning and Supply

SECTION - VIII

Appendix- I Data Sheet 140-142

Appendix-II Declaration Sheet 143

Appendix-III Certificate of Declaration For Confirming 144
knowledge On site Conditions
Appendix-IV Check list 145-147

Bill of Materials for Electrical / C&I/Illumination Package 148-171

Appendix-V Price Bid (Separate Book) 13

General Conditions of Contract (Separate Book) 73

 BHARAT HEAVY ELECTRICALS LIMITED
(A Government of India Undertaking)
Power Sector, Southern Region
690, Anna Salai, Nandanam, Chennai - 35

Tender Specification No. BHEL:PSSR:SCT: 1308

Messrs Date:

Dear Sir,

SUB: Handling at Site Stores / Storage yard, Transportation to

site of work, Erection, Testing and Commissioning of

Electrical Package for unit- 10, of 120 MW at Nalco CPP
Expansion Phase II, Angul, Orissa.

Please find enclosed one set of non-transferable tender Specification along

with Separate Booklets for general conditions of contract and Rate schedule for
the above work.

You are requested to go through the tender documents, GCC Booklet and offer
your most competitive rate and submit the tender documents duly filled in as per
procedure indicated in the tender specification along with requisite EMD of Rs.
2,00,000/- (Rupees Two lakhs only ) in the form Demand Draft drawn in favour of
M/[Link] Heavy Electrical Limited Chennai - 35.

Bids with Deviations from the tender conditions will be rejected.

A SEPARATE LETTER SHALL BE FURNISHED INDICATING THAT THERE ARE NO
DEVIATIONS FROM THE TENDER CONDITIONS (As in Page 8.)

The completed quotations shall reach the office of the under signed on or before
17.9.2008 at 15.00 Hrs. The Technical bids, will be opened on the same day at
15.30 hrs.

We shall separately intimate the date for opening the price bids only to those parties
who are technically qualified. You are requested to depute your authorized
representative at the time of opening.

ANY REVISION OF RATES / PRICES WHAT SO EVER AFTER THE TIME AND
DATE MENTIONED IN TENDER SPECIFICATION FOR
SUBMISSION OF COMPLETED QUOTATIONS SHALL NOT BE
ENTERTAINED UNLESS CALLED FOR SPECIFICALLY BY BHEL.

Kindly acknowledge receipt of the tender documents and confirm your

participation.

Kindly note that BHEL reserves the right to reject any or all tenders without assigning
any reason.

Thanking you,

Yours faithfully,
For and on behalf of

BHARAT HEAVY ELECTRICALS LIMITED

ADDL. GENERAL MANAGER / CONTRACTS

This Tender document is not transferable.

Place : Chennai -35

Encl: One set of Tender documents along with GCC Booklet & Drawings
 BHARAT HEAVY ELECTRICALS LIMITED
(A Government of India undertaking)
Power Sector : Southern Region
690, Anna Salai, Nandanam, Chennai - 600 035.

SPECIAL INSTRUCTIONS TO BIDDERS

The Bidder must submit their bids as requested in a sealed cover prominently super
scribing the Tender Specification number, due date and time of submission as mentioned in
the TENDER NOTICE.

The following information shall be furnished by the Bidder along with their offer
(Technical Bid cover)

01. Details of previous experience during the last Seven years indicating contract value,
duration, completion period and present engagement as per G.C.C.

02. Organization structure of the Company as per GCC.

03. Financial status of the firm enclosing balance sheet and profit and loss account for
the past 3 years and certificate from the Company’s Banker as per G.C.C

04. Turnover of the Company in last 3 Financial years pertaining to this scope of work
only.

05. Latest Income Tax clearance certificate.

06. BIO DATA of key personnel presently in the Rolls of the company and proposed
site organization for carrying out the work including deployment of Engineers and
Supervisors.

07. Declaration sheets as per Appendix of Tender Specification.

08. Checklist and Schedule of General particulars as per Appendix in GCC.

09. T & P owned/deployment details as per G.C.C.

10. Technical manpower deployment details as per G.C.C

11. Other relevant details as per GCC and checklist.

12. These terms and conditions will be read and construed along with General
Conditions of contract and incase of any conflict or inconsistency between the
General conditions and the Terms and conditions of the tender specification, the
provisions contained in the Term and conditions (NIT, Rate Schedule, Common
conditions, Special Conditions including Appendices) shall prevail.
13. THE BIDDERS ARE REQUESTED TO FURNISH THE DOCUMENTS LIKE COPIES
OF LOI’S, WORK ORDER’S ETC PERTAINING TO THE EXPERIENCE
INDICATED IN QUALIFYING REQUIREMENTS, AS GIVEN BELOW.
14. Qualification Criteria

The bidder should have completed erection, testing and commissioning of HT/LT
Electrical works consisting of HT oil cooled transformer of rating of min 10 MVA,
HT bus ducts of rating min 3.3 KV and other related works like HT / LT cable,
switch gear, trays and tray supports, etc. in the last seven years.

(OR)

The bidder should have completed erection, testing and commissioning of Total
C&I systems of boiler or Turbine or station C&I and LT electrical works in a
power plant of capacity min 210 MW in last seven years.

(OR)

The bidder should have completed erection, testing and commissioning of LT

Electrical package comprising of bus ducts, transformers, switch gears, cables,
tray work, earthing etc in a power plant of capacity min 110 MW in last seven
years.

b) The bidders should have a minimum average financial turn over of Rs. 77.00
Lakhs per year in the preceding three years ending 2007.

The bidder must have earned profit in any one of the last three
financial years ending 31.03.2007 and should have positive net worth as
on 31.03.2007

The bidder should submit audited balance sheet and profit and loss
account of the company for the last three years ending 31.03.2007 in
support of above requirement.

c) Notwithstanding the above, BHEL reserves the right to reject any Tender or all
the Tenders for reasons whatsoever beyond its control and the decision of BHEL
is final.

d) Approval of agency by customer.

e) LD / Penalty shall be leviable as per the applicable clauses of GCC.

15. A DECLARATION SHEET INDICATING THAT THERE IS NO DEVIATION IN

TENDER DOCUMENTS (AS IN PAGE 8) IS TO BE FURNISHED. TENDERERS MAY
FURTHER NOTE THAT THIS DECLARATION IS A PREREQUISITE FOR BHEL TO
CONSIDER THEIR BIDS. BIDS SUBMITTED WITHOUT “NO DEVIATION
DECLARATION” WILL BE REJECTED BY BHEL.

16. SAFETY PLAN

Bidder may further note that the submission of safety plan is a prerequisite
for BHEL to consider their bids.
 BHARAT HEAVY ELECTRICALS LIMITED
(A Government of India undertaking)
Power Sector : Southern Region
690, Anna Salai, Nandanam, Chennai - 600 035.

PROCEDURE FOR SUBMISSION OF SEALED BIDS

The Tenderers must submit their bids as required in two parts in separate sealed covers
prominently super scribed as Part I “Technical Bid” and Part II “Price Bid” and also
indicating on each of the covers the tender specification number and due date and time
as mentioned in the Tender Notice.

Part I (Technical Bid) Cover I

Excepting Rate Schedule, all other schedules, data sheets and details called for in the
specification shall be enclosed, in part I Technical Bid only.

Part II (Price Bid) Cover II

All indications of price shall be given in this part II Price Bid only

Tenderers are requested to quote their rates, only in the price bid (part II)
provided by BHEL. Quoting of rates in any other form / formats will not be
entertained.

These two separate cover I & II (Part I and Part II) shall together be enclosed in a third
envelope (Cover III) along with requisite EMD as indicated and this sealed cover shall
be super scribed and submitted to Addl. General Manager/Contracts at the above
mentioned address before the due date as indicated. The Tenderers will be intimated
separately in case clarifications are required.

NOTE:

Tenderers are issued with 2 Nos. of Technical Bids, 2 Nos. of Price Bids and 2 Nos. of
GCC booklet., out of which one set of each document shall be retained by them for their
reference. Balance one set shall be submitted along with their offer as per procedure
indicated above.

EMD amount for this Tender is Rs.2,00,000/-(Rupees Two lakhs only). This EMD amount
shall be submitted in the form demand draft only drawn in favor of M/s. Bharat Heavy
Electricals Limited, Chennai - 35.

EMD amount in the form of Bank Guarantee / fixed deposit receipt or in any other form
will not be Accepted.

ANY REVISION OF RATES / PRICES WHAT SO EVER AFTER THE TIME AND
DATE MENTIONED IN TENDER SPECIFICATION FOR SUBMISSION OF
COMPLETED QUOTATIONS SHALL NOT BE ENTERTAINED UNLESS CALLED
FOR SPECIFICALLY BY BHEL.

Addl. General Manager/Contracts.

 BHARAT HEAVY ELECTRICALS LIMITED
(A Government of India Undertaking)
Power Sector, Southern Region
690, Anna Salai, Nandanam, Chennai - 35

TENDER NOTICE

Sealed Tenders are invited from reputed contractors with sufficient previous experience
in the under mentioned nature of work and meeting the Qualification Requirements.

Tender Specification No. BHEL:PSSR:SCT: 1308

Description EMD

Handling at Site Stores / Storage yard, Transportation

to site of work, Erection, Testing and Commissioning of Rs.2,00,000/-

Electrical Package for unit- 10 – of 120 MW at Nalco CPP (Rupees Two Lakhs only)
Expansion Phase II, Angul, Orissa.

Cost of Tender Documents : Rs.1040/-

(Including all Taxes)

Sale Starts on : 27.08.2008

Sale closes on : 16.09.2008

Due date and Time for

Submission : 17.09.2008 15.00 HRS

Date and time for opening

Of Technical Bids : 17.09.2008 1
15.30 HRS
QUALIFICATION REQUIREMENT

a) The bidder should have completed erection, testing and commissioning of HT/LT Electrical
works consisting of HT oil cooled transformer of rating of min 10 MVA, HT bus ducts of rating
min 3.3 KV and other related works like HT / LT cable, switch gear, trays and tray supports,
etc. in the last seven years.
(or)

The bidder should have completed erection, testing and commissioning of Total C&I systems of
boiler or Turbine or station C&I and LT electrical works in a power plant of capacity min 210
MW in last seven years.

(Or)

The bidder should have completed erection, testing and commissioning of LT Electrical
package comprising of bus ducts, transformers, switch gears, cables, tray work, earthing etc
in a power plant of capacity min 110 MW in last seven years.

b) The bidders should have a minimum average financial turn over of Rs.77.00 Lakhs per
year in the preceding three years ending 2007.

The bidder must have earned profit in any one of the last three financial
years ending 31.03.2007 and should have positive net worth as on 31.03.2007

The bidder should submit audited balance sheet and profit and loss account of
the company for the last three years ending 31.03.2007 in support of above
requirement.

c) Notwithstanding the above, BHEL reserves the right to reject any Tender or
all the Tenders for reasons whatsoever beyond our control and the decision of BHEL is
final.

d) Approval of agency by customer.

Penalty shall be leviable as per the applicable clauses of GCC.

Interested parties can get the Tender documents from the office of the Additional
General Manager / Contracts on all working days (except Second and last Saturdays) by
remitting the cost of tender documents either by Cash ( 10.00 AM- 4.00 PM) or A/c Payee
Demand Draft (10 AM- 4.30 PM ) drawn in favour of M/s. Bharat Heavy Electricals
Limited, Chennai - 600 035. Money order, Cheques and Postal Orders will not be
accepted.

Bharat Heavy Electricals Limited takes no responsibility for any delay, loss or non receipt
of tender documents sent by post and also reserves the right to reject any or all the tenders
without assigning any reason there for.

ADDL. GENERAL MANAGER/CONTRACTS

 TENDER SPECIFICATION : BHEL:PSSR:SCT:1308

CERTIFICATE FOR NO DEVIATION

I, Of M/s.

hereby certify that there is no deviation from the Tender

conditions either technical or commercial and I am agreeing

to all the terms and conditions mentioned in the Tender

Specification.

SIGNATURE OF THE TENDERER

 OFFER OF CONTRACTOR

Addl. General Manager/Contracts

Bharat Heavy Electricals Limited,
Power Sector: Southern Region
690, Anna Salai,
Nandanam, Chennai - 600 035.

Sir,

I/We hereby offer to carry out the work detailed in Tender Specification No. BHEL:
PSSR: SCT: 1308 issued by Bharat Heavy Electricals Limited, Power Sector: Southern
Region, in accordance with the terms and conditions thereof.

I/We have carefully perused the following documents connected with the above work and
agree to abide by the same.

1. Instructions to Tenderer
2. General Conditions of Contract
3. Special conditions of Contract
4. Other Section, Appendices and Schedules
 I/We have deposited/forwarded herewith the Earnest Money Deposit/a sum of
Rs.2,00,000/- (Rupees Two lakhs only) vide DD No. Dt.
which shall be refunded should our offer not be accepted. Should our offer be accepted,
I/We further agree to deposit such additional sum which along with the sum of
Rs.2,00,000/- (Rupees Two lakhs only ) mentioned above, to make up the Security
Deposit for the work as provided for in the Tender Specification within the stipulated time as
may be indicated by BHEL, Power Sector : Southern Region, Chennai - 600 035.

I/We further agree to execute all the works referred to in the said documents upon the terms
and conditions obtained or referred to therein and as detailed in the appendices annexed
thereto.

DATE: CONTRACTOR:

PLACE: ADDRESS:

Witness with their address

Signature Name Address

 PROJECT INFORMATION

1.0 PROJECT:

Customer : M/s NATIONAL ALUMINIUM COMPANY LTD

(A Government of India Enterprise)
NALCO BHAVAN , NAYAPALLI,
BHUBANESHWAR 751 013

Project Site : NALCO CAPTIVE POWER PLANT EXPANSION

UNIT NO. 9 & 10 AT ANGUL , ORISSA STATE

Location - Angul in Orissa about 3 Km on the north of the

junction of the National Highways Nos 42 and 43 and
just by the side of NH42.

2.0 CLIMATIC CONDITIONS

The following site conditions shall be considered for the purpose of design
and selection of equipment and materials:

Temperature
Dry Bulb Temperature 27.70 C (Mean)
Dry Bulb Temperature 31.60C (Max)
Wet Bulb Temperature 23.80 C (Mean)
Wet Bulb Temperature 27.20C (Max)
Extreme Lowest Temperature 27.70C (Mean)
Extreme Maximum temperature 46.70 C
Maximum ambient temperature 41.60 C
Minimum ambient temperature 10.80 C
Rainfall Maximum Monthly rainfall 649.9 mm (October)
Average minimum rainfall 678.5 mm (2002)
Average annual rainfall 1700 mm
Relative Humidity- Maximum 84 %
Minimum 57 %
Wind
Wind Load 55 m/sec
Predominant Wind direction South-west to North-East South to North
Seismic Zone Zone III, as per IS - 1893
Plant Elevation 65 m above mean seal level
 SECTION III

COMMON CONDITIONS OF CONTRACT

3.1 SCOPE OF CONTRACT

3.1.1 The Intent of this specification is to provide erection and commissioning

services for execution of projects according to most modern and proven
techniques and codes. The omission of specific reference to any method and
equipment or material necessary for the proper and efficient services towards
installation of the Plant shall not relieve the contractor of the responsibility of
providing such services, facilities to complete the project or portion of project
awarded to him. The quoted rate shall deem to be inclusive of all such
contingencies.

3.1.2 The contractor shall carry out the work in accordance with
Instructions/drawings / specification / standard practices supplied by BHEL
from time to time.

3.1.3 Provisions of all types of labour, Supervisors, Engineers watch and ward as
required tools and tackles as required consumables as required under various
clauses of tender specification for handling, transportation, erection testing and
commissioning.

3.1.4 Proper out-turn as per BHEL plan and commitment.

3.1.5 Completion of work in time.

3.1.6 Good quality and accurate workmanship for proper performance of

equipment/systems.

3.1.7 Preservation of all components at all stages of pre-assembly / erection / testing

and commissioning till unit is handed over as specified in detail in clause.

3.2.0 FACILITIES TO BE PROVIDED BY BHEL:

3.2.1 OPEN SPACE

Minimum Open space for building of 1 No temporary office / store shed will
be provided free of charges. Contractor has to make his own
arrangements for labour colony, including Electricity and water for the labour
colony.

3.2.2 ELECTRICITY

For construction purpose and for contractor’s office and store sheds
electricity will be provided at one single point on chargeable basis, as
provided by Nalco. The current rate is around Rs.2.85/- per KVA which
shall be subject to variation as applicable from time to time. Further
distribution shall be arranged by the contractor at his own cost including
supply of energy meter with calibration certificate.
 BHEL is not responsible for any loss or damage to the contractors equipment as
a result of variations in voltage / frequency or interruptions in power supply.

Before connecting any equipment the contractor shall ensure that it is

rated for the correct voltage to which it is being connected and the
equipment is not likely to cause a fuse blow out.

The contractor shall endeavour to minimize the current consumption as far

as possible and avoid wastage.

3.2.3 WATER

For construction purpose, water will be provided at one point free of

cost nearer to the project site. Further distribution shall be arranged by the
contractor at his own cost. For drinking purpose the contractor has to make his
own arrangement at his cost.

3.2.4 TOOL AND TACKLES

All the Tools & Plants and instruments required for the complete
erection of components shall be arranged by the contractor.

3.2.5 CONSUMABLES

All consumables, electrodes including Oxygen / Acetylene, Argon , Gases,

paints etc., shall be arranged by the contractor at his own cost.

3.3.0 FACILITIES TO BE PROVIDED AND DEVELOPED BY THE CONTRACTOR

AT HIS COST.

3.3.1 CIVIL CONSTRUCTION

It shall be the responsibility of the contractor to construct his own office

shed, stores shed with all facilities like electricity, water supply,
sanitary arrangements in the area allotted to him for this purpose.

3.3.2 WATER DISTRIBUTION

Distribution of water for various work fronts from the single point shall
be arranged by the contractor at his cost.
3.3.3 ELECTRICITY DISTRIBUTION

Distribution of electrical power from the given single central common point to
the required places with proper distribution boards, approved cable and cable
laying including, supply of all materials like cables, switch boards, pipes etc.
Observing the safety rules laid down by electrical authority of the State / BHEL
/ their customer with appropriate statutory requirements shall be the
responsibility of the tenderer / contractor. Any duty, deposit involved in getting
the electricity shall be borne by the bidder. As regards contractors office shed
also all such expenditure shall be borne by the contractor. Necessary meters
for recording consumption of power for cost calculation purpose and
maintenance of the same during execution period shall be contractor’s
responsibility.

3.3.4 POSSESSION OF GENERATORS

As there are bound to be interruptions in regular power supply power cut/load

shedding in any construction site due to inherent power shortage in State ,
suitable extension of time if found necessary only be given on this account
and Contractor is not entitled for any compensation. It shall be the
responsibility of the tenderer / contractor to provide maintain the complete
installation on the load side of the supply with due regard to safety
requirements at site. The contractor shall adjust his working shifts
accordingly and deploy additional manpower, if necessary to achieve the
target.

3.3.5 LIGHTING FACILITIES

Adequate lighting facilities such as flood lamps, low volt hand lamps and Area
lighting shall be arranged by the contractor at the site of construction,
contractor’s material storage area etc, at his cost.

3.3.6 POWER REQUIRMENT

For the purpose of planning, contractor shall furnish along with tender the
estimated requirement of power (month wise) for execution of work in terms of
maximum KW demand.

3.3.7 CONTRACTOR’S OBLIGATION ON COMPLETION

On completion of work all the temporary buildings, structures, pipelines, cable etc.
shall be dismantled and levelled and debris shall be removed as per instruction
of BHEL, by the Contractor at his cost. In the event of his failure to do so BHEL will
undertake such work and the cost of the same will be recovered from the
Contractor including overhead charges. The decision of BHEL. Engineer in this
regard is final.
3.4.0 GASES

3.4.1 All required gases like Oxygen / acetylene / argon / Nitrogen required for work
shall be supplied by the Contractor at his cost. It shall be the responsibility of the
contractor to plan the activities and store sufficient quantity of those gases. Non-
availability of gases cannot be considered as reason for not attaining the required
progress of erection.

3.4.2 BHEL reserves the right to reject the use of any gas in case required purity is
not maintained.

3.4.3 The contractor shall submit weekly / fortnightly / monthly statement

report regarding consumption all consumables for cost analysis purposes.

3.4.4 The contractor shall ensure safe keeping of the inflammable cylinder at
a separate place away from normal habit with proper security etc.

3.4.5 The contractor shall arrange air/gas manifold ensuring proper distribution and
reduction of handling time.

3.5.0 ELECTRODES & FILLER WIRES

3.5.1 All required electrodes shall be arranged by contractor at his cost. It shall
be the responsibility of the contractor to obtain prior approval of BHEL,
before procurement regarding suppliers, type of electrodes etc. On
receipt of the electrodes at site, it shall be subject to inspection and
approval of BHEL. The contractor shall inform BHEL details regarding
type of electrodes, batch number and date of expiry.

3.5.2 Storage of electrodes shall be done in an air conditioned / controlled

humidity room as per requirement, at his own cost by the contractor.

3.5.3 All low hydrogen electrodes shall be baked / dried in the electrode drying
oven (range 375 deg. C - 425 deg. C) to the temperature and period
specified by the BHEL Engineer before they are used in erection work and
each HP elder should be provided with one portable electrode drying oven
at the work spot. Electrode drying oven and portable drying ovens
shall be provided by contractor at his cost.

3.5.4 In case of improper arrangement of procurement of above electrodes

BHEL reserve the right to procure the same from any source and
recover the cost from the contractor’s first, subsequent bill at market
value plus departmental charges of BHEL. Postponement of such recovery is
not permissible.

3.5.5 BHEL reserves the right to reject the use of any electrodes at any stage
if found defective because of bad quality, improper storage, date of
expiry, unapproved type of electrodes etc. It shall be the
responsibility of the contractor to replace at his cost without loss of time.
3.6.0 TOOLS & TACKLES

3.6.1 All T & P required for the satisfactory execution of work shall be
arranged by contractor at his cost.

3.6.2 All instruments, measuring tools etc., are to be calibrated periodically as

per the requirement of BHEL and necessary calibration certificates are
to be submitted to BHEL before use.

3.6.3 All the T & P, lifting tackles including wire ropes, slings shackles
and electrically operated equipment shall be got approved by BHEL
engineer before they are actually put on use. Test certificates
should be submitted before their usage.

3.6.4 All the T & P arranged by contractor including electrical connections

wherein required shall be reliable / proven / tested and necessary test
certificate to be submitted as per statutory rules of the State / Central
Government in force from time to time.

3.6.5 For the movement of cranes etc., it may become necessary to lay
sleeper bed for obtaining leveled safe approach for usage of
equipment. It shall be the contractor’s responsibility to lay
necessary sleepers. Required sleepers shall be arranged by
the contractor at his cost.

3.7.0 SUPERVISORY STAFF AND WORKMEN

3.7.1 The Contractor shall supply all the skilled workmen like Welders, Gas cutters,
electricians, Riggers, Serangs, Erectors, carpenters, fitters etc. in addition to
other skilled, semi-skilled and unskilled workmen required for all the works of
handling and transportation from site stores/storage yard to erection site,
transportation, erection, testing and commissioning contemplated under this
specification. Only fully trained and competent men with previous experience
on the job shall be employed. They shall hold valid certificates wherever
necessary.

BHEL reserves the right to decide on the suitability of the workers and
other personnel who will be employed by the contractor, BHEL reserves right
to insist on removal of any employee of the contractor at any time, if
they find him unsuitable and the contractor shall forthwith remove him.

3.7.2 The supervisory staff employed by the contractor shall be qualified (Engineers
- Graduates in Engineering and Supervisors - Diploma Holders) and
experienced in the area of work. They shall ensure proper out-turn of work
and discipline on the part of labour put on the job by the contractor and in
general see that the works are carried out in safe and proper manner and in
coordination with other labour and staff employed directly by BHEL or BHEL’s
client.
3.7.3 The Contractor shall furnish daily labour report showing by classification the
number of employees engaged in various categories of work and a
progress report of work as required by BHEL Engineer. The contractor shall
also give a summary report at the end of the month and plan of
deployment for the consequent month as per the plan of activities as
required by BHEL, to meet the overall contract requirement.

3.7.4 The work shall be executed under the usual conditions existing in major power
plant construction and in conjunction with numerous other operations at site.
The bidder and his personnel shall co-operate with other personnel and other
contractor’s personnel working in site and proceed in a manner that shall not
delay or hinder the progress of work as a whole.

3.7.5 The contractor’s supervisory staff shall execute the work in the most
substantial and workman like manner in the stipulated time. Accuracy of work,
good workmanship and aesthetic finish are essential part of this contract. The
contractor shall be responsible to ensure that assembly and workmanship
conform to the dimensions and tolerances given in the drawings/instructions
given by BHEL Engineers from time to time. Wherever finish or tolerances are
not specified in drawings/documents, BHEL Engineers instruction are taken as
final.

3.7.6 The contractor shall employ the necessary number of qualified and approved
full time electricians at his cost to maintain his temporary electrical installation
till the completion of work.

3.7.7 It is the responsibility of the bidder to engage his workmen in shifts or on

overtime basis during erection, commissioning and testing period for achieving
the target set by BHEL . The contractor’s quoted rate shall include all these
contingencies.

3.7.8 If the contractor or his workmen or employees shall break, deface, injure or
destroy any part of a building, road, kerb, fence, enclosure, water pipes,
cables, drains, electric or telephone posts or wires, trees or any other property
or to any part of the erected components etc. The contractor shall make the
same good at his own expense or in default, BHEL may cause the same to be
made good by other workmen or by other means and deduct the expenses (of
which BHEL’s decision is final) from any money due to the contractor.

3.8.0 CIVIL WORKS

3.8.1 Foundations of all equipments and plants and necessary civil works shall
beprovided by BHEL. The dimensions of the foundation and anchor bolt pits
shall be checked by the contractor for their correctness as per drawings.
Further top elevation of foundations shall be checked with respect to bench
mark etc. All minor adjustments upto 25 mm of foundation level,
dressing, chipping of foundation surface enlarging the pockets in
foundations and grouting of equipments etc. as may be required for the
erection of equipment/plants shall be carried out by the Contractor. All
the materials like cement, sand, gravel etc. and cleaning consumables shall
also be arranged by the contractor at his
 cost. The required special cement like CONBEXTRA-GP2 and SHRINKOMP
N 30 etc or its equivalent grade cement for grouting of columns, equipments
etc. shall be arranged by the contractor at their cost. The contractor
should also arrange required nos. of mixing machines and vibrators at their
cost.

3.8.2 The contractor shall ensure perfect matching of packer plates with foundation
by dressing the foundation and between the packer plates and the base plate
of structural column/equipment to the satisfaction of BHEL Engineer.
Machining/matching of packer shall be carried out by the Contractor at his own
cost.

3.8.3 The contractor shall arrange for grouting of foundation bolt holes of equipment
and final grouting of equipment as per the drawings / specification or as
advised by the Engineer or BHEL after preparing the foundation surface for
grouting.

3.8.4 Contractor has to carry out the grouting as per the work instructions for
grouting available at site.

3.8.5 The contractor at his cost shall arrange for grouting of anchor points of
T & P issued to him and also grouting of winches or any other supports
required for T & Ps. Necessary grout materials are to be arranged by the
contractor at his cost.

3.9.0 SCOPE OF MATERIAL HANDLING AND SITE STORAGE AND OTHER

RESPONSIBILITIES

3.9.1 While BHEL will endeavour to store/stack/identify materials properly in their

open/closed storage yard/shed it shall be contractor’s responsibility to assist
BHEL in identifying materials well in time for erection, taking delivery of the
same in time following the procedure indicated by BHEL and transport the
material safely to pre-assembly yard/erection site in time according to
programme.

3.9.2 The contractor shall identify necessary supervisor/labour for the above work in
sufficient quantity as may be needed by BHEL for areas covering their scope.

3.9.3 It shall be contractor’s responsibility to arrange necessary cranes/tractors,

trailer or trucks/slings/tools and tackles/labour including operators Fuel
lubricants etc., for loading from storage yard and on to transport equipment,
move it to erection site/pre-assembly yard and unload the same at pre-
assembly yard/ erection site and the quoted rate shall include the same.

3.9.4 All equipment so used by contractor shall be of proven quality and safe in
operation as approved by BHEL site Engineers from time to time.
3.9.5. Any loss/damage to materials issued to contractor shall be made good by him
or BHEL will arrange for replacement at cost recovery basis and decision
of BHEL shall be final.

3.9.6 All the surplus, damaged, unused materials, package

materials/containers/special transporting frames, gunny bags etc. supplied
by BHEL shall be returned to the BHEL Stores by the contractor and
maintain records.

3.9.7 The contractor shall take delivery of the components and equipments and
special consumables from the storage area after getting the approval of the
BHEL Engineer on standard indent forms to be specified by BHEL. At
periodic/intervals of work, complete and detailed account of the equipment so
erected and electrodes used shall be submitted to the BHEL Engineer.

3.9.8 The contractor shall submit monthly plan for erection and the same will be
mutually agreed upon after discussion. The contractor shall arrange for
Engineers, Supervisors and labour force and tools and plants and consumables
to suit the above plan and execute the work accordingly.

3.9.9 The Contractor shall have total responsibility for all equipment and materials in
his custody, stores, loose, semi-assembled, assembled or erected by him at
site.

3.9.10 The contractor shall make suitable security arrangement including employment
of security personnel to ensure the protection of all materials/equipments and
works from theft, fire, pilferage and any other damage and loss.

3.9.11 The contractor shall ensure that the packing materials and protection devices
used for the various equipments during transit and storage are removed before
these equipments are installed.

3.9.12 All equipments 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 equipments without the specific written permission of the Engineer. The
equipments from the storage yard shall be moved to the actual site of erection
/ location at the appropriate time as per the direction of BHEL Engineer so as
to avoid damage for such equipments at site.

3.9.13 The work covered under this scope of work is of highly sophisticated nature
requiring best quality / precision workmanship engineering and construction
management. He should also ensure successful and timely commercial
operation of equipment installed. The contractor must have adequate quantity
of precision tools, construction aids in possession. Contractor must also have
adequate trained qualified and experienced supervisory staff and skilled
personnel.

3.9.14 All the necessary certificates and licenses required to carry out this scope of
work are to arranged by the contractor then and there at no extra cost.
3.9.15 The contractor shall take all reasonable care to protect the materials and work
till such time the erected equipment has been taken over by BHEL/their
client. Wherever necessary suitable temporary fencing and lighting shall
have to be provided by the contractor as a safety measure against accident
and damage of property of BHEL. Suitable caution notices shall be displayed
where access to any part may be deemed to be unsafe and hazardous.

3.9.16 The contractor shall be responsible for taking all safety precautions during the
construction and keeping the site safe at all times. When the work is
temporarily suspended he shall protect all construction materials, equipments
and facilities from causing damage to existing property interfering with the
operations of the station when it goes into services. The contractor shall
comply with all applicable provisions of the safety regulations clean-up
programme and other precautionary measures which the BHEL has in effect at
the site.

3.9.17 All lifting tackles including wire ropes, slings, shackles etc. used by the
contractor shall be got approved by BHEL Engineer at site before they are
actually put on the work. It will be the responsibility of the contractor to ensure
safe lifting of the equipment taking due precautions to avoid any accidents and
damage to other equipments and personnel. All piping shall be adequately
supported and protected to prevent damage during handling and erection. The
history cards for major equipments to be maintained by the contractor.

3.9.18 The contractor shall take delivery of equipment from storage

yard/stores/sheds. He shall also make arrangements for verification of
equipment, maintain records and keep safe custody, watch and ward of
equipment after it has been handed over to him till these are fully erected,
tested and commissioned and taken over by BHEL’s client. The
stolen/lost/damaged goods shall have to be made good by the contractor at his
own cost.

3.9.19 Sometimes it may become necessary for the contractor to handle certain
unrequired components in order to take out the required materials. The
contractor has to take this contingency also into account. No extra payment is
payable for such contingencies.

3.10.0 PRESERVATION OF COMPONENTS

3.10.1 It shall be the responsibility of the contractor to apply preservative painting on

all equipment before erection. It shall be contractor’s responsibility to arrange
for required labour, brush and other consumables like cotton waste, cloth etc.
for carrying out preservative painting. The quoted rates shall be inclusive of
above work. The required paint and thinner shall be arranged by the contractor
at his cost.

3.10.2 The contractor shall effectively protect the finished work from action of
weather and from damage or defacement and shall cover the finished parts,
then and there for their protection.
3.10.3 Any failure on the part of contractor to carry out work according to above
clauses will entail BHEL to carry out the job from any other party and recover
the cost from contractor.

3.10.4 Due to atmospheric conditions erected materials are likely to get rusted more
frequently. It is the responsibility of the contractor to preserve the erection
materials drawn from stores for erection till these are commissioned and
handed over to customer. The required paint and thinner shall be provided by
BHEL free of cost. All other consumables like painting brush, emery paper,
cotton waste, cloth etc. have to be arranged by the contractor at his cost. The
contractor should ensure that the materials are not rusted on any account till
they are handed over to customer. The decision of the BHEL Engineer is final
with regard to frequency of application of paint.

3.11.0 DRAWINGS AND DOCUMENTS

3.11.1 The detailed drawing specification available with BHEL Engineers will form part
of this tender specification. These documents will be made available to
the contractor during execution of work at site.

3.11.2 One set of necessary drawings to carry out the erection work will be furnished
to the contractor by BHEL on loan which shall be returned to BHEL Engineer at
site after completion of work. Contractor’s personnel shall take care of these
documents given to them.

3.11.3 The data furnished in various appendices enclosed with this Tender
Specification, describes the equipment to be installed, tested and
commissioned under this specification briefly. However, the changes in the
design and in the quantity may be expected to occur as is usual in any such
large scales of work.

3.11.4 Should any error or ambiguity be discovered in the specification, or

information, the contractor shall forthwith bring the same to the notice of BHEL
before commencement of work. BHEL’s interpretation in such cases shall be
final and binding on the contractor.

3.11.5 Deviation from design dimensions should not exceed permissible limit. The
contractor shall not correct or alter any dimensions/details without specific
approval of BHEL.

3.12.0 SITE CLEANLINESS AND SAFETY REQUIREMENTS

3.12.1 Contractor shall strictly follow all safety regulations/conditions as per clause
2.15 and its sub clauses of general conditions of contract booklet enclosed
with this tender, including specification of Health, Safety and Environment
(HSE) management of customer / consultant.
3.12.2 Non-conformity of safety rules and safety appliances will be viewed seriously
and the BHEL has right to impose fines on the contractor as under:

SNo Safety Fine ( Rs)

01 Not wearing safety helmet 50/-
02 Not wearing safety belt 100/-
03 Grinding without goggles 50/-
04 Not using 24V supply for internal work 500/-
05 Electrical plugs not used for hand machines 100/-
06 Not slinging properly 200/-
07 Using damaged sling 200/-
08 Lifting cylinders without cage 500/-
Not using proper welding cable with lot of joints
09 200/
and not insulated properly
10 Not removing small scrap from platforms 200/-
11 Gas cutting without taking proper precaution or not
200/-
using sheet below gas cutting
12 Not maintaining elec. winches which are being
500/-
operated dangerously
13 Improper earthing of electrical T & Ps 500/-

3.12.3 The contractor should exclusively deploy one safety Engineer along with a
safety supervisor for effective implementation and co-ordination of safe
working conditions.

3.12.4 Contractor shall necessarily fill up the safety plan format available in
general conditions of contract book let enclosed with this tender and
submit along with their offer.

3.13.0 PROGRESS OF WORK

3.13.1 During the course of erection if the progress is found unsatisfactory or if the
target dates fixed from time to time for every milestone are to be advanced or
in the opinion of BHEL, if it is found that the skilled workmen like fitters,
operators, technicians etc. employed are not sufficient, BHEL will induct
required additional workmen to improve the progress or take over a part of the
job and get it done on risk and cost of the contractor and recover from
contractor’s bill, all charges incurred on this account including all expenses
together with BHEL overheads from contractor’s bill.
3.13.2 The contractor shall submit daily, weekly and monthly progress reports,
manpower reports, material reports, consumables reports and other
reports considered necessary by the BHEL Engineer.

The manpower reports shall clearly indicate the manpower deployed

category wise daily specifying also the activities in which they are engaged.

3.13.3 The progress reports shall indicate the progress achieved against planned with
reasons indicating delays if any and shall give remedial action which the
contractor intends to make good the slippage or lost time so that further works
can proceed as per the original programme and the slippage do not accumulate
and affect the overall programme in a format designed and approved by BHEL
site engineer.

3.13.4 The contractor shall arrange for weekly progress review meeting with the
“Engineers” at site during which actual progress during the week vis-à-vis
scheduled programme shall be discussed for action to be taken for achieving
targets. The programme for subsequent work shall also be presented by
contractor for discussion. The contractor shall constantly update/revise his
work programme to meet the overall requirements and suit the material
availability.

3.13.5 The contractor shall arrange for submitting three sets of progress photographs
every month to BHEL office the areas to be photographed will be as per the
instruction of BHEL Engineer. The quoted rate shall include this contingency.

3.13.6 The contractor must obtain the signature and permission of the security
personnel of the customer for bringing any of their materials inside the site
premises, without the Entry Gate Pass these materials will not be allowed to be
taken outside.

3.13.7 The contractor shall maintain a record in the form as prescribed by BHEL for all
operations carried out on each weld and maintain a record indicating the
number of welds, the name of welders who welded the same, date and time of
start and completion, preheat temperature, radiographic results, rejections, if
any, percentage of rejection, etc. and submit copies of the same to BHEL
Engineer, as required.
 SPECIFIC REQUIREMENTS FOR ISO 9001 - 2000

3.14.0 IMPORTANT NOTE

Contractors shall ensure that all their Staff/Employees are exposed to

periodical training programme conducted by qualified agencies/ personnel
on ISO 9002 Standards.

Contractors shall ensure that the Quality is maintained in all the

works connected with this contract at all stages of the requirement of BHEL.

Contractor shall ensure that all Inspection, Measuring and Testing

equipment that are used, whether owned by the contractor or used on loan,
are calibrated by the authorized agencies and the valid calibration certificate
will be availableith them for verification by BHEL. A list of such
instruments possessed by contractor at site with its calibration status is to
be submitted to BHEL Engineer for control.

Contractors shall arrange for the inspection of the works at various stages
as required by BHEL. Immediate corrective action shall be taken by the
contractor for the non-conformances if any, observed and pointed out by
BHEL.

3.15.0 INSPECTION / QUALITY ASSURANCE / QUALITY CONTROL

STATUTORY INSPECTION
3.15.1 Various Inspection / quality control / quality assurance procedures/methods at
various stages of erection and commissioning will be as per BHEL / Customer
quality control procedure/codes/IBR and other statutory provisions and as per
BHEL Engineer’s instructions.
3.15.2 Preparation of quality assurance log sheets and protocols with customer’s
Engineers, welding logs and other quality control and quality assurance
documentation as per BHEL Engineer’s Instructions, is within the scope of work
/ specification.
3.15.3 The protocols between contractor and customer/BHEL shall be made prior to
installation for correctness of foundations, materials, procedures, at each stage
of Installation, generally as per the requirement of Customer/BHEL. This is
necessary to ensure elimination of errors or keeping them within tolerable
limits and to avoid accumulation and multiplication of errors.
3.15.4 A Daily log Book should be maintained by every supervisor/Engineer of
contractor on the job in Duplicate (One for BHEL and one for Contractor) for
detailing and incorporating Alignment/clearance/centering/ Leveling Readings
and Inspection details.
3.15.5 Approval Given by Customer/BHEL for welding, results tests etc. shall also
be recorded in the log book.
3.15.6 All the Electrical/Technical Measuring and Testing Instruments / Gauges, Feeler
Gauges, Height Gauges, Dial Gauges, Micrometers, Levels, Spirit Levels,
Surface plates, straight Edges, vernier calipers and all measuring instruments
shall be provided by the contractor for checking, Levelling, Alignment,
 centering etc of Erected Equipments at various stages.
The Instruments/gauges/Tools etc. provided should be of Brand,
Quality and Accuracy, Specified by BHEL Engineer and should have
necessary calibration and other certificates as per the Requirements of BHEL
Engineer.
3.15.7 Total Quality is the Watch Ward of the work and standards, Procedures laid
down by BHEL. We shall follow all the Instructions as per BHEL Drawings and
Quality / Standards. Contractor shall provide for the services of quality
Assurance Engineer.

3.16.0 STAGE INSPECTION BY FES / QA ENGINEERS

3.16.1 Apart from Day-to-Day Inspection by BHEL Engineers Stationed at site and also
by Customer’s Engineers, Stage Inspection of Equipment under Erection and
commissioning at various stages of Erection and commissioning by TEAMS of
Engineers, from Field Engineering Services of BHEL’s Manufacturing units and
Quality Assurance Teams from Field Quality Assurance Unit/ Factory Quality
Assurance and commissioning Engineers. Contractor shall arrange all labour,
Tools and Tackles, etc. for such stage inspections free of cost.

3.16.2 Any modifications suggested by FES and QA Engineers Team shall be carried
out. Claims of Contractor, if any shall be dealt as applicable.

3.16.3 Any minor rectifications of minor repairs of defective work found out during
stage Inspection shall be rectified free of cost, by the contractor.

3.16.4 Any major Rectification or Major Repair / Major Rework of Defective work
found out during stage Inspection verification / checking, But not attributable
to contractor shall also be carried out. Claims of contractor if any, shall be dealt
as applicable.

3.17.0 STATUTORY INSPECTION

The scope includes getting the Approvals from the statutory authorities (Like
Electrical Inspector and Labour Officers). This includes Arranging for Inspection
Visits of Inspector Periodically as per BHEL Engineer’s Instructions, Submitting
Documents, Radiographs, Etc. and following up the matter with them.
All fees connected with the contractors for Testing his Welders/Men / Works
and Testing, Inspection, calibrating his instruments and equipments, shall be
paid by the contractor. It shall be contractor’s responsibility to obtain approval
of Statutory Authorities, Wherever Applicable, for the conducting of Any work
which comes under the Purview of these Authorities. Any cost arising from this
shall be contractor’s Account.

However, BHEL shall pay all other Fees (FEES FOR VISITS, INSPECTION FEES,
REGISTRATION FEES, ETC.) In case these Inspection have to be Repeated due
to Default/Fault of the Contractor and Fees have to be paid again, the
Contractor shall have to Bear the charges. These would be Deducted from his
Bills.
3.18 HSE SPECIFIC REQUIREMENT

OCCUPATIONAL HEALTH & SAFETY MANAGEMENT SYSTEM

SUB CONTRACTOR TO ENSURE COMPLIANCE OF THE FOLLOWING HEALTH

RELATED POINTS

01. Sub-contractor to identify nearest hospital for Health check up of his staff and
workers and intimate BHEL site office & PSSR HQ.

02. To arrange for occupational health check up / screening of contractor’s staff and
workers engaged in sub contracting activities. In this, category of workmen such
as welders, gas cutters, grinders, radiographers, crane operators are to be given
exclusive attention in respect of health screening.

03. Sub-contractor to arrange an ambulance vehicle or emergency vehicle on

a continuous basis to meet any emergency situation arising at site work
in which his staff and workers are engaged.

04. To provide appropriate facilities for prompt first aid treatment of injuries and illness
at work. One first Aider for each sub contractor to be provided. First Aider should
undergo training on first aid.

05. To provide filtered drinking water at selected place in a clean container.

SUB CONTRACTOR TO ENSURE COMPLIANCE OF THE FOLLOWING SAFETY

RELATED POINTS

01. Personnel protective equipment (PPES): Required number of following PPES

(Confirming to Relevant is Standards ) to be made available to workmen at site
and ensured that they are used

™ Helmet
™ Safety goggles
™ Welding face shields
™ Safety belts for working at heights k Safety shoes
™ Ear plugs
™ Rubber gloves and mats for low tension (I.T) electrical works
™ Gum boots & aprons
™ Other items as required by BHEL site

02. Sub contractor to liaise with nearest fire station and inform contact telephone
number and contact person to meet any emergency.

03. To provide appropriate fire fighting equipment at designated work place and to
provide fire fighting training to selected persons in his group of workmen to meet
emergencies.
04. To provide adequate number of 24 V power supply points to work in a constrained
and enclosed space.

05 . All power tapping points / switch boards /power & control cabling should fulfil
required electrical safety aspects as per relevant BIS standard.

06 ELCH‘s (Earth leak circuit breakers) at all electrical distribution points to be

provided.

07. Red and white caution tape of proper width ( 1.5 to 2 inch ) to
be used for cordoning unsafe area such as open trench,
excavated area, etc.

08. To provide sub-contractors company logo or clothing to all staff and

workers for identification including identity cards with photographs approved
by BHEL.

09. High pressure and structural welders to be identified with colour clothing and
to display copy of welders certificate with photographs of welder at the
work place. They also should be in possession of valid welding procedure.

10. To display safe handling procedure for all chemicals such as lube oil, grease,
sealing compound, kerosene, diesel etc. At stores & respective work place.

11. Contractor should authorise a person at site to stop work if there is a unsafe work
noticed as per his knowledge.

12. Fitness for use of erected scaffolding to be certified by the contractors approved
scaffolder and the certificate should be displayed on the scaffolding itself. If the
scaffolding is unsafe , the same will not be used. the certificate to be updated
daily. The scaffolding to be made as per the relevant is standard.

13. For making platform on the scaffolding , proper thickness and size
of the plank of required quality wood to be used. The safe
working load of the platform to be displayed on the scaffolding
itself. Proper use of platform to be explained to the user.

14. All plant equipment should have inspection report before put in to
use.

15. All T&Ps should be of reputed brand and having quality

certificates..

16. All IMTEs should have valid calibration certificate from recommended
institution / testing lab and these should be in place.

17. All lifting tackle and plant equipment should have safe working load certificate.

18. The right worker should be deployed for right job and the resume of site
in charge, supervisors, and key workers to be submitted before
commencement of work.

19. Sub-contractor should submit inspection / testing matrix of all T&Ps and to
be approved by BHEL.
20. Sub-contractor to display safety slogan, safety board, caution boards
wherever required in consultation with BHEL.

21. Sub-contractor to provide gas detectors of reputed make at desired locations.

22. Sub-contractor to conduct emergency mock drills. one drill per 6 month and
submit report to BHEL.

23. Safe handling and storing of all equipment with adequate space to be
ensured.

24. Sub contractor to deploy safety supervisor till the completion of the project.

25. Sub contractor to comply the safety reporting procedure of BHEL as practiced at
present and also additional requirements that may arise out of
future improvements in the safety management system. This includes
computation of safety indices such as frequency rate, severity rate & incident
rate.

26. Sub contractor to identify probable emergency situations such as electric shocks to
workmen , caving in of shored earth , fall from height, collapse of scaffolding fire
etc., and should have clear action plan to overcome them. Sub contractor to take
required guidance from BHEL in this regard.

27. Sub contractor to identify hazardous activities which he may carryout and should
train his workmen in those activities with the relevant operation control
procedures. Sub contractor to take required guidance from BHEL in this regard.

28. Safe work permit system to be followed while working in confined space / near
electric systems.

SUB CONTRACTOR TO ENSURE COMPLIANCE OF THE FOLLOWING ENVIRONMENT

RELATED POINTS

1. HOUSE KEEPING : Sub contractor to carry out daily house keeping of work
areas / stores through a check list prepared in consultation with BHEL.

2. Sub contractor shall adopt pollution prevention / reduce /control approach in all
his site activities. this shall include:

a. Transporting of oil / chemicals from stores to site safely without causing

spillage. In case of any spillage, the area shall be cleaned and the remnant
spilled oil disposed off to a safe place, identified for such disposal.

b. To use required containers / cans / safety gadgets /appliances for

transporting and for usage of oil / chemicals at site.

3. Sub contractor shall arrange for segregation / collection of scraps and dispose off
to the identified place meant for scrap collection.

4. Sub contractor to adopt good erection practices / procedures with the objective of
reduction of waste generation / rework
OTHER HSE REQUIREMENTS TO BE COMPLIED BY SUB CONTRACTOR

1. Sub contractor to clearly understand and accept the HCE policy of PSSR with a
commitment to comply the requirements of the policy.

2. Sub contractors to arrange for daily meeting of their supervisors and work force
before they disperse for their daily planned activities where in the relevant
health, safety and environment aspects of the job and use of PPES are explained

3. Sub contractor to conduct monthly HSE meeting ( internal ) and submit the report
to BHEL.

4. HSE slogans to be displayed in a proper board - hoarding at designated places in

consultation with BHEL.

5. Sub contractor to submit a structured programme for training & occupational

Health Screening of their work force at site after the Award of LOI.
 SCT 1308 SECTION – VI
INDEX

6.1.0 Scope of work

6.2.0 Electrical - General
6.3.0 Detailed Scope of work
6.3.1 Transformers
6.3.2 Isolated Phase Bus Duct
6.3.3 LT MCC & Power Distribution Boards
6.3.4 AVR/Generator Control /Relay Panel/Other Panels
6.3.5 Battery & Battery Charger
6.3.6 Diesel Generator set
6.3.7 Ash Level Indicator
6.3.8 Heating Elements
6.3.9 (Not Applicable)
6.3.10 Cables
6.3.11 Cable Trays/Conduits/Flexi Conduits
6.3.12 Junction Box, Marshalling Box & PB Box
6.3.13 Fabrication and Erection of Steel Materials
6.3.14 Above Ground Earthig & Lightning Protection
6.3.15 Painting
6.3.16 Civil Works
6.3.17 Calibration
6.3.18 Commissioning of Equipments Erected by Mech Contractor
6.3.19 Pre Commissioning, Commissioning and Post Commissioning
6.4.0 Time Schedule
6.5.0 Over Run Charges
6.6.0 Measurement, Wastage & Cutting Allowances
6.7.0 Collection of Materials
6.8.0 Storage
6.9.0 Tools & Plants to be arranged by Contractor
6.10.0 Materials / Consumables to be arranged by Contractor
 SCT – 1308 SECTION VI
INDEX

6.11.0 Technical requirements for Supply Items

6.12.0 Terms of Payment
6.13.0 Guarantee
6.14.0 Electrical Inspectorates Approval
6.15.0 Price Variation Clause
6.16.0 Taxes & Duties
6.17.0 Provident Fund and Minimum wages
6.18.0 Important Conditions for payment
6.19.0 Other Statutory requirements
6.20.0 e-Remittance
6.21.0 (Not Applicable)
6.22.0 Progress & Monitoring of works
6.23.0 Extra work charges for Modification
6.24.0 Reporting Damages and carrying out repairs
6.25.0 Inspection of works
6.26.0 Details to be provided by Vendor
6.27.0 Documentation
6.28.0 Recommended List of T&P / Instruments by Contractor
6.29.0 Recommended list of T&P Instruments for Electrical works
6.30.0 Drawings for reference
VI A Month-wise Manpower Deployment
VI B Deployment Plan for major T&P
VI C Calibration Record-Format
 SECTION VI

NALCO ANGUL CPP EXPANSION 2 X 210 MW (UNIT - 10)

ELECTRICAL PACKAGE

SCOPE OF WORK AND SPECIAL CONDITIONS

6.1.0 SCOPE OF WORK:

The scope of work shall comprise but not limited to the following:

6.1.0 Identification of equipment at storage yard, technical assistance for checking and
making the shortage/damage reports, taking delivery at stores/ storage yard,
transportation to erection site and pre-assembly of equipment wherever required,
checking, erection testing, commissioning along with the supply of all
consumables, tools and tackles, testing instruments as per BHEL Engineer’s
instruction/ supervision and providing assistance for troubleshooting, trial
operation and maintenance of the complete equipment and materials enumerated
in the rate schedule of this tender till handing over to customer or till completion
of the contract period which ever is earlier.

6.1.1 It is not the intent to specify herein all details of equipment and material. Any
Electrical item related to this work, that is necessary to complete the system shall
be deemed to have been included in the scope of the work, even if not covered
by this.

6.1.2 All the work shall be carried out as per instructions of BHEL engineer. BHEL
engineer's decision regarding the correctness of the work and method of working
shall be final and binding on the contractor.

6.1.3 Contractor shall erect all items/materials etc. as per sequence prescribed by BHEL
at site. BHEL engineer depending upon the availability of materials/work fronts
etc will decide the sequence of erection/commissioning methodology. No claims
for extra payment from the contractor will be entertained on the grounds of
deviation from the methods of erection/commissioning adopted in
erection/commissioning of similar job or for any reasons whatsoever.

6.1.4 After completing all the works, contractor shall hand over all remaining extra
materials with proper identification tags in packed condition to BHEL stores. In
case of any use over actual design requirements, BHEL reserves the right to
recover the cost of material used in excess or misused. Decision of BHEL
engineer in this regard will be final and binding on the contractor.
6.1.5 The contractor shall ensure that his premises are always kept clean and tidy to
the extent possible. Any untidiness noted on the part of the contractor shall be
brought to the attention of the contractor’s site representative who shall take
immediate action to clean the surroundings to the satisfaction of the Engineer-in-
Charge

6.1.6 All the surplus, damaged, unused materials, package materials, containers,
special transporting frames, etc. shall be returned to the BHEL stores /
customer's stores by the contractor.

6.1.7 The work shall be executed under the usual conditions without affecting power
plant construction and in conjunction with other operations and other agencies at
site. The contractor and his personnel shall co-operate with the personnel of
other agencies, co-ordinate his work with others and proceed in a manner that
shall not delay or hinder the progress of work as a whole.

6.1.8 Contractor shall remove all scrap materials periodically generated from his
working area in and around power station and collect the same at one place
earmarked for the same. Loads of scrap is to be shifted to a place earmarked by
BHEL. Failure to collect the scrap is likely to lead to accidents and as such BHEL
reserves the right to collect and remove the scrap at contractor's risk and cost if
there is any failure on the part of contractor in this respect. All the package
materials, including special transporting frames, etc. shall be returned to the
BHEL stores / customer's stores by the contractor.

6.1.9 Any wrong erection shall be removed and re-erected promptly to comply with the
design requirements to the satisfaction of Site Engineer.

6.1.10 The contractor shall take delivery of item, materials, from the storage yard /
stores / sheds of BHEL / customer which is within a radius of 5 kms. He shall also
make arrangements for safe custody, watch and ward of equipment after it has
been handed over to him till they are fully erected, tested and commissioned till
the contract period. The contractor shall note that items/materials shall be
transported to erection site / assembly yard etc. by the prescribed route without
disturbing and causing damage to other works in the most professional manner.
All items, Hardware, etc. shall be stored in appropriate manner as per BHEL's
instructions.

6.1.11 The contractor shall take delivery of items/materials, and consumables from the
stores/ storage area / sheds of BHEL / customer after getting approval of
engineer / customer in the prescribed indent forms of BHEL / customer.
6.1.12 Contractor shall, transport all materials to site and unload at site / working
area,or pre-assembly yard for inspection and checking. All material
handling equipment required shall be arranged by the contractor.

6.1.13 The contractor at his cost shall arrange necessary security measures for adequate
protection of his machinery, equipment, tools, materials etc. BHEL shall not be
responsible for any loss or damage to the contractor’s construction equipment
and materials. The contractor may consult the Engineer-in-Charge on the
arrangements made for general site security for protection of his machinery
equipment tools etc.

6.1.14 During the course of erection, testing and commissioning of Electrical works,
certain rework/modification / rectification / repairs / fabrication etc. may be
necessary on account of feedback from other power stations that are already
commissioned or under erection or due to change in design or manufacturing
defects or to meet operational / maintenance requirements. Contractor shall
carryout above such rework promptly and expeditiously, subject to extra works
clause.

6.1.15 Site testing wherever required shall be carried out for all items/materials installed
by the contractor to ensure proper installation and functioning in accordance with
drawings, specifications and manufacturer's recommendations.

6.1.16 The contractor shall co-ordinate and provide assistance for satisfactory testing,
pre-commissioning, commissioning and trial run of the connected equipment to
meet the system requirement and customer satisfaction.

6.1.17 Contractor shall retain all T&P/Testing instrument/Material handling instrument

etc at site as per advice of BHEL engineer and same shall be taken out from site
only after getting the clearances from engineer in charge

6.1.18 All necessary certificates and licenses required to carry out this work are to be
arranged by the contractor expeditiously at his cost.

6.1.19 Scope of work covered under this specification requires quality workmanship,
engineering and construction management. The contractor shall ensure timely
completion of work. The contractor shall have adequate tools, measuring
instruments, calibrating equipment etc. in his possession. He shall also have
adequate trained, qualified and experienced engineers, supervisory staff and
skilled personnel. The manpower deployed by contractor shall match with above
scope of works

6.1.20 The scope of specification covers the installation, testing and providing assistance
for commissioning of the instrument, hardware along with accessories as detailed
in Bill of Materials.
6.1.21 If any Electrical equipment or item not covered, but requires to be
erected/commissioned, same shall be carried out by the contractor. Equivalent
unit rate for those items or equipment shall be considered from the Rate
Schedule.

6.1.22 The contractor shall have valid ELECTRICAL LICENSE to carry out the Electrical
Works. All the necessary certificates and licenses required to carryout this work
are to be arranged by the contractor expeditiously at his cost.

6.1.23 The installation of all the electrical equipments/items shall conform to the
technical requirements specified elsewhere in the tender. The contractor shall
arrange statutory inspection and obtain necessary certificate for the installation
work at his cost. Any modification work required by inspector shall be attended
by the contractor at his cost.

6.1.24 MANPOWER REQUIREMENT FOR ERECTION.

Manpower requirement for Erection and Commissioning shall as follows:

There shall be a Resident manager as Site In Charge, under whom there shall be
3 erection engineers who shall be in charge of TRANSFORMER&BUSDUCT,
SWITCHGEAR&CONTROL PANELS AND CABLES.

Each area engineer shall be provided with minimum four supervisors and
adequate number of Technicians/electricians and other erection staff and T&P
etc. The testing Engineers/supervisors/electricians shall be identified separately
for each package and the minimum requirement shall be as indicated in the
relevant Clause. Besides, there shall be separate engineers for Planning, Safety
and Quality.

The Site in charge shall be provided with PC and good communication facilities
like telephone, fax, email etc. at the cost and expense of the contractor. Lack of
communication facilities shall not be an excuse for extension of completion date.

All instructions from BHEL/Customer shall be directed to the contractor through

the Site in-charge and he shall be responsible for all the contractor’s activities at
site. The contractor shall name his authorized representative prior to or
immediately on commencement of operations at site.

The Site In charge shall be present at site during all normal working hours and
his contact address after normal working hours shall be made available to BHEL
so that if any emergency arises, the presence of the contractor’s site
Representative at site can be called for.
 The contractor shall not change the site Representative without the consent of
BHEL. Should BHEL require the replacement of the contractor’s site
Representative for justifiable reasons (including inadequate progress of work) the
contractor shall ensure that replacement is made as soon as possible and work is
not allowed to suffer delay on this account.

6.1.25 The contractor shall provide to the satisfaction of BHEL sufficient and qualified
staff for the execution of works. If and whenever any of the contractor’s staff is
found guilty of any misconduct or be incompetent or insufficiently qualified in the
performance of his duties the contractor shall remove them from site as directed
by Site Engineer.

6.1.26 The contractor shall ensure that all his supervisor’s staff and workmen conduct
themselves in a proper manner. They shall all be persons who are familiar with
and skilled at the jobs allocated to them. Any misconduct / inefficiency noted on
the part of the contractor’s personnel shall be brought to the attention of the
contractor’s site representative who shall immediately take such action as
necessary including the removal of such misconducting / inefficient persons, if so
required by the Engineer-in-Charge.

6.1.27 The contractor shall ensure that replacement for such persons removed from site
are provided immediately and the work is not allowed to suffer delay on that
account.

6.1.28 The quantity of various instruments/ hardwares indicated in the BOQ is

approximate only. Payments shall be made on unit rate basis.

6.1.29 Unit rate quoted on lump sum basis shall include installation of all loose items
which are not explicitly mentioned, but comes as part of the system, integration
of total system and commissioning. No separate rate shall be payable for loose
items. The quantities of loose supplied items are approximate only. No
proportional rate will be applicable for any variation in quantity or for any
additional items supplied as part of equipments.

6.1.30 The scope of work in general covers loading from store, transportation, unloading
at site , keeping in safe custody, erection, testing and commissioning along with
supply of consumables as detailed in the respective clause, deployment of skilled
/ unskilled manpower, engineers / supervisors, T & P, Testing instruments and
handing over.
6.2.0 SCOPE OF WORK IN GENERAL

Scope of Electrical works covered in this tender are as follows:

6.2.0 Erection and commissioning of Generator and Unit Auxiliary Transformers.

6.2.1 Erection and commissioning of IP Bus Ducts.

6.2.2 Erection and commissioning of LT MCC, AC/DC Distribution Boards, Starter

Panels, Excitation Panels, Control Panels etc.

6.2.3 Erection and commissioning of Generator and Transformer protection Panels and
other Electrical protection and control panels

6.2.4 Erection and commissioning of Battery & Battery Charger panels.

6.2.5 Erection and commissioning of Diesel Generator.

6.2.6 Erection of Trays & accessories and Trays supports.

6.2.7 Installation of local push button stations, local starter, Junction Boxes etc.

6.2.8 Laying and termination of HT/ LT power and control cables

6.2.9 Supply and Installation of lugs, ferrules, tag plates, and cable dressing materials
and installation of cables glands.

6.2.10 Supply and Installation of items for below ground cable installation like cable
markers, cable joint markers etc. (if applicable)

6.2.11 Installation of above ground earthing grid, equipment earthing of all equipment,
cable racks, trays etc and supply and installation of test pits.

6.2.12 Installation of Lightning protection.

6.2.13 Fabrication and installation steel supports wherever required.

6.2.14 Testing and Commissioning of HT/ LT-drives, MOVs and electrically operated
equipment erected by Mechanical contractor.

6.2.15 Installation of other items that have not been specifically indicated, but required
for completing installation.

6.2.16 Supply of paints and painting of all steel fabricated items.

6.2.17 Excavation of earth in any type of soil and refilling earth (if applicable)

6.2.18 Supply of river bed sand and spreading (if applicable).

6.2.19 Supply and Erection of RCC Hume pipes (if applicable).

6.2.20 Supply of standard Bricks and spreading (if applicable).

6.3.0 DETAILED SCOPE OF WORK

6.3.1. TRANSFORMERS

[Link] SCOPE OF WORK AND SPECIFICATION OF TRANSFORMERS

The scope of Transformer covers E&C of Generator and Unit Auxiliary

Transformers and commissioning of ESP rectifier Transformer. Generator and
Unit auxiliary Transformers shall be located adjacent to the powerhouse building
in the transformer yard. ESP Transformer shall be erected by Mechanical
contractor at ESP roof and commissioning of Transformer only is in the scope of
work.

A) Technical details of 150MVA Generator Transformer:

Description: The Generator Transformer shall be of 150 MVA, 10.5/235 kV,

Three phase, OFAF cooled, YNd1, with loose accessories like 2 Nos. of Radiator
banks, on load tap changers, HV/LV/HVN bushings, bushing CTs, Turrets,
conservators, cooler control cabinet, marshalling box, pipings, common KIOSK
etc. Loose items like raise/lower [Link], tap changer indicators, facia windows,
W.T.I. repeaters, buzzers, signal lamps,

Accessories: PRV-1, Drain valve2, Cooler control cabinet-1, inlet-2 & out let
valves-1 (1 each), 36kv22kVpost insulator-3 4, 17.5kv, 1000A bushing -2 (HV
bushing-3),

Conservator: Main conservator tank with air cell, bucholz relay, breather &
connected pipelines

Cooling system: Radiator assembly -24, Header -4, A frame support-4, Fan
motor-10, Oilpump-4, Turret and bushing: HV line 3& neutral bushing1each, LV
bushing -3,HV turret 3, LV turret - 1,valves and fittings as per drg no 3 459 00
00241

Approximate dimensions of each transformer: (l x b x h)

a) Shipping dimensions: 7900 x 3400 x 3800 mm 7170 x 3450 x 3450 mm

b) Overall dimensions : 15,000 x 10,500 x 7000 mm

Approximate weight of Transformer Components

a) Tank & fittings 43,000

b) Total wt of transformer 1,83,000
c) Untanking Weight 10,000
d) Shipping weight (gas filled) 1,20,000
e) Total oil (49,440 lts) 44,000

QUANTITY 2 Nos
 B) Technical details of 16MVA UAT Transformer:

Description: UAT shall be of 16 MVA 10.5 / 6. 9 kV, 3 Phase, ONAN, with OLTC
on HV Side with bushing CTs, radiators, cooling fans, conservator, cooler control
panel, marshalling panels, piping etc. including NGR.

Loose items: like raise/lower [Link], tap changer indicators, facia windows, W.T.I.
repeaters, buzzers, signal lamps, etc. will be supplied loose, to be mounted and
wired in control panel.

Approximate Dimensions : (mm)

a) Overall dimension: 7700 x 6800 x 5000 mm

b) Shipping. dimension 4400 x 2900 x 3250 mm

Weight of Transformer Components: (Kg)

a) Tank & fittings 14,800

b) Total wt of transformer 46,600

c) Untanking Weight 17,800

d) Shipping weight (gas filled) 25,000

e) Total oil (15700 lts) 14,000

QUANTITY 2 Nos.

C) NEUTRAL GROUNDING RESISTOR

Neutral Grounding Resistor (NGR), Indoor Type, 6.9Kv, 9.95 ohms, 400A with
mounting and connected accessories

Size: 1200 x1200 mm

Total Weight (NGR+ Support structure): 600 kg

[Link] SCOPE OF WORK OF TRANSFORMER

1. Receipt of Transformer and associated loose supplied accessories & Spares

including oil in drums from site store/ yard, inspection, transporting the above to
the respective erection location up to plinth, storage, maintenance of N2 gas
pressure in transformer tank, erection of Transformer and all the accessories
including NGR, cabling from transformer accessories to marshalling KIOSK &
OLTC panel, oil filling, oil pressure testing, dry out, pre-commissioning test,
commissioning of equipment and final painting and handing over.
2. Generator and UAT Transformer shall be dispatched to site in several package
swhich shall be transported from BHEL storage yard in a suitable trailer to
their respective locations. Before loading and transporting the
Transformers, contractor shall study the soil condition and identify route for
transportation.

3. The contractor shall unload the transformers on rails, turn the wheels/ rollers if
necessary, roll the transformers to their respective locations and position them
on the foundation. The necessary sleepers, winches, jacks, trailer, etc. required
for this operation shall be arranged by the contractor at his cost.

4. Samples of each and every drum of Transformer oil shall be tested and pre-
treated to achieve the desired value before filling in to the transformer tank. The
entire arrangement for testing the oil sample, filtering whenever required to
achieve the desired PPM, BDV within the shortest time shall be made by the
contractor at his cost, in consultation with BHEL Engineers at site. All the test
equipment for testing specific gravity, PPM, BDV of the oil including testing
equipment required for the Tan-Delta Test of the transformer winding and HV
Bushing shall be arranged by the contractor. Testing instruments for Dew
measurement of N2 gas, if required, shall also be arranged by the contractor

5. All the transformers protective system such as Buchholz relay, explosion vent, oil
and winding temperature detectors etc., shall be checked under the guidance of
BHEL Engineer.

6. Contractor shall carry out all tests with his own testing equipments and testing
team.

7. If the charging of Transformers is delayed after filtration, the contractor shall

carryout filtration again if necessary before charging the transformers at the
discretion of BHEL Engineer in charge without any additional cost. However if the
charging of Transformers got delayed after filtration beyond 6 months due to
any unforeseen reasons, the filtration shall be carried out at extra cost as per
provisional rate quoted and agreed upon.

8. All the T&P, material handling equipment like cranes, Trailer, Transformer oil
filtering machines, 5 kV motorized megger and oil tank of suitable capacity shall
be arranged by the contractor at his cost. The transformers may have to be
suitably lagged/covered during the drying out operation by the contractor at no
extra cost.

9. The contractor shall arrange minimum one No. 6000 litre/hour for mineral oil
and one number 1000-600 L/H filtering machines for silicon oil for ESP
Transformer.
10. The contractor shall engage his men on three-shift operation during drying out of
the transformers.

11. The auxiliaries components of the above transformers are to be cleaned and
checked before the assembly as instructed by BHEL Engineer.

12. Test value of dielectric strength/PPM, specific gravity and Tan-Delta test shall be
as per recommended value of BHEL. If the test results are not satisfactory and if
the customer desires to carry out the tests through some other agency, the same
shall be carried out at contractor’s cost.

13. The scope of erection work includes final painting for all the oil filled
Transformers, minor civil work such as chipping and grouting of the support
structure as well as for the support of the transformer, including supply of
grouting material. The scope of final painting involves supply of paints, thinner
and other consumables at the cost of the contractor. No separate rate shall be
paid for painting. Painting shall be as per details given in the painting clause.

14. During the oil circulation of the transformer, the contractor shall employ
sufficient number of personnel who shall take care of the operation of the filter
machine as well as safety of the transformer.

15. Calibration of Testing equipment: All testing equipment (IMTE) shall be

calibrated before putting into service at site. A copy of calibration certificate to
be this effect shall be furnished to BHEL-Engineer for his verification and
approval.

16. The contractor shall prepare all log sheets, test certificates, protocols etc. as per
field quality plan, get it signed by concerned BHEL/CUSTOMER Engineer and
submit to the concerned BHEL Engineer.

17. Preservative gas like N2 shall be supplied by BHEL free of cost to maintain the N2
pressure during preservation.

18. The contractor shall provide assistance to maintain the equipment erected and
commissioned by him until taken over by CUSTOMER or up to the contract
period.

19. ESP transformers will be erected by the mechanical contractor. Testing and
commissioning of ESP Transformer alone is covered in Electrical contractor’s
scope.

20. For scope of work for ESP Transformer, refer Clause [Link]
6.3.2. ISOLATED PHASE BUSDUCTS

The isolated phase busducts is connected to the low voltage side of the generator
transformer and generator. The bus consists of cylindrical/octagonal conductor
made of Aluminium alloy supported on post insulators. Flexible connections and
expansions joints are provided at terminal and intermediate points to alleviate
stresses due to expansion and to arrest vibration. All the CTs shall be mounted
inside the busducts.

Isolated phase taps connect the potential transformer, surge protection

equipment and unit transformer to the main bus. Each phase of protection
equipment and potential transformers shall be housed in metal clad cubicles.

A totally enclosed neutral grounding cubicle is provided to connect the Generator

neutral point. The neutral grounding cubicle shall be at 5Mtrs level which houses
neutral grounding transformer & resistors. All the generator-isolated busducts are
supplied with one set of Air pressurization equipment unit.

The tentative details are as under:

[Link] Technical Details

1. Rated working voltage at 50 Hz 10.5 KV

2. Highest system voltage 12 KV

3. Basic impulse level 75 KV PEAK (1.2/50 micro-sec wave)

4. Short time current rating (rms) 85 KA for 3 Sec. (Main Run)

152 KA for 3 sec. (Tap-off Run)

5. Continuous current rating Within 10000 A (Main Run),

busduct under the site conditions
1000 A (Tap -off Run)

6. Busbar

a) Material and grade Al Alloy

i) Main Run Gr-19501

ii) Tap Off Run Gr-63401

b) Shape & Size

i) Main Run Round 450 O/D,15TK

ii) Tap Off Run Square-2x152.4,8.1TK

7. Enclosure

a) Material Al Alloy

i) Main Run Gr 19500,

ii) Tap Off Run Gr 31000,

b) Shape& Size Main: 1000 O/D,6.35 TK

Tap off : 780 O/D,4.78 TK

8 Type of cooling Air Natural

9 Type of busbar joints Bolted (silver plated)

10 Applicable standard IS: 8084

11 Degree of protection Air and water tightness as per Appendix ‘F’

of IS: 8084

12 Neutral grounding transformer

i) Type Epoxy cast Resin dry type

ii) Transformer Rating

Primary Voltage 10.5 KV

Secondary Voltage 240 V

Phase Single

13 Neutral grounding resistor

a) Type S.S. Punched Grid Type

b) Voltage 240

c) Resistance 0.477 Ohms

d) Current 400 Amps for 5 minutes duty cycle.

14 No. of Rubber Bellows (Approx.) 12 Nos

15 No. of Seal off bushing 3Nos

16 Weight of duct (Approx.) including Main: 200 kg /Mtrs, Tap off :140 kg /Mtrs
inside mounting arrangement. Top camber: 3000Kg(Total)

Star Duct:1500 Kg(Total)

17 Max length of busduct 6Mtrs

18 Max weight of busduct 1200 Kg(approx)

[Link] Welding:

There will be make-up pieces supplied in two halves (one plain and another with
window). Most shipping section (assembly of enclosure & conductor) will have
conductor projected outside. When two adjacent shipping sections are erected the
two conductors will be welded together. The enclosures shall be joined through
make-up pieces which will be overlapping 25 mm. on both sides. The two halves of
the make-up pieces shall then be welded. All the terminal ducts shall be having
bolted connections with rubber bellow and copper connection for conductor
termination. No. of rubber bellows and flexible connections are indicated above as
well as in the layout drawing.

Recommended welding electrodes and procedure for welding:

The material grade, thickness and other specification have been given in the
technical data sheet above. On this basis, welding electrodes, welding procedure
shall be decided at site in consultation with BHEL welding Engineer.

[Link] Shorting Bars

One set of shorting bar common for both the sets shall be supplied for generator
dryout.

[Link] LA VT Cubicle

LA & VT Cubicle shall be of draw out type with VT mounted on trolleys, fabricated
out of 3 mm thick steel sheet, complete with illuminating lamps, space heater,
busbars, mounting insulators, marshalling box, etc. The cubicle shall be
selfsupporting type. Each set shall comprise of the following:

a. Single phase epoxy cast dry type VT 09 Nos.

b. Lightning Arrestor ( KV, KA) 03 Nos.

c. Surge Capacitor (28 KV, 0.125 micro Farad) 03 Nos.

d. Weight of the cubicle 1000kg

e. Overall dim : 900 x 2250 x 2400 mm.

f. Degree of protection IP54

g. LAVT Cubicle: 3 Nos.

[Link] NG Cubicle

NG Cubicle shall be fabricated out of 3 mm thick steel sheet complete with

illuminating lamps, space heater, busbars, mounting insulators, marshalling box,
etc. The cubicle shall be self-supporting type and degree of protection shall be
IP54/IP23. Each cubicle shall house the following:
 a. Dry type epoxy cast NG transformer 1 No.

(35 KVA (cont), 10.5 KV/240 V; 1 ←, Class of Insulation: B)

b. NG Resistor (240 V, 400 A (for 5 min), 0.477 ohms)

NG Cubicle: 2000 x 1250 x 1690 mm; 1400 kg approx.

[Link] Busduct Supporting Structure.

Busduct supporting structure shall be fabricated from standard steel sections

welded/bolted and hot dip galvanized. All structure hardware shall be HTS hot
dipped/electro-galvanized.

Weight of structure: 3.5 MT

[Link] Hot Air Blowing equipment (HAB)

HAB equipment consisting of Blower with Heater box, Centrifugal Fan. Drive
Motor, Filter box, Tem indicator and manometer, Flexible pipe, Control panel
and other loose supplied items.

Capacity: 6000 cum/ hour, Approx size: 1500 x 1200 x 1500 mm

[Link] Scope of works for Busducts

1. The scope of works of bus duct covers receipt from BHEL stores/yards,
transportation, unloading all the busduct materials and accessories and
equipment at the area where the busducts are to be erected, inspection,
installation of all the materials as indicated in the BOM and relevant drawings,
testing and commissioning of total busduct items, painting and handing over.

2. Dimensions & weights indicated in the Tender specification and BOQ for isolated
phase bus ducts are approximate only. The relevant drawings are enclosed for
the purpose of detailed study and quoting. The contractor has to ascertain the
quantum of work involved and quote the lump sum value for IP Bus ducts as
called for in the rate schedule.

3. There may be variations in the weight and dimensions of Busducts with respect to
the drawings furnished due to revisions. Any such variation in Busduct length
within ±20% shall not be considered for payment. However, for variations in
Busduct length beyond ±20%, payment shall be considered proportionally.
Variations in size of enclosure/ conductors or weight including support structure
shall not be considered for payment.

Detailed scope of work for busducts shall be as below:

4. Cleaning of enclosure and conductors, insulators and other panels before

assembly and erection.

5. Placement of embedment and erection and alignment of steel support structures.

6. Assembly and checking of busduct at ground level if necessary.

7. Fixing of wall bushings/wall frame assembly

8. Minor civil work such as chipping and grouting of bus duct support structures
including supply of grouting materials.

9. Providing earthing connections as per site conditions.

10. Earthing of Busducts and connecting to earth grid /earth pits as detailed in the
relevant bus duct drawings.

11. If any modification is required in the support structures due to site conditions, the
same shall be carried out without any extra cost.

12. Pockets will be provided during casting in which anchor bolts will be grouted for
supporting the structures.

13. Extension of embedment if required and erection of required supports structures

as detailed in the drawing.

14. Tightening of all bolts in the joints and flanges by torque wrench to the approved
pressure (Anti oxidation compound shall be used for joints which shall be
arranged by contractor)

15. Fixing of Space Heaters and wiring from Space Heaters terminal to junction box,
taking through rigid/flexible conduit pipe

16. Fixing of Breather wherever required

17. Erection and commissioning of NGT cubicle with all its accessories if supplied as
loose.

18. Fixing of neutral side flexible connections to generator and positioning of neutral
CTs after testing.

19. Erection and commissioning of LAVT cubicles and its loose equipment/items such
as lightning arrestors, voltage transformers, fuses, etc.

20. Erection and alignment of Tap off busducts for unit auxiliary transformer, LAVT
cubicle, excitation transformer etc.

21. Erection and commissioning of Air Blower/drier equipment with all the
accessories.

22. Carrying out Aluminium welding for bus conductor and on enclosure as detailed in
the drawing using MIG/TIG machine with the Aluminium filler wire as per BHEL
specification.
23. Supply of MIG/TIG welding machine, Aluminium filler wire, Argon gas of high
purity and other required consumables as per BHEL standard for efficient
aluminum welding,

24. covering supporting insulators with asbestos cloth whenever aluminum welding is
carried out near the supporting insulator.

25. Making necessary modifications of make up pieces, if required, and welding of

isolated phase busducts along with NGT, LAVT cubicle, UAT, Excitation
transformer tap-offs.

26. Providing well-experienced Aluminium welder to be arranged to meet the

radiography quality.

27. Conducting 10% radiography and LPT

28. Grouting the ground bus provided on the entire length of entire length of
busducts, all parts of supporting structures and one end of each enclosure.

29. Conducting air-tightness test after erection to meet the requirement of

BHEL/Customer Standards. Rectification of leakage, if any without any extra
charges- For air tightness test, contractor shall arrange necessary pipe, PVC,
hoses, fitting, valve, pressure regulator, rotameter etc. at their cost. Contractors
shall tap the air from nearest Instruments air tapping point available at site. The
contractor shall prepare detailed test procedure for the above and get it
approved by BHEL.

30. Conducting high voltage test, short circuit test and other tests as detailed in
Section VII for IP bus ducts as per instruction of BHEL engineer after cleaning
inside as well as outside of the busduct & arranging all testing equipment
required for carrying out busduct testing.

31. Fixing of Current transformers in busducts including wiring from CT terminal to

junction box/Marshalling box, taking through rigid/flexible conduit pipe.

32. Carrying out final painting as per the standard color codes
recommended by BHEL including supply of paints, thinner and other
consumables etc. as required as part of erection. (For more details,
refer scope of painting).

33. Carrying out minor repair, rectification of enclosure/conductors, wherever

required.

34. Arranging all T&P, material handling equipment required for erection.

35. Arranging all Testing instruments, which have been calibrated

36. Furnishing copy of the calibration certificate to the concerned BHEL Engineer for
verification and approval.
 37. Submitting necessary log sheets, protocols, test certificate as per Field Quality
Plan and getting them signed by BHEL/Customer Engineers, and submitting the
same to BHEL.

38. Other requirement for Erection/Commissioning of IP Busducts.

a. Aluminium welders shall appear for test as directed by the BHEL welding
Engineer and only test qualified welders shall be permitted to do the
welding.

b. For MIG/TIG welding only high purity argon gas shall be used. If the
contractor is unable to arrange the required high purity Argon gas, the same
shall be arranged by BHEL on chargeable basis. The cost of gas shall be
recovered from the running bills as per BHEL norms.

c. Aluminium filler wire/rod shall be procured in consultation with BHEL Welding

Engineer from approved Vendors of BHEL.

d. Make up pieces shall be supplied along with bus ducts. Necessary MIG/TIG
welding of different sections of enclosures, make up pieces and bus shall be
carried out at site.

e. Holes on the flanges/Flexible may not be adequate or may not match and
any additional holes, if required, shall be drilled at site to facilitate matching
of busduct enclosure flanges including generator flange.

f. Matching and connecting the Busduct with other equipment erected by other
agencies shall be included in the scope.

g. The contractor shall carry out testing and commissioning works with their
own testing equipments and Testing teams and should not engage outside
agency for testing. Testing shall be done under the supervision of
BHEL/CUSTOMER Engineers.

6.3.3. SCOPE OF LT MCC AND POWER DISTRIBUTION BOARDS.

1. LT MCCs are simple module type with isolators and fuses. However, some of the
MCCs are Double Front draw out type consisting of circuit breakers unit,
contactors/starter fuse switch units, MCB etc. arranged in multi-tier construction.

2. AC/DC Distribution Boards are single front non-draw out type, consisting of
circuit breaker, contactors, starter, fuse unit, MCB etc. arranged in multi-tier
construction. AC/DC DBs, cater to the power supply requirement of Boiler and
shall be located in MCC room. These MCCs and AC DBs are mainly supplied to
cater the requirement of drives, valves, etc. All the LT Switchgear, AC DB shall
be located in Switchgear room of Power House.
3. The base frames shall normally be supplied along with the switchgear boards.
These shall be aligned, leveled and grouted in position as per approved
drawings. Wherever the base channels are not available, the same shall be
fabricated, erected and painted at site. The material for this shall be supplied by
BHEL. Base channels shall be grouted on the opening of the floor. All minor
concrete chipping and finishing works are deemed to be included in the scope of
the job. If base frame is to be fabricated/ erected, separate rate shall be paid on
Tonnage basis. This is applicable for local start/stop push button box also. If any
grouting bolts are required for the panel, the same shall be supplied within the
quoted rate.

4. For the panels to be mounted on the trenches, channel supports have to be

provided across the cable trenches over which the base frames of the panels
shall be mounted. The contractor shall carry out fabrication and erection of these
support structures and separate rate shall be paid on Tonnage basis.

5. Panels will be delivered in different shipping sections. The contractor shall set
each section of equipment on its foundation or supporting structures and
assemble the panels as required. Skilled manpower shall be engaged for
installation of panels with parallel, horizontal and vertical alignment.

6. Necessary interconnection of busbar, inter panel wiring, etc. will have to be done
by the contractor as part of panel erection.

7. Normally the panels shall be supplied with complete instrument mounting and
wiring. However, if necessary, dismantling of the existing components, making
minor modifications in the wiring to suit operating conditions, mounting and
rewiring of new components shall be carried out without any extra cost.
However, if any major wiring modification is involved inside the panel, the same
shall be carried out at extra cost. Mounting and wiring of any instruments,
meters, relays, push buttons, indicating lamps, contactors etc. if supplied loose
for safety in transit, will also be included in the scope of the job, within the
quoted rate.

8. The contractor shall carryout touch up painting for panels, including

supply of paints, wherever required.

9. The commissioning of Switchgear shall involve the trial runs and commissioning
of all connected equipment like servomotors and drives etc. The contractor will
have to keep his personnel round the clock, if necessary during the trial runs and
promptly take action for any repair, checks and rectification etc. required in the
equipment erected by him.

10. All T&P, Material handling equipment including cranes and Relay Testing/ HV
Testing Calibration equipment/ Instruments shall be arranged by contractor.
11. The contractor shall calibrate and commission all switchgear/panel mounted
instruments, protection relays, transducers, Recorders, Indicators, energy meters
etc

12. MCC incomer bus shall be connected to PCC of customer. The contractor shall
co-ordinate for proper connection at PCC.

13. Contractor shall co-ordinate with other cable-laying agency for proper cable
termination.

14. All testing Instruments/ Equipment deployed to site shall be calibrated before
putting it into service. A copy of calibration certificate shall be submitted to BHEL
Engineer for his verification and approval

15. If any removal/ Re-fixing of contactors/relays becomes necessary for the

completion of the system, the same shall be done by the contractor at no extra
cost.

16. Any loose supplied items like lamps, lens, contactor, fuse/relays/instruments
missed from the custody of the contractor shall be replaced by the contractor at
no extra cost.

17. Contractor shall put his watch and ward for the equipment under his custody and
erected in location against theft and damage by other agencies working on the
same area.

18. Laying of rubber mats will be part of panel erection works and no separate rate
shall be applicable for the same.

19. Scope of work shall also cover drilling of bottom gland plates for cable entry as
required.

20. Closing unused opening at the panel bottom plate with suitable material shall be
part of panel erection.

21. Erection of Resistance box of DC drives shall be part of DC starter panels.

22. Contractor shall prepare log sheets, protocol sheets etc. and get approval from
BHEL/ Customer. Contractor shall be responsible to get the protocol signed with
customer, as per field quality plan.

23. Dimensions & weights indicated in the BOQ against various panels are
approximate only. There may be variations in the weight and dimensions.
Variations in depth, height or weight of the panel shall not be considered for
payment.
 24. Any variation in length within ±20% shall not be considered for payment. If the
panels have any variation in length beyond ±20% as compared to actual length
indicated in the BOQ, payment shall be considered proportional to the length of
the panel only.

6.3.4. SCOPE OF AVR/ GENERATOR CONTROL/ RELAY PANELS/ AND OTHER

CONTROL PANELS

1. The panels shall be supplied with different type of protection relays, Instruments
like Meters, Transducers, etc and these panels shall be installed in unit control
room.

2. The scope of work will be generally in line with Electrical MCC panels as detailed
under above clause.

3. Unit rate shall also include testing, calibration and adjustment of relays,
electronic cards and instruments, transducers mounted on the panels. All testing
instruments like Relay Testing/ Calibration Instruments, primary/secondary
injection kits, CRO, frequency counter etc. shall be arranged by the contractor.

4. If panels are supplied with monitor, printers, furniture, controller etc. or any
loose items or equipments, the erection of above shall be part of respective
panel. No separate rate shall be payable for loose supplied items.

5. Normally the panels shall be supplied with instruments / modules mounted and
wired. No separate payment shall be made for commissioning of any instrument/
cards/ components. If dismantling of such instruments and rewiring are needed
at site, the same shall be carried out at no extra cost. If any instruments/ cards/
components supplied as loose items for safe transit, the same shall be mounted
and wired at no extra cost. However, if any major installation/modification/wiring
are involved, the same may be carried out as extra work. The decision of BHEL
engineer shall be final in respect of above extra works.

6. BHEL shall provide vendors’ support for commissioning of proprietary type of

microprocessor based instruments, protection relays which requires software
loading and programmer etc. However overall responsibility lies with contractor
and the contractor shall provide all support like manpower, standard T&P,
instruments etc. for calibration and commissioning of above proprietary type
instruments.
6.3.5. BATTERY AND BATTERY CHARGER

The batteries are of heavy duty type capable of providing normal and emergency
DC loads. The cells will be mounted on insulators carried on suitable wooden
stands. The rectifiers/inverters are fully thyristorised and shall comprise of Silicon
Controlled Rectifier with transformer, switchgear and automatic regulation.
Tentative details are given in the BOM.

Lump sum shall be quoted for Erection and commissioning of UPS and Battery.
No additional payment shall be made for any variation in the number of cells. The
unit rate quoted for erection of UPS and battery will include the following works.

[Link]. Scope of Work for Battery

1. Collecting the batteries and all the accessories like cable connectors, inter
lock connectors, equalizing connectors, rack insulators, fuse box, loop
cables etc from stores and assembling on the racks and fixing all loose
supplied items as per drawings, laying and termination of loop cables.

2. Filling the individual cells with Acid/alkali - if applicable.

3. Arranging suitable resistive load banks for charging and discharging during
charging and discharging cycles.

4. Arranging manpower in shift during battery charging and discharging

cycles that may be carried out round the clock as per the code of practice,
and conducting other routine tests as per IS under the supervision of BHEL
Engineer.

5. Modifications or changes if any for the loose supplied items or any minor
changes in wiring.

6. Arranging necessary tools, T&P, Testing equipments required for erection

and commissioning of the battery.

Note:- If the length of loop cables exceeds 15 Mtrs, separate unit rate shall be
considered for the excess length as per the equivalent unit rate available in the
BOQ.

[Link]. Scope of Work for Battery Charger

The scope of work will be in line with scope of work for electrical control panels,
as detailed under Clause 6.3.4
6.3.6. SCOPE OF WORK OF DIESEL GENERATOR SET

The DG sets of rating 630 KVA, 3 phase, 415 V skid-mounted type set with
diesel engine, AVR, Radiator ,Air Intake System, Exhaust system, Fuel Day Tank ,
battery sets, Acoustic enclosure, panels etc.

Following items shall be supplied as loose.

1. DG Control Panel (Local): size : 2600x1300x2250 mm.

2. DG Control Panel (Remote): size: 2600x1300x2250 mm.

3. DG PCC : size: 3200x1300x2250 mm

4. Aux Distribution Board: size: 1800x600x2250mm

5. Battery Charger panels ( Starting) : 2Sets & Battery,size:550x400x800 mm;

6. Battery Charger panels ( Control) : 2Sets & Battery,size: 550x400x800 mm;

7. Power/control cables, Trays, Earthing Materials ,trays supports etc. 1Lot

Other Details

1. Static Weight of DG Set: 11500 kg (approx.)

2. Static Weight of Acoustic Enclosure: 6500 kg (approx.)

Cooling system comprising of radiators, engine mounted water pump,

selfcontained pipe, thermostat etc.

Fuel system consisting of PT fuel pump, injectors, fuel filters, self-contained

piping.

Lubricating system consisting of oil pumps, strainers, lube oil cooler, bypass
filter, self-contained piping.

Air Intake System consisting of dry type filter, air intake manifold with
necessary connectors, turbo charger with after cooler.

Exhaust system consisting of exhaust manifold, flexible piping, residential

silencer etc.

Diesel Generator sets shall be located at Diesel Generator Building adjacent to

the Power House building.
[Link]. Scope of Work for DG Set

1. The scope of works covers erection skid mounted Diesel Generator and
erection of all loose supplied items mentioned above under Sl.1to 8.

2. Minor civil works like drilling, chipping and punching holes and opening in
concrete floors, slabs, brick-walls, and cleaning of all debris, Grouting,
supply of cement, sand, concrete etc. required for installation of DG sets
shall be included in the erection cost of equipment. No separate payment is
applicable.

3. If any major civil foundations/modifications/alterations are required for

proper installation of Diesel Generator, the same shall be carried out at extra
cost. The decision of BHEL Engineer regarding the above will be final.

4. All T&P, material handling equipments, including crane shall be arranged by

the contractor.

5. All calibration and testing instruments required for relay testing, high voltage
testing and load testing shall be arranged by the contractor.

6. Erection of cable trays, loop cabling between Diesel Generator to Control

Panel/MCC and between Control Panel to MCC, i.e., within the DG Building
shall be part of the erection and no separate rate shall be paid for erection
of trays and cables

7. The DG set shall be maintained by the contractor after

commissioning until full load testing is completed.

* Lump sum rate to be quoted

6.3.7. SCOPE OF WORK FOR ASH LEVEL INDICATOR:

1. Scope of Ash level indicator consists of erection of transmitters (electronic

unit), PTFE wires, probes (for high and low level sensing), flexible conduits
etc. All PTFE cables shall be routed through ¾” GI flexible conduits.

2. The unit rate quoted for each set consists of erection of transmitters
(electronic units), fixing of probes, laying and termination of PTFE cables
through conduits, clamping of flexible conduits etc. The unit rate also
covers supply of metallic clamps, lugs etc. Lumpsum rate shall be quoted
for each set and no separate payment shall be made against erection of
any individual item.
 3. If any mounting frames are required for installation of transmitters same
shall be carried out on tonnage basis as applicable for other fabrication and
erection.

6.3.8. SCOPE OF WORK FOR HEATING ELEMENTS:

1 Two types of heating elements shall be supplied (panel type and standard
heating elements)

2 All heating elements shall be fixed by the mechanical contractor.

3 The panel type heating elements shall be supplied with extension cables
and flexible conduits. Unit rate quoted for panel type heating element
includes routing the extension cables through flexible conduits, dressing,
terminations and checking of the heating elements.

4 Unit rate quoted for thermostat and other standard heating elements
covers only checking of elements/thermostat.

6.3.9. = DELETED =

6.3.10. SCOPE OF WORK OF CABLES :

BHEL will supply HT and LT cables (11kV/ 1.1 kV, Armoured/ Unarmoured,
Aluminium/Copper PVC FRLS insulation) of different sizes. The scope of work for
cables covered in this tender is as below.

1. The scope includes laying & termination of cables, fixing of glands, ferrules,
tag plates with necessary numbering and dressing of cable, as per BHEL
specification and BHEL engineer's instructions.

2. Unit rates shall be on meter basis. The unit rate quoted for the cabling
laying shall also include supply of clamping materials, ferrules, tag plates,
lugs up to 2.5 sq. mm. Contractor scope of supply of materials shall be as
per BHEL's specification as detailed in Section VI

3. Cables shall generally be laid on cable trays. However, if the cables are to
be routed through or laid duct bank, cable shaft etc., the same rate shall
be applicable.

4. Separate rate shall be paid for LT Power cable termination , for cable size of
4 sqmm and above only.

5. For single core Power cable Trefoil clamps shall be fixed as part of laying
and termination rate.

6. If the cables are to be routed on steel angles as per site condition, steel
angles will be supplied by BHEL.
7. All the dressing material such as Aluminium/GI strips, PVC ties etc
required for cable shall be arranged by the contractor within the rate
quoted .

8. The contractor shall carry out cable dressing and clamping for all the cables
laid by the contractor. However, if cables like illumination cables or any
other cables of lesser quantity for which no separate trays have been
allotted and are to be laid on the same trays, the contractor shall do
clamping such those cables also along with the cables laid by him.

9. The unit rate quoted for cable laying shall also cover the following works.

a) Modification such as rotating the terminal box through 90° or 180° as

required.

b) Enlargement of cable entry holes, if necessary, by chipping/tapping or

any modification required fixing of cable glands

c) Reaming and relocating holes at actual point of entry of cable or

conduit in terminal boxes, outlet boxes, pull boxes etc. cleaning off the
debris/trapped material from conduit/ducts.

d) In case any existing structure is affected/damaged due to installation

work of cables the contractor shall repair the same to the satisfaction of
Site Engineer

e) However any major modification like drilling, tapping etc. are involved
in fixing of glands in JBs and Terminal boxes same shall be considered
as extra on man hour rate basis as per extra works clause.

10. The approximate number of termination for the purpose of estimation to be

for control and pair cable shall be assumed as follows: The average RUN
length shall be considered as 150 mtrs. However, 10% of the cable the
average length shall be considered as 30 mtrs.

CABLE TERMINATION

11. For LT control cable terminations, no. separate rate shall be paid.

12. The scope of termination shall include, termination of cables on various

panels/ JBs/ Pushbuttons etc. installed by other agencies. The contractor
shall co-ordinate with such agencies and do the termination, including
drilling of gland plates for fixing cable glands, if required.

13. The insulating sleeves shall be of fire resistant and be long enough to over
pass conductor insulation and shall be properly sized.
 14. The contractor shall provide Tools/ equipment required for the connections
and termination of cable wherever necessary.

15. For HT cable termination suitable termination kits shall be supplied and HT
cable termination shall be part of installation of HT termination kits. No
separate cost shall be paid for HT termination

16. Only printed ferrules should be used and necessary ferrules printer shall be
brought and used by contractor at site.

6.3.11. CABLE TRAYS / CONDUITS/ FLEXIBLE CONDUITS

Scope of cable tray works covers erection of various sizes of ladder & perforated
trays with accessories in Power House building & ESP area that includes cable
galleries/cable vault and cable shaft and trays required for routing of cables for
some of the BOP building. All type of cable trays including standard trays
accessories shall be supplied by BHEL.

The scope of work for cable trays shall be as follows:

A- CABLE TRAYS

1. Scope of cable tray works covers erection of various sizes of trays with
accessories such elbow, cross, TEEs, bends (90° vertical and Horizontal),
reducers, coupler plates/fixing plates, anchor bolts, fasteners etc.

2. If accessories such as TEEs, reducers, bends (90° vertical and Horizontal),

cross etc. are not supplied, the same shall be fabricated wherever required
from straight trays. The accessories supplied maybe modified to suit site
routing as part of work.

3. The scope also covers making offsets by cutting standard tray sections and
inserting suitable size of trays to match with the existing arrangement.

4. The unit rate for erection of trays shall be on meter basis which includes
erection of trays and accessories, fabrication of tray accessories and
modification of straight trays, if required.

5. No separate rate shall be paid for any fabrication of tray accessories or any
modification on straight trays.

6. If tray covers are supplied, the same shall be erected after completion of
cable lying and no separate payment will be made for fixing these covers.
GI strip clamps are to be used for fixing the tray covers.
 7. Welded Joints of trays shall be painted with red lead and aluminium paint in
turn with bitumen as per IS 3043. The unit rate shall also include supply of
paints, thinner, other consumables and brush etc.

8. Cable tray mounting structure shall be welded to the plate inserts or to steel
structural beams/ members. Welding of cable tray mounting structure to
steel structural beams/ members shall be done with prior approval of
Customer/ BHEL Engineer.

B- RIGID & FLEXIBLE CONDUITS

1. Cables shall normally be laid on cable trays. However, in case of shorter

routes where trays are not possible, suitable GI pipe/flexible conduits shall
be used. Unit rate shall be paid on running meter basis.

2. The scope of works for flexible conduit includes drilling of the holes on the
plates, fixing of the end connectors, providing suitable supports and fixing
tag marks wherever specified. The supply of suitable clamps, fasteners and
tag plates are in contractor's scope.

3. In the case of flexible conduit laying for fixing end connectors, no separate
payment will be made for connectors.

6.3.12. SCOPE OF WORK OF JUNCTION BOXES/ MARSHALLING BOX/ STARTER

BOXES AND PUSH BUTTON BOXES:

Different type of Junction boxes/Push button boxes shall be supplied. The scope
of installation of Junction boxes/Push button boxes shall be as follows:

1. The unit rate quoted for erection of junction boxes/push button boxes shall
include providing necessary supports, drilling of bottom gland plates for cable
glands as required, Painting the tag No of JB or fixing a separate tag plate as
required on junction boxes/push button boxes, minor chipping, grouting as
required for mounting the JBs/PB and supply of all bolts and nuts (Fasteners)
including grouting bolts as required for mounting the junction box/push
button.

2. Fabrication and fixing of supports shall be on tonnage basis.

3. The contractor shall close all unused holes on the gland plates using
grommet or other suitable material issued by BHEL, at no extra cost.
 4. If any intermediate JBs are required to terminate power cables for drives, the
same shall be installed and also any modification like replacement of
terminals, enlarging gland holes etc. required to accommodate power cables
shall be carried out as part of this works. Equivalent Unit rate shall be paid
for installation of such JBs. Decision of site engineer will be final regarding
the equivalent rate.

6.3.13. SCOPE OF WORK FOR FABRICATION & INSTALLATION OF STEEL

MATERIALS

1. Scope of steel fabrication and installation covers, fabrication and installation of

various type of supports for cable tray, GI pipes, JB, Control Box/Panel, local
Push Buttons, bus ducts etc. with angles and channels of different sizes.

2. The fabrication steel materials such as angles, channels, plates, etc shall be
supplied in standard lengths by BHEL.

3. Fabrication shall be carried out by the contractor as per schemes in

consultation with site engineers.

4. For fixing frames or supports if any minor grouting is required the same shall
be carried out by the contractor. After installation of frames, grouting of the
same is in the scope of contractor. Supply of all cement, sand etc. required for
grouting of supports is in the scope of contractor. All site fabricated items, all
supports or brackets needed for installation shall be fabricated and painted by
the contractors with two coats of red chromate Zinc primer and two coats of
epoxy based paint. The paint shade shall be approved by BHEL Site in charge.
Immediately after fabrication, primer shall be applied to prevent corrosion. The
installation shall be carried out only after applying the primer as detailed in
painting clause.

5. A composite single rate shall be quoted for fabrication and installation of steel,
on tonnage basis. The above rate shall include supply of paints and painting,
grouting and grouting material as required.
6.3.14. ABOVE GROUND EARTHING & LIGHTNING PROTECTION
INSTALLATION

A) Above ground earthing

a. The scope of work shall include installation of earthing and lightning protection
system materials and associated fittings. Civil agency will provide earthing
grid system comprising of main earthing conductor buried in soil, embedded in
concrete inside the building. Installation of earthing conductors for connecting
equipment pertaining to BOILER/TG/BOP area to the plant main earth grid shall
be carried out by the contractor.

b. Different types of earthing materials like GI Flats, wires etc shall be supplied by
BHEL and the contractor shall lay and connect the earthing materials as per
site requirement. The unit rate shall be quoted for earthing on meter basis and
shall cover supply of fasteners, saddles, spacers, lugs for earthing wires, minor
civil works, painting on he welded joints including supply of anti corrosive
primer and paint etc.

c. Drawings of main earth grid system provided by others will be made available
to the contractor to enable them to carry out rest of the earthing system work.

d. Treated test pits as per drawing No:PE-DG-219-509-E763 shall be provided.

e. Unit rate for test pit shall be on Nos. basis. The unit rate quoted for Test pit
will cover casting of test pit chambers, supply of all other materials like
cement, brick, sand ,salt, charcoal etc. except Earth Electrode. Earth Electrode
shall be supplied by BHEL in standard length and contractor shall fabricate
suitably as per the drawing.

f. Earthing System Installation scope covers, earthing of all cable trays in

inside/outside plant building as well as inside the trenches at an interval as
detailed in section VII metallic frames of all current carrying equipment,
supporting structures adjacent to current carrying conductors, neutral points
of various /equipment, panels, motors, JB, push button boxes etc. as listed in
various drawings

g. The connection between earthing pads/ terminal to the earth grid shall be
made short and direct and shall be free from kinks and splices.

h. Metallic conduits and pipes shall not be used as earth continuity conductor.
Pipe racks shall be earthed at every 25 meters. Earth continuity shall be
ensured across all flanges joints etc as per earthing drawing.
 i. Connection between the equipment earth lead and the grid conductor shall be
welded. For rust protection, the welds shall be painted with anti- corrosive
primer & paint.

j. Supply of anti- corrosive primer & paint is in the scope of the contractor.

k. Generator neutral from the NGT/NGR cubicle shall be earthed using two
dedicated rod electrodes, which shall in turn be connected to the main plant
grid.

l. Generator transformer neutral shall be earthed using 2 dedicated rod

electrodes.

m. All electrical equipment operating above 250V shall have two separate and
distinct connections to the earth pit.

n. Transformers shall be provided with two dedicated earth electrodes for

earthing of neutral and transformer tank earthing. The contractor shall carry
out earthing for all Electrical equipment, which may be erected by other
agency.

o. If the equipment is not available at the time of earthing conductor laying tap
connections from the main earthing conductor shall be brought out up to slab
equipment foundation level with at least 200 mm spare length left for further
connections to equipment earthing terminals.

p. For different floors in a building, localized internal earthing ring shall be formed
and connected to the ground earthing through vertical risers. The earthing
mat shall be common to both power and lighting installation

q. Each RCC steel column of the building will be interconnected to the floor-
earthing grid in basement/ground floor.

r. For Electronic earthing, separate conductor shall be used for flow of earth fault
current. All Electronic panels shall be connected separately to Electronic bus
which in turn will be connected to electronic earth pit.

B) Lightning protection system installation

1 The scope of works for Lightning Protection system includes installation of

vertical air terminations, Horizontal conductors, vertical down conductors,
fabrication of fixing clamps, test links, supply of saddles, Spacers and
associated minor civil works etc as per drawing PE-DG-217-509-E014.

2 HORIZONTAL AND VERTICAL DOWN CONDUCTORS: The horizontal conductors

shall be installed on the top of the building with suitable clamps/saddles
arrangements. This horizontal conductor shall be connected with down
conductors which in turn will be connected to risers through test links. Both
 horizontal and down conductors shall be supported on the clamps/saddles and
spacers which will be fixed on the walls/columns or on top of the parapet walls.
The clamping arrangements shall be provided at a span as specified in the
earthing drawing.

3 The unit rate quoted for horizontal and vertical conductor on meter basis shall
include supply of supports clamps, saddles, spacers Anchors/ fasteners etc.

4 TEST LINKS: The unit rate quoted for Erection of Test links shall include supply
of TEST LINK which shall be supplied as per drawing PE-DG-247-507-E002 and
installed at different places as shown in the lightning protection drawings.

5 The unit rate quoted for the test link on sets (Nos.) basis shall cover supply of
GI fasteners like washer/bolt/nut required for fixing Test Link and
connecting Test Link to riser rod of MS 40 mm size. by welding. If the riser rod is
provided already , Test Link shall be directly shall be directly welded to riser rod
with down conductor.

6 RISER ROD:(If applicable)The unit rate quoted for riser rod shall also covers
excavation of earth for laying of riser rod , welding with lightning earth
electrodes and Test link down conductor, refilling of the excavated earth,
consolidation etc . Even if the building plinth area has already been
consolidated, the same shall be removed, conductors shall be installed ,welded,
refilled and consolidated

7 VERTICAL AIR TERMINATIONS: The vertical air terminations shall be located in

different locations of the buildings as shown in the drawings. The vertical
terminal shall mostly be fixed on the top of peripheral wall using a GI base
plate of size 150x150x6 mm. The vertical air terminal shall be grouted on the
wall and minor civil works required for grouting the air terminals as shown in
drawing PE-DG-247-507-E002 and supply of grouting materials are in the
scope of Contractor. The supply of above base plate is in the scope of
Contractor.

8 The unit rate quoted on sets (Nos) basis for vertical air terminal includes supply
of base plates, bolt with nuts & washer, chipping and minor civil works,
grouting and supply of grouting materials

9 Entire system shall be earthed in accordance with the provisions of the relevant
IEC recommendations/IS code of practice IS 3043-1947 and Indian Electricity
Rules, so that the values of the step and contact potentials in case of faults are
kept within safe permissible limits. Parts of all electrical equipment and
machinery not intended to be alive shall have two separate and distinct earth
connections each to confirm to the stipulation of the Indian Electricity Rules
and apparatus rated 240 V and below may have single earth connections.
6.3.15. SCOPE OF PAINTING

1. The scope of painting generally includes painting of all steel items such as
supports, racks, frames, Transformer, Bus ducts etc, as detailed in Scope of
work of respective equipment besides touch up paints wherever required.

2. The scope also includes supply of paints, primers,

tools/consumables like brushes, rollers, emery papers, thinner
etc., at no additional cost.

3. Touch up painting is generally required for trays, control panels, junction

boxes. Full painting shall be required for specific equipments as per the
scope of erection.

4. All damaged painted surfaces shall be cleaned and painted as detailed

above.

5. All damaged galvanized surfaces including cable trays shall be coated with
cold galvanizing paint.

6. No separate rate shall be paid for painting and supply of paints, and other
consumables. Painting shall be accommodated in the unit rate quoted for
items which calls for painting as per scope of work.

6.3.16. SCOPE OF CIVIL WORKS

1. Only minor civil works like chipping, drilling and punching in concrete floors/
slabs/ brick walls, grouting of bus duct /Transformer supports in foundation,
base frame of panels/ push button stations/ Junction Boxes, etc. are
covered in the scope of this contract.

2. Scope of civil works includes supply of grouting materials like grouting

cement, sand, etc., and cleaning of all debris.

3. More details regarding scope of civil works are given in the respective
equipment erection.

4. No separate payment will be applicable for above civil works.

6.3.17. SCOPE OF CALIBRATION

1. Contractor shall calibrate all the local instruments, panel mounted

instruments including transducers, protective relays, Recorders, Indicators
etc. that will be supplied along with equipments mounted in or in loose

2. Contractor shall maintain calibration records as per the format CP:PEX:FOX

enclosed in the tender specification.
 3. All testing Instruments/ Equipment deployed for calibration shall be
calibrated before taking it into service. A copy of calibration certificate shall
be submitted to BHEL Engineer for his verification and approval.

4. All testing instruments shall have calibration certificate issued by

recognized/accredited agencies.

5. BHEL shall provide vendors supports for proprietary type of

microprocessor-based instruments, protective relays, which
requires software loading and programmer etc. However overall
responsibility lies with contractor and Contractor shall provide all
supports like manpower, standard T&P, Instruments etc for
calibration and testing of above proprietary type instruments

6. If BHEL is unable to provide or arrange vendor support for above

mentioned proprietary instruments, contractor shall carry out the
calibration through authorized agency, at extra cost. The actual
cost of such calibration carried out by out side agency shall be
reimbursed by BHEL. However if above such calibrator is available
with BHEL at site the calibration shall be carried out by the
contractor within the quoted rate.

6.3.18. SCOPE OF COMMISSIONING OF EQUIPMENT ERECTED BY THE

MECHANICAL CONTRACTOR

1. All types of HT Drives and Generator

a- Cable identification, checking and meggering.

b- IR value of motor, measurement of winding resistance etc. c-

Dryout all the motors if required to improve IR value.

d- Checking direction of rotation of motors and testing and commissioning

from local as well as remote.

e- Checking the bushing and HV test/Tan delta test

f- Attending to any defects till the handing over of the unit to customer

2. ESP Transformer

a- Dry out of transformers (Oil filtration) till achieving desired BDV, IR Value,
Calibration of oil temperature gauges, Checking of breather gauge, HV
Test etc. i.e. scope of commissioning of ESP Transformer shall be in line
with transformers erected by the contractor.
 b- Replacing defective components like Temperature gauges, breather glass
etc.

c- Attending to any defects till handing over of the unit to customer by BHEL

3. All types of drives and motor operated valves

a- Cable identification, checking and meggering.

b- IR value of motor, measurement of winding resistance etc.

c- Dryout all the motors if required to improve IR value.

d- Limit switch and torque switch setting

e- Calibration of Electronic cards, modules etc. and fixing the same if

supplied as loose item.

f- Checking direction of rotation of motors and testing and commissioning

from local as well as remote.

g- Attending to any defects till the handing over of the unit to customer by
BHEL

h- Replacing defective components like limit switches, electronic cards etc.

4. Panels.

The panels shall be mostly skid mounted and the skid will be erected by
mechanical contractor. The scope of commissioning of Panels covers
checking of internal wiring and associated loop cables from panels to field
instruments, Push Buttons, JBs, drives, replacing defective
components/instruments/electronic cards etc.

If any loop cables (power or control) are to be laid or replaced, the same
shall be carried out at unit rates available in the BOQ.

5. Hoist :

All cabling will be carried out by the vendors. However the scope of works
of hoist covers besides works mentioned in Sl No1, the checking of control
panels wiring, field wiring like push button, motors, limit switch etc., fixing of
Trailing cables, and making ready for load test by mechanical agency.

6. ESP Heating Elements and Thermostats

a- Checking the healthiness of Elements and Thermostats.

b- Setting the value

c- Replacement of defective Elements and Thermostats.

6.3.19. SCOPE OF PRE-COMMISSIONING/ COMMISSIONING AND POST
COMMISSIONING WORKS:

1. The scope of commissioning works covers arranging suitable skilled

manpower - technician, supervisor and engineer as required for
commissioning of all Electrical equipments covered in the BOQ including
loop checking and establishing the operation of equipments/systems to
meet plant commissioning/operation. BHEL will provide vendor supports for
special or proprietary type instruments/systems and contractor
engineers/supervisors shall associate with the vendors and provide
necessary manpower, T&P etc.

2. Scope of commissioning starts with the commissioning of various Elect

equipment erected by the contractor and making them available, as
required, for the various commissioning activities of the main plants. The
commissioning activities of the main plant shall be as below:

a. Trial run of various equipment.

b. Light up of boiler.

c. Boiler acid cleaning.

d. Boiler alkali boil out.

e. Turbine barring gear.

f. Steam blowing of piping.

g. Turbine rolling.

h. Safety valve floating.

i. First synchronisation

j. Heavy oil firing and synchronisation.

k. Coal firing.

l. Trial Operation / Full load.

3. The above commissioning activities, tests, trial runs may have to be

repeated till satisfactory results are obtained to the satisfaction of customer
/ consultant. Contractor shall co-ordinate with other contractors during the
above main plant commissioning activities to ensure proper commissioning
of total plant.
4. The pre-commissioning activities of the main power plant shall start with
energizing of start up power supply systems followed by trial run of various
drives prior to light up of boiler. Commissioning operations shall continue
till trial operation of the unit. The contractor shall simultaneously start
checking cables erected by him to match with the various milestone
activities /commissioning programme of the project. Contractor shall
earmark separate manpower for various commissioning activities. The
manpower shall not be disturbed or diverted for erection work

5. Contractor shall arrange commissioning engineers, supervisors, electricians,

in each area to be associated with BHEL commissioning staff. Contractor
shall earmark separate manpower for various commissioning activities. The
manpower shall not be disturbed or diverted. It shall be specifically noted
that above employees of the contractor may have to work round the clock
along with BHEL commissioning engineers involving considerable payment
of overtime, which forms part of Contractors Scope

6. The mobilization of these commissioning groups shall be such that planned

activities are taken up in time and also completed as per schedule and the
work undertaken round the clock if required. It is the responsibility of
contractor to discuss on day to day / weekly / monthly basis the
requirement of manpower, consumables, tools and tackles with BHEL
engineer and arrange for the same.

7. If the contractor fails to arrange the requisite manpower, consumables,

T&P to meet the schedule, BHEL shall make alternate arrangements and
recover the cost with overhead from the running bills of the contractor.

8. The contractor shall make necessary protocols with BHEL/ customer after
erection as well as testing/ commissioning of various equipments. The
contractor shall prepare the formats and obtain approval from BHEL. The
approved formats shall be printed by the contractor in adequate numbers.

9. In case any rework/repair/rectification/modification/fabrication etc. is

required because of contractor's faulty erection which is noticed during
commissioning at any stage, the same has to be rectified by the contractor
at his cost. If during commissioning, any improvement / repair / rework /
rectification / fabrication / modification due to design improvement /
requirement is involved, the same shall be carried out by the contractor
promptly and expeditiously. Claims if any, for such works from the
contractor shall be governed by clauses covered elsewhere.
10. During commissioning activities and carrying out various tests, if any of the
instruments has to be temporarily erected and commissioned to suit the
commissioning activities, the contractor have to carry out the erection of
the same. After completion of activities the temporary systems have to be
removed and returned to stores and no extra rate shall be paid for this.

11. Minimum requirement of Man Power for testing/checking works shall be as

follows:

TRANSFORMER/BUS DUCT SWITCHGEAR/CONTROL

- Engineer 1 1

- Supervisor 1 2

- Technician 2 6

12. The above commissioning group shall be identified at the Pre-

commissioning and commissioning time. The above commissioning group
shall have the knowledge of various systems referred in the tender and also
should have adequate experience. The above manpower for
commissioning is only tentative and for any additional manpower as per
site requirement the same shall be arranged by the contractor.

13. If the contractor fails to deploy the above Engineer/Supervisor/ Technician

at appropriate time of commissioning, no payment shall be made against
commissioning activities as per terms of payment.

14. All the T&P instruments required for commissioning are to be arranged by
the contractor. (However, any special instruments, which are of
proprietary nature, shall be arranged by BHEL.)

15. It shall be the responsibility of the contractor to arrange and complete all
the testing, pre-commissioning and commissioning activities for the
particular equipment as per relevant standard, code of practice,
manufacturer's instructions and BHEL norms. All the above will be
witnessed by BHEL engineers and reports signed jointly. Contractor shall
follow checklist of BHEL and testing & commissioning activities shall be
carried out in accordance with the checklist.

16. The scope of commissioning by the contractor shall cover the

equipment/drives erected by the mechanical contractors as detailed in the
BOQ.
6.4.0 TIME SCHEDULE

6.4.1 The entire scope of work erection, testing and commissioning shall be completed
within 10 months as detailed in overall erection commissioning programs.

The contractor shall mobilize his resources and work force within two weeks from
the date of telegraphic LOI in such a manner that the entire electrical work
covered in his scope is completed to match the following commissioning program
for Unit-9.

a. Boiler Light up : 2 months from start of work.

b. Barring Gear : 5 months from start of work.

c. Synchronization : 6 months from start of work.

d. Full Load/ Trial operation : 8 months from start of work

e. Handing over : 10 months from start of work
6.4.2 = DELETED =

6.4.3 BHEL, owing to its commitment to their customer, may ask contractor to compress
the total completion schedule. Contractor shall plan his activities and mobilize
additional resources accordingly to the satisfaction of BHEL engineer within the
quoted rates.

6.4.4 The contractor shall reach site and establish his site office and mobilize to
commence the work as per directions of BHEL engineer. The date of starting the
work at site shall be fixed in consultation with BHEL's engineer and the same shall
be recorded in measurement book while entering the first RA bill.

6.4.5 Subject to availability of materials and other inputs, it is the responsibility of the
contractor to carry out work to achieve the monthly progress and keep up the
schedules.

6.4.6 Contractor shall draw the monthly erection programme along with BHEL engineer
indicating the work to be achieved and events to be completed. Once the
programme is drawn, he shall adhere to the same. Contractor shall plan and erect
the materials as it is received at site. The monthly planned percentage shall take
into consideration the material available at site before the start of the month and
also any material received during the month. Contractor shall mobilize his
resources required to achieve the monthly programmes.

6.4.7 = DELETED =

6.4.8 The work under this scope of contract is deemed to be completed in all respects
only when all the items/materials/equipment are erected and trial runs, testing and
commissioning the equipment are completed. The decision of BHEL in this respect
shall be final and binding with the contractor.
6.4.9 During the tenure of contract, if BHEL is not satisfied with the progress of work,
BHEL has the right to withdraw any portion of work / balance work and get the
same done through any other agency at the risk & cost of the Contractor. The
contractor shall not be entitled for any compensation whatsoever in this regard.

6.5.0 OVER RUN CHARGES

6.5.1 In case due to reasons not attributable to the contractor, the work gets delayed
and completion time gets extended beyond 10 months from the date of
commencement of work. Contractor shall be entitled to claim ORC after 10
months from the commencement of work .If eligible, the contractor shall be paid
Over Run compensation of Rs.50,000/- (Rupees Fifty Thousand only) per
month for the extended period beyond 10 months.

6.5.2 Contractor is not entitled to avail ORC for the work for which sufficient work front
and time was available during the contract period and if the contractor could not
attend due to his own reasons during the contract period and try to complete
after the contract period, ORC payments shall be paid only after approval of
competent authority.

6.5.3 The payment of over run charges for extended stay for reasons not attributable
to contractor will be subject to achieving the monthly programme of work as
mutually agreed upon during the extended stay.

6.5.4 The period of over run compensation will have to be ascertained before
commencement of the ORC period

6.6.0 MEASUREMENTS & WASTAGE & CUTTING ALLOWANCES:

6.6.1 For all payment purposes, measurement shall be made on the basis of the
execution of drawings/physical measurements. Physical measurements shall be
made by the contractor in the presence of the Engineer.

6.6.2 The measurement for cable, impulse pipes/tubes, GI pipe, conduits, flexible
conduits, trays etc. shall be made on the basis of length actually laid.

6.6.3 All the surplus, scrap and serviceable materials, out of the quantity issued to the
contractor shall be returned to BHEL in good condition and as directed by the
engineer.
6.6.4 All materials returned to stores should carry an aluminium tag indicating the size
and type. More than 5 metres length termed as serviceable material and shall be
returned size wise and category wise to the owner's stores/yard. Cable of
serviceable length being returned to the stores in drums shall have their free
ends sealed and the balance lengths on the drum(s) shall be noted and certified
by the Engineer-in-charge. This shall be applicable only for the purpose of
accounting the cables issued for installation.

6.6.5 While carrying out material appropriation with contractor, all the above points will
be taken into account. All serviceable material returned by the contractor shall be
deducted from the quantities issued for the respective sizes and categories and
the balance quantity(ies) will be taken as the net quantity(ies) issued to the
contractor. Material appropriation shall be done and allowable scrap quantity
calculated as per wastage allowance specified in Section VII. Any scrap/wastage
generated by the contractor in excess of the allowable percentage shall be
charged at the rates decided by the Engineer whose decision shall be final and
binding on the contractor.

6.6.6 For all site-fabricated steel items such as supports, racks, frames etc. physical
measurement shall be made and then converted to tonnage. For steel material
supplied to the contractor, all scrap shall be returned to BHEL stores with due
accounting.

6.6.7 Every month the contractor shall submit an account for all the materials issued to
him by BHEL in the standard proforma prescribed for this purpose by the site in
charge/ Engineer.

6.6.8 The erection contractor shall make every effort to minimize wastage during
erection work. In any case, the wastage shall not exceed the following limits:

[Link]. Item % Wastage on issued Qty

01. Fabrication steel 2
02. Each size of power cables 1
03. Each size of control cables 2
04. Impulse pipe/ tubes/GI pipes/ Cu tube 1

If the actual wastage be more than the specified figure, then equivalent price of
the excess portion will be deducted from the contractor's bill.
6.6.9 The cable take off from drums shall be planned strategically such that jointing in
the run of cables and wastage are avoided. For this purpose the exact route
length between various equipment/panels as per the cable schedule shall be
measured and the route length recorded before laying of the cables. Depending
upon the route length the type of cable required for various destinations, the
cable drums shall be suitably selected for cable laying. Any jointing which may be
approved by the engineer all the cut pieces/bits of cables which are not used/
unused shall be returned to BHEL Stores for accounting towards wastage. The
cables damaged by the contractor shall have to be replaced by the contractor at
his own cost.

NOTE:

Salvageable scrap shall mean lengths of pipes, multicables, other cables etc.,
that can be used one time or other at a later date and normally they are
recovered from the cut-pieces of tubes, pipes, multicore cables, cables etc.
Non - Salvageable scrap means the lengths of tubes, pipes, multicore cables,
cables etc., and they are from cut-pieces of tubes, pipes, multicore cables, cables
etc., that cannot be used at all.

6.7.0 COLLECTION OF MATERIALS

1. BHEL shall issue materials covered in BHEL scope from their stores/ storage yard
at site. The contractor shall collect such materials from BHEL stores/ storage
yard and transport to his worksite at the contractor’s cost.

2. The contractor shall inspect such materials as soon as received by the contractor
and shall bring to the attention of the Engineer-in-Charge any shortage / damage
or other defects noticed before taking over the materials. Materials once taken
over will be deemed to have been received in good condition and in correct
quantities except for intrinsic defects which cannot be observed by visual and
dimensional inspection and weighing.

3. Upon receipt by the contractor the responsibility for any loss, damage and / or
misuse of such materials shall rest with the contractor.

4. All materials issued by BHEL shall be properly stored and systematic records of
receipts, issue and disposal will be maintained. Periodic report on inventory shall
be made available to BHEL Engineer-in-Charge.
 5. All materials issued by BHEL shall be utilized as directed by Engineer-in-Charge
or most economically in the absence of such direction. The contractor shall be
responsible for the return to BHEL Stores of all surplus material, as determined
by the Engineer-in-Charge.

6. If the materials issued by BHEL are lost, damaged or unaccounted, the cost of
such items shall be recovered from payments to the contractor. However, the
contractor shall raise FIR for lost/ stolen itemsand inform BHEL all details.
6.8.0 STORAGE:

6.8.1 The equipment should be preferably in its original package and should not be
unpacked until it absolutely necessary for its installation. The equipment should be
best protected in its cases. It should be arranged away from walls.

6.8.2 The wooden pallet provided for packing itself can be retained for raised platform
to protect equipment from ground damps, sinking into around and to circulate air
under the stored equipment. This shall also help in lifting the packing with fort lift
truck.

6.8.3 Periodic inspection of silica gel placed inside the equipment is necessary. It has to
be replaced when decolorisation takes place or regenerated. BHEL shall supply
the material and the contractor shall replace the same.

6.8.4 Due care should be taken to ensure that the equipment is not exposed to fumes
gases etc. which can affect electrical contacts of relays and terminal boards.

6.8.5 The storage room and the equipment should be checked at regular interval of 3
months to ensure protection from termites, mould growth, condensation of water
etc. which can damage the equipment. Contractor shall keep BHEL informed
about such problems.

6.8.6 All the equipment, materials and goods kept in the store room should be
identified and registered in a book. Inspection report should be recorded. Any
discrepancy observed should be communicated to site.

6.8.7 Packing material shall be retained if the cubicle to be repacked after inspection.

6.8.8 Sub-Assemblies

a) All sub-assemblies should be kept in a separate place where it is easily

accessible.

b) Sub-assemblies should have a protective cover in case it is stored without

wooden packing/case to prevent accumulation of dust. Silica gel packets
should also be kept along with it.

c) Sub-assemblies should not be stacked one above the other.

6.8.9 Loose items (wherever applicable)

The loose items supplied for the main equipment falling into various categories
like tools, cables, recorders and display units, cable glands, frames etc. are to be
categorized and stored separately.

6.9.0 TOOLS AND PLANT TO BE ARRANGED BY THE CONTRACTOR

6.9.1 Equipment, vehicles, tools and plants and materials brought to site by the
contractor from his resources shall have distinctive identification marks and the
description and quantity shall be intimated to BHEL in writing by the contractor.

6.9.2 All construction materials brought by the contractor shall have prior approval
regarding quality and quantity by BHEL. The contractor shall also provide without
extra cost necessary enclosures containers and protective materials for proper
storage of materials inside, whenever so instructed by the purchaser without any
extra cost.

6.9.3 No material or equipment or tools etc. shall be taken out of the work-site without
the written consent of BHEL.

6.9.4 BHEL shall not be responsible for the safety and protection of the materials of the
contractor and the contractor shall make his arrangements for proper watch and
ward for his materials.

6.9.5 Until such time the work is taken over by BHEL, the contractor shall be
responsible for proper protection including proper fencing, guarding, lighting,
flagging, watching. The contractor shall during the progress of work properly
cover up and protect any part of the work liable to damage by exposure to the
weather and shall take every reasonable precaution against accident or damage
to the work from any cause.

6.10.0 MATERIALS/CONSUMABLES TO BE ARRANGED BY THE CONTRACTOR

WITHIN THE QUOTED RATE FOR E&C OF RESPECTIVE EQUIPMENT/
ITEMS

01 All type of welding electrodes, Gases

02 Provision for Temporary Scaffoldings.

03 Insulation tape.

04 Paints required for primer coating and final coating and for protective
coating.

05 Solder wire (Lead) -(60/40)

06 Protocol/Calibration report sheets as per BHEL Format.

 07 Panel/ JB Sealing compound material (for cable entry from bottom/Top
of Panel).

08 Materials required for cable dressing.

09 Ferrules and Tag plates

10 Lugs upto 2.5 Sqmm

6.11.0 TECHNICAL REQUIREMENTS FOR SUPPLY ITEMS

1 CABLE LUGS:

a) Type: Solderless crimping type

b) Material Copper / Aluminium
c) Whether tinning required (For Yes.
copper cable lugs)
d) Thickness of tinning: 10 microns
e) Applicable Standard for LT Cables IS:8309
f) Approved Vendors Dowels/ Lotus/ Jainson/ Power
Engineering/ KlipOn/ Multi
(Any other make proposed by
bidder shall be subject to BHEL’s
approval)

2 FERRULES:
a) Colour of ferrules: Yellow/White
b) Colour of engraving Black

3. TAGS:
a) Material : Al/Fiberglass/ Stainless Steel
b) Markings: Engraving/Embossing/Printing
6.12.0 TERMS OF PAYMENT

The contractor should submit his monthly on account monthly bill with all the
detail required by BHEL on specified date every month covering progress of work
in all respects and areas from the 25th of previous calendar month to 24th of the
current month For erection and commissioning. Upto 93 % of the value will be
released progressively against running bills, as per break up details furnished
below.

6.12.1 Transformers :

a. Receipt, transport to the placement of erection on Placement, 50%

assembly, alignment, grouting mounting and wiring loose parts
on pro rata basis

b. Oil filling (gas filling) filtration, mechanical operation checking on 20%

pro rata basis

c. Pre commissioning checks, tests, calibration and energisation and 20%

commissioning on pro rata basis

d. On painting 3%
6.12.2 LT switchgear and control panels.

a. Receipt, transport to erection site on Placement, assembly 50%

fixing and clamping on pro rata basis

b. Adjustment, Alignment, grouting and on pro rata basis 20%

electrical interconnections

c. Pre-commissioning tests, checks, calibration and making 23%

ready for energisation on pro rata basis

6.12.3 Battery, Charger:

a. Receipt, transport to erection site, checking, Placement, 50%

assembly, grouting Mounting and wiring of loose components
b. Adjustment, alignment, inter connections and pouring of Alkali 20%
c. Pre commissioning test checks, and making ready for 20%
Energisation
d. Completion of pending points 3%
6.12.4 Laying and termination of HT cable

a. Laying /tagging /termination on pro rata basis and protocol 70%

signed

b. Checking, Fixing Trefoil calmps and Highpo test on pro rata basis 20%
and protocol signed

c. On submission of as built drawing 3%

6.12.5 Laying and termination of LT Power and control cable.

a. Laying and tagging on pro rata rate basis 70%

b. After termination and dressing on pro rata rate basis 20%
c. On submission of as built drawings 3%

6.12.6 For Cable Trays, Tray Supports, Rigid & Flexible Conduits, Above
Ground Earthing

a. After satisfactory completion of work on pro rata rate basis 70%

b. After completing drawing wise on pro rata rate basis 23%

6.12.7 Fabrication and installation of Steel material

a. After fabrication and applying of primer on pro rata basis 50%

b. After installation on pro rata basis 40%
c. On completion of painting 3%

6.12.8 DG Sets

a. Receipt, transport to the placement of erection, Placement, 70%

assembly, alignment, grouting, mounting loose parts- on
prorata basis
b. Pre commissioning checks, tests, calibration and 20%
energisation and commissioning on prorata basis
c. Load test 3%

6.12.9 OTHER ITEMS WHICH ARE NOT COVERED IN THE ABOVE TERMS OF
PAYMENT, THE PAYMENT SHALL BE MADE AS UNDER

a) 70% of the accepted rate for the respective item of work on pro rata basis
on satisfactory completion of work.

b) 23% of the accepted rate on commissioning of the system.

6.2.10 2 % of the total value will be paid on submission and acceptance of final bill.

5 % of the total value will be paid after a guarantee period of 12 months.

However, the above 5 % of guarantee amount shall be released against

submission of bank guarantee for an equivalent amount from a
nationalized/scheduled bank in the prescribed pro forma of BHEL valid for the
total guarantee period.
6.13.0 GUARANTEE

6.13.1 All the works executed by the contractor including supplies are to be guaranteed
for a period of 12 months from the start of guarantee period.
For all categories of above works, the guarantee period shall be 12
months. The guarantee period shall commence from the date of
handing over of work to Customer or 6 months from the date of first
synchronisation, whichever is earlier.

The contractor shall be responsible for the quality of workmanship and shall
guarantee the work done, shall rectify/replace at no extra cost all defects
due to faulty supply/erection and commissioning during the guarantee period.

6.13.2 In the event of contractor failing to replace/repair the defective supplies/works

within the time required BHEL may proceed to undertake the replacement/repairs
of such defective supplies/works at the contractor's risk and cost without
prejudice to any other points/right.

6.14.0 ELECTRICAL INSPECTORATE’S APPROVAL:

6.14.1 The contractor shall be responsible for getting Electrical Inspector/ Statutory
authority’s approval for all electrical installation covered in his scope. This also
includes the Electrical equipments that are erected by mechanical contractor for
which commissioning is to be carried out by the Electrical contractor.

6.14.2 For getting the approval of electrical Inspector, the contractor shall arrange the
following:

a. Erection Completion certificate.

b. Details of equipment (Specification)

c. Test results conducted at site

d. Any other documents as required by statutory authority.

6.14.3 Contractor shall carry out the modifications/rectifications as suggested by the

authority at his cost. However, it is not applicable for equipment erected by
Mechanical contractor.

6.14.4 The contractor shall also conduct re-test if required by the statutory authority at
his cost.

6.14.5 Contractor shall also have valid electrical installation license on his company as
well as for individuals acceptable to respective state electrical inspectorate
requirement.
6.14.6 BHEL shall pay all other fees (FEES FOR VISITS, INSPECTION FEES,
REGISTRATION FEES, ETC). However any expenditure related to documentation
shall be borne by contractor.

6.15.0 PRICE VARIATION CLAUSE

Price Variation will be applicable as per following Price Variation clause:

1 The finally accepted rates for scope of work as defined in this tender are subjected

to price escalation provisions as per the following formulae.

P1 = 0.75 x P0 (F1-F0)/F0

P1 = Increase in billing amount (escalation for the particular month of billing)

P0 = Billing amount calculated on the accepted contract rate

F1 = New All India Average CPI published by Labour Bureau, Simla, Government of India

for Industrial workers (Base 2001 - 100) applicable for the month under consideration

i.e. for which bill has been raised.

F0 = New All India Average CPI published by Labour Bureau, Simla, Government of India
for Industrial workers (Base 2001-100) applicable for the month of commencement
of work.

2 Price escalation as per above formula shall be calculated and paid (excluding payments
towards extra works and overrun, if any), on month to month basis.. BHEL however
reserves the right to freeze escalation for that such of duration of delays, from time to
time, which are entirely attributable to the contractor.
3 With the provision of prior escalation as per above clause, no claim/compensation on
account of any increase whatsoever, (irrespective of whether escalation are steep/
unanticipated or not compensated by the above escalation provisions in full towards
minimum wages, consumables, electrodes, gases or any other items/reason) shall be
payable during the entire period of execution including extended period, if any.
4 The payment of PVC shall be restricted to 10 % of the contract value.
5 However the contractor shall maintain sufficient work force and other resources required
for completion of the job expeditiously for the entire contractual period including total
extended period.
6.16.0 TAXES & DUTIES
6.16.1 Value Added Tax (VAT) for the works

Price quoted shall be inclusive of VAT except service tax.

Notwithstanding the fact that this is only an erection service contract not involving any
transfer of materials whatsoever and not attracting VAT liability, being labour oriented
job work, for the purpose of VAT the contractor has to maintain the complete data
relating to the expenditure incurred towards wages etc. in respect of the staff/workers
employed for this work as also details of purchase of materials like consumables,
spares etc., interalia indicating the name of the supplier, address and VAT
Registration No. and VAT paid and should furnish to BHEL at the year end.

The bidder shall get registered with State VAT authorities and the registration certificate
shall be forwarded to BHEL immediately after commencement of work. In case the
bidder had already registered under Orissa State VAT, they must quote their
registration Number and forward copy of Registration Certificate while submitting this
tender. The bidder has to obtain VAT clearance certificate from the concerned
authorities, for the completed project, and submit along with the final bill as one of the
document for contract closure.
In case the Bidder decides to include any VAT element along with the quoted price,
they shall specify the value of VAT included in the quote, the rate of VAT adopted and
also reason for such inclusion as additional information. If no VAT element is included
in the price, the same shall be indicated in the quote.
6.16.2 Service Tax
Price quoted shall be exclusive of Service Tax. The service tax as statutorily
leviable and payable by the bidder under the provisions of service tax Law / Act shall
be paid by BHEL as per bidder claim through various running bills. The bidder shall
furnish proof of service tax registration with Central Excise Department
specifying the name of services covered under this contract. Registration
Certificate should also bear the endorsement for the premises from where the billing
shall be done by the bidder on BHEL for this project. The bidder shall obtain prior
consent of BHEL before billing the service tax amount.

6.16.3 Other Taxes & Levies

Any other taxes and duties (except VAT & Service Tax) viz. Entry Tax, Octroi, eigniorage,
Licenses, Deposits, Royalty, Stamp Duty, other charges / levies, etc. prevailing /
applicable on the date of opening of technical bids and any variation thereof during the
tenure of the contract are in the scope of bidder. In case BHEL is forced to pay any
such taxes, BHEL shall have the right to recover the same from the bidder either from
running bills or otherwise as deemed fit.
6.16.4 New Levies / Taxes
In case Government imposes any new levy / tax after award of the work during the tenure
of the contract, BHEL shall reimburse the same at actuals on submission of documentary
proof of payment subject to the satisfaction of BHEL that such new levy / tax is
applicable to this contract.
6.16.5 Statutory variations
Statutory variations are applicable only in the cases of Value Added Tax and Service Tax.
The changes implemented by the Central / State Government in the VAT Act / Service Tax
during the tenure of the contract viz. increase / decrease in the rate of taxes, applicability,
etc. and its impact on upward revision / downward revision are to be suitablypaid/
adjusted from the date of respective variation. The bidder shall give the benefit of
downward revision in favour of BHEL. No other variations shall be allowed during the
tenure of the contract including extended period, if any.

6.16.6 Direct Tax

BHEL shall not be liable towards Income Tax of whatever nature including variations hereof
arising out of this contract as well as tax liability of the bidder and their personnel.
eduction of tax at source at the prevailing rates shall be effected by BHEL before release of
payment as a statutory obligation, unless exemption certificate is produced by the bidder.
TDS certificate will be issued by BHEL as per the provisions of Income Tax Act.

6.17. 0 PROVIDENT FUND & MINIMUM WAGES

The contractor is required to extend the benefit of Provident Fund to the labour employed in
connection with this contract as per the Employees Provident Fund and Miscellaneous
Provisions Act 1952. For due implementation of the same, Contractor is required to get
himself registered with the Provident Fund authorities for the purpose of reconciliation of PF
dues and furnish to us the code number allotted by the Provident Fund authorities within
one month from the date of issue of this letter of intent. Incase the contractor is e exempted
from such remittance, an attested copy of authority for such exemption is to be furnished.
Please note that in the event of failure to comply with the provisions of said Act, if recoveries
there for are enforced from payments due to us by the customer or paid to statutory
authorities by us, such amount will be recovered from payments due to the [Link]
contractor shall ensure the payment of minimum labour wages to the workmen under him as
per the rules applicable from time to time in the state.

The final bill amount would be released only on production of clearance certificate from
PF/ESI and labour authorities as applicable.
6.18. 0 IMPORTANT CONDITIONS FOR PAYMENT

It may be noted that the first running bill will be released only on production of the following.
1. PF Regn. No.
2. Labour Licence No.
3. Workmen Insurance Policy No.
4. Un Qualified Acceptance for Detailed L.O.I.
5. Initial 50% Security Deposit.
6. Rs. 100/- Stamp Paper for Preparation of contract

6.19.0 OTHER STATUTORY REQUIREMENTS

The Contractor shall submit a copy of Labour License obtained from the Licensing Officer
(Form VI) u/r25 read with u/s 12 of Contract Labour (R&A) Act 1970 & rules and Valid
WC Insurance copy or ESI Code (if applicable) and PF code no along with the first
running bill.

The contactor shall submit monthly running bills along with the copies of monthly wages
(of the preceding month) u/r78(1)(a)(1) of Contract Labour Rules, copies of monthly
return of PF contribution with remittance Challans under Employees Provident Fund Act
1952 and copy of renewed WC Insurance policy or copies of monthly return of ESI
contribution with Challans under ESI Act 1948 (if applicable) in respect of the workmen
engaged by them.

The Contractor should ensure compliance of Sec 21 of Contract Labour (R&A) Act 1970
regarding responsibility for payment of Wages. Incase of “Non-compliance of Sec 21 or
non-payment of wages” to the workmen before the expiry of wage period by the
contactor, BHEL will reserve its right to pay the workmen under the orders of Appropriate
authority at the risk and cost of the Contractor.

The Contractor shall submit copies of Final Settlement statement of disbursal of

retrenchment benefits on retrenchment of each workmen under I D Act 1948, copies of
Form 6-A(Annual Return of PF Contribution) along with Copies of PF Contribution Card
of each member under PF Act and copies of monthly return on ESI Contribution – Form 6
under ESI Act1948 ( If applicable) to BHEL along with the Final Bill.

In case of any dispute pending before the Appropriate authority under I D act 1948, WC
Act 1923 or ESI Act 1948 and PF Act 1952, BHEL reserve the right to hold such amounts
from the final bills of the Contractor which will be released on submission of proof of
settlement of issues from the appropriate authority under the act.
In case of any dispute prolonged/pending before the authority for the reasons not
attributable to the contractor, BHEL reserves the right to release the final bill of the
contractor on submission of Indemnity bond by the contractor indemnifying BHEL against
any claims that may arise at a later date without prejudice to the rights of BHEL.
6.20.0 e- Remittance

It may be noted that all payments due to the contractor will be made cheque
payment or ‘e-Payment’. The tenderer is requested to fill the form below for e-
remittance. This e-remittance is also applicable for the return of EMD to the un-
successful bidder.

6.21.0 FROM TO BE FILLED BY VENDORS FOR REGISTERING FOR E-PAYMENT

BHEL : PSSR : CHENNAI

DETAILS OF CONTRACTORS / SUPPLIER FOR E-REMITTANCE OF PAYMENTS BY

BHEL/PSSR

1 NAME & ADDRESS OF THE CONTRACTOR / :

SUPPLIER

2 BANK A/C NO. :

3 TYPE OF A/C (CC / CURRENT) :

4 NAME OF THE BANK :

5 NAME OF THE BRANCH :

6 BRANCH CODE :

7 BANKER’S ADDRESS (BRANCH) :

MICR NO. :

IFSC CODE

Note : THE ABOVE DETAILS ARE TO BE FURNISHED IN THEIR LETTER HEAD BY THE
CONTRACTOR / SUPPLIER, DULY ATTESTED BY THEIR BANKERS.
6.22 ROGRESS AND MONITORING OF WORK

6.22.1 The contractor shall provide all the relevant information on a regular basis
regarding erection progress, welding progress, labour availability, equipment
deployment, consumption of electrodes, gases, etc.

6.22.2 The contractor shall submit daily, weekly and monthly progress reports,
manpower reports, material reports, equipment reports etc. as per formats
specified by BHEL. The progress reports shall indicate the progress achieved
against planned with reasons indicating the delays, if any. The report shall also
give the remedial actions which the contractor intends to make good the slippage
or lost time so that further works can proceed as per the original programme and
the slippage do not accumulate and affect the overall programme.

6.22.3 Contractor shall monitor the progress of works as per the format furnished by
BHEL.

6.23 EXTRA CHARGES FOR MODIFICATION AND RECTIFICATION WORK

6.23.1 BHEL may consider payment for extra works on man day basis for such of those
works which require major revamping / rework / rectification / modification which
is totally unusual to normal erection or commissioning work which are not due to
contractor’s faulty erection.

6.23.2 The All the extra work, if any, carried out should be done by a separate gang
which should be identified prior to start of work for certification, of man hours.
Daily labour sheets should be maintained and should be signed by contractor’s
representative and BHEL Engineer. Signing of the labour sheets does not
necessarily mean the acceptance of extra works. Only those works which are
identified as not usual to normal erection and certified so by the Project Manager
and accepted by designers/supplier or competent authority only shall be
considered for payment .

6.23.3 The decision of BHEL in this regard shall be final and binding on the contractor.

6.23.4 The following man hour rates shall be applicable for modification/rectification work.
Average single manhour rate including overtime if any, supervision, use of tools
and tackles and other site expenses and incidentals, including consumables for
carrying out any rework revamping as may arise during the course of erection -
Rs. 40/- per man hour.

Average single man hour rate including overtime if any, supervision, use of tools
and tackles and other site expenses and incidentals excluding consumables for
carrying out any rework/revamping as may arise during the course of erection -
Rs. 25/- per man hour
6.23.5 Extra works are broadly defined as below:

- Design changes which shall be intimated to the contractor after the start of
the work which calls for dismantling of the erected components, rectification,
modification, etc.

- Modification, rectification of erection wrongly erected /fabricated at site as

per drawing subject to acceptance by approving authority.

- Jobs which require major modification, major repair, major reworks etc which
shall be identified as major and warrant extra, payment, certified as such by
the Project Manager and accepted by the designers/competent authority of
BHEL.

[Link] However prior to carryout the repair/rework BHEL site will obtain
administrative approval with the estimate before starting the works.

[Link] The decision of BHEL in this regarding the Extra works shall be final and
binding on the contractor.

6.24 REPORTING DAMAGES AND CARRYING OUT REPAIRS

6.24.1 Checking all components/equipments at siding/site and reporting to transport

and/or insurance authorities of any damages/losses shall be by BHEL.
Contractor shall render all help to BHEL in assessing and preparing estimates
for repairs of components damaged during transit, storage and erection,
commissioning and preparing estimates for fabrication of materials lost/
damaged during transit, storage and erection. Contractor shall help BHEL to
furnish all the data required by railways, insurance company or their surveyors.
6.24.2 Contractor, on drawing the materials from stores, shall report to BHEL in
writing any damages to equipments/components. The contractor shall also
report in writing to BHEL, damages while in transit to site and unloading at
place of work and any damages during erection and commissioning. The
above report shall be in as many number of copies as required and in the
proforma prescribed by BHEL site management. Any consequential loss arising
out of non-compliance of this stipulation shall be borne by contractor.

6.24.3 Contractor shall carry out fabrication of any material lost for which insurance
claim has been made only after getting written instructions from BHEL
engineer.

6.24.4 BHEL, however, retains the right to award or not to award to the contractor
any of the rectification/rework/repairs of damages and also fabrication of
components.

6.24.5 All the repairs/rectification/rework of damages and fabrication of materials

lost, if any, shall be carried out by a separately identifiable gang for
certification of manhours. Daily log sheets should be maintained for each
work separately and should be signed by contractor’s representative and BHEL
engineer. Signing of log sheets does not necessarily mean the acceptance
of these as extra works.

6.24.6 Payments for all extra works for repair/rectification/reworks of damages and
fabrication of materials lost shall be as per provisions of clause 3.8

6.24.7 In case the repairs/rectification/rework and fabrication of materials lost, the

work has been done by more than one agency including the contractor, the
payment towards extra charges shall be on pro-rata basis and the decision of
BHEL in this regard is final and binding on the contractor.

6.25 INSPECTION OF WORKS

BHEL/Customer shall have full power and authority to inspect the works at any
time, either on the site or at the contractor’s premises. The contractor shall
arrange every facility and assistance to carry out such inspection. On no
account shall the contractor be allowed to proceed with work of any type
unless such work has been inspected and entries are made in the site
inspection register by CUSTOMER. Wherever the performance of work by the
contractor is not satisfactory in respect of workmanship, deployment of
sufficient labour or equipment, delay in execution of work or any other matter,
BHEL shall have the right to engage labour at normal ruling rates and get the
work executed through other agency and debit the cost to the contractor and
the contractor shall have no right to claim compensation thereof. In such a
case, BHEL shall have the right to utilize the materials and tools brought by the
contractors for the same work.
6.26 DETAILS TO BE FURNISHED BY THE TENDERERS

Apart from other details called for in the tender document under the various
other provisions, the tenderers shall submit the following details also along with
their offers. Please also refer the check list.

a. HQ Organization chart

b. Site Organization Chart Covering various function

c. Month wise Manpower deployment plan

d. T&P deployment plan

e. Erection Schedule.

f. A copy of Electrical license

Tenderers shall go through very carefully all the provisions under section VI and
shall submit manpower deployment plan as per appendix VI A. The list of T&P
and instruments that are available with him for mobilization for the work, as
specified in Appendix VI B, shall also be submitted by the contractor along with
his offer. Tenderers shall indicate the present location and submit a schedule of
tools and plants for this site to meet the schedules of erection and
commissioning.

6.27 DOCUMENTATION

6.27.1 The following information shall be furnished within two weeks of award of contract
for purchaser’s approval

a) Erection Schedule/ Bar chart covering planned activities at site

b) Detailed organization chart

c) Experience details of staff

d) Details of T&P available with contractors with documents proofs.

6.27.2 The following information shall be furnished during the progress of work:

Test certificates of various tests conducted at site.

Erection and commissioning protocols signed by customer & BHEL.

6.27.3 As built drawings: After successful completion, testing and commissioning of

installation work, all the E&C drawings/documents shall be updated in line with the
actual work carried out and as built drawings/documents for the project shall be
submitted by the contractor.
6.28 RECOMMENDED LIST OF TOOLS AND TACKLES /INSTRUMENTS FOR
ELECTRICAL WORKS.

a) Insulation tester:

i) Motorised megger - 0 - 1000 - 2000 - 5000V, 0 - 25000 M ohms

ii) Hand operated megger - 0.5 KV/1.0 KV/2.5 KV, 200 - 100 M ohm

b) Earth resistance tester 0 to 1, 10, 100 ohms

c) Transformer oil test kit

d) Torque wrench

e) Voltmeter ac 0 - 125 - 250 - 625 V ac

f) Ammeter ac 0 - 2A - 10A ac.

g) Wattmeter - ac/dc - 0 - 125 - 250 V 0-5-10A.

h) Multimeter - analogue: acV 2.5V - 2500V, ac A - 100 mA - 10 A

dc V 25.V - 2500V, dc A - 50mA - 10A
Resistance - 0 - 200 M ohms
digital : voltages ac & dc - 100mv - 1000 V
current 10-mA - 10A Resistance - 0-20 M ohms

i) High vacuum stream line oil filter of 6000 LPH for mineral oil and 1000- 600 LPH
for silicone oil for transformer dryout.

j) Variac - 1 phase - 5A, 15A 3 phase - 10A, 20A.

k) Primary injection kit - 0-5000 A.

l) Secondary injection kit - 0-5A.

m) HV Test kit - 50 KV AC 400kVA.

n) Wheatstone bridge - 0.05 m ohm - 100 ohm.

o) Oscilloscope.

p) Oil. Tank for transformer oil.

q) Air compressor.

r) Vacuum pump.

s) Phase sequence meter - 110V - 450V - 25 to 65 Hz.

t) Frequency meter - 0 - 115 - 230 - 4500 - 45 -601/s.

u) Tong tester - 0 - 5A - 10A, 30A, 60A, 150A - 600A.

v) Tachometer etc.

x) mA Source

y) Standard temperature gauges

z) Temperature oil bath

aa) Micro Ohm Meter for contact resistance measurement of circuit breakers.

bb) Event recorder for measurement of closing and opening time (with micro second
accuracy)

cc) DC Power Supply , 24 V ; 5A

dd) Single Phase Variac 250V; 10A

ee) Three Phase Variac 415V

ff) Function Generator

Soldering irons, soldering pump, Vacuum cleaner, Air blower etc.

hh) Tan Delta Test kit

ii) Oil specific gravity and PPM measuring equipment

jj) Dew point measurement instrument

6.29 RECOMMENDED LIST OF TOOLS & PLANTS TO BE ARRANGED BY
CONTRACTOR FOR ELECTRICAL WORKS

[Link] DESCRIPTION
01 Steel wire ropes
02 Chain pulley block/turfer
03 2 " size pipe bending machine
04 Grinding machine
05 Drilling machines : 1/4" , ½" , 3/4" , 1 "
06 Copper tube bender and cutter sizes 6 mm ;8 mm ;1/2",1/4"
07 Dye sets for threading upto 2 " pipe
08 Set of spanners
09 Allenkey sets
10 Bench vice
11. Spirit level
12 Tap sets for both BSP & NPT threads upto 1 "
13 Measuring instruments like micrometers, calipers etc.

14 Welding generator
15 Welding transformer
16 TIG Welding set
17 Mechanical tool kit for fitters
18 Electrician tool kit
19 Crimping tool
20 Flood light fittings
21 Fire extinguishers
22 Distribution boards with power cable complete as required
23 Hydraulic test pump rating 750 Kg/[Link]
24 Painting brush
25 Fire proof tarpaulin
26 Safety belts & safety helmets
27 Telephone sets
6.29.1 ACCURACY REQUIREMENT OF TESTING INSTRUMENTS

Sl. INSTRUMENT /
RANGE ACCURACY
No TOOL
1 Power Pack 0 to 50V DC, 3A + 2%

2 Analog Multimeter Voltage 2.5 to 2500V AC + 1.0%

Current 100 mA to 10A AC + 2.0%

Current 250 micro A to 1A DC + 1.5%

Resistance upto 100 ohms + 3.0%

Voltage 2.5V to 2500V DC + 1%

3 Digital Multimeter Voltage 200mV to 1000 V DC + 1% + 1 digit

Philips Voltage 200mV to 1000 V + 1% + 1 digit

AC
Hcl Current 200mA to 20 A AC + 0.8% + 1 digit

Philips Current 20 mA to 20 A AC + 0.8% + 1 digit

Resistance (Hcl) 2120 200* to + 0.5% + 1 digit

200M*
Resistance (Hcl) 2105 200* to + 0.25% + 1 digit
200M*
Hcl Voltage 200mA to 750 V + 0.8% + 1 digit
Sl. INSTRUMENT /
RANGE ACCURACY
No TOOL
Philips Current 20 mA to 20 A DC + 0.5% + 1 digit

Hcl Current 200 mA to 010 A AC + 1% + 1 digit

4 Vibration Measuring Velocity upto 50 mm/sec. + 0.5% mm/sec

Equipments
Displacement upto 300 microns + 2 microns

5 Secondary Injection Upto 5A + 0.5mA

Kit
6 Motor operated Upto 200 Ohms + 5% at Centre scale
Megger
7 Tongue tester 0/300/600A AC + 5%

0 to 300A DC + 5%

8 Tachometer (Hand 0 to 4000 rpm + 5%

held
9 Phase Sequence N/A
Meter
10 Three Phase Variac 15 A Capacity N/A

11 Feeler gauges 300 mm long and 100 mm long + 2 microns

12 Dial gauges Q + 0.01 mm

13 Hand operated Upto 200 M Ohms + 5% at Centre

Megger 500 V / Scale
1000V + 10% at end of
Scale
14 Motorised Megger Upto 200 M Ohms + 5% at Centre
2.5 KV Scale
+ 10% at end of
Scale
15 Earth Megger 0 to 1, 10, 100 Ohms + 5% at Centre
(Tester) Scale range
16 AC tongue Tester 0 to 300A AC + 3%

17 DC Tongue Tester 0 to 300A DC + 5%

18 High Voltage test Upto 50 KV AC + 10%

Kit
Upto 70 KV DC + 10%

19 Tacho Generator 0 to 4000 rpm + 0.25%

(Mech)
20 DC Ammeter 0 to 300 A + 10%

21 DC Voltmeter 0 to 500 V + 10%

6.29.2 OTHER REQUIREMENTS OF CONTRACTORS’S INSTRUMENTS T&P

a. The contractor shall arrange all the above. T&P, equipment and instruments
as indicated except testing instruments which are proprietary in nature.

b. The contractor at his cost shall arrange all cranes and truck/tractor, trailers
required for material handling purpose and also cranes required for erection.
If contractor requires any equipments other than what is mentioned as free
issues from BHEL same can be hired from BHEL on chargeable basis subject
to availability.

c. Any other tools and plants instruments and equipment required in addition to
the above other than propriety type T&P/Instruments for the successful
completion of this job shall be arranged by the contractor at his cost.

d. Necessary accessories for the above shall also be provided by the contractor.

e. The above instruments/equipment shall be sent for testing and calibration

wherever from time to time and maintained by contractor as required by
BHEL.

f. List of such agencies and periodicity of calibration required for different

instruments shall be furnished by BHEL at site.

i. Contractors shall arrange experienced/qualified persons for using these

calibration instruments at laboratory and also at work spot.

j. Wherever frequent calibration is required, contractor shall arrange adequate

number of instruments such that the work does not suffer for want of test
instruments.

6.30 DRAWINGS FOR REFERENCE ( BID PURPOSE ONLY)

The following drawings are enclosed for general information to the tenderer.

1 Out line General arrangement of 150 MVA Transformer

2 Table of fittings for OGA -150 MVA Transformer
3 Outline General Arrangement of 16 MVA Transformer
4 Table of fittings for OGA - 16 MVA Transformer
5 Line Diagram for IP Bus duct
6 Layout of IP Bus Duct -12 KV
7 Structural Layout of Bus Duct support
8 GA of LAVT Cubicle
9 GA of NGR Cubicle
 APPENDIX - VI A

MONTHWISE MANPOWER DEPLOYMENT

( NUMBER TO BE INDICATED CATEGORYWISE IN EACH MONTH ) BY THE

CONTRACTOR

[Link] CATEGORY MONTHS

1 2 3 4 5 6 7 8 AND SO ON ...

01 Resident Manager

02 Engineers

03 Supervisors

a. Mechanical

b. Electrical

c. Industrial Relations/
Safety

04 Riggers

05 Fitters

06 HP Welders

07 Structure Welders

08 TIG welders

09 Electricians

10 Store Keeper

11 Semi skilled and

unskilled workers

12 Watchman/Security
 NOTE

01. Minimum Number of persons to be indicated monthwise.

02. Above deployment plan shall be discussed with BHEL Site Engineer and
necessary changes shall have to be made by the contractor as per discussion.
If required, any additional deployment during execution of the work shall have
to be arranged by the contractor for meeting various schedules/targets set by
BHEL without any additional compensation.

03. Resident Engineer should have a minimum qualification of Engineering Degree

or Diploma in Engineering with 15 years of experience in Thermal Power
Station.

04. Supervisor should have a minimum qualification of Diploma in Engineering or a

graduate with 10 to 15 years of experience in Thermal Power Station.

05. Lab Technicians should have experience in Thermal Power Stations.

06. Contractor should have one Store Keeper and one Transport Supervisor for the
safe transportation of materials.
 APPENDIX - VI B

DEPLOYMENT PLAN FOR MAJOR TOOLS AND PLANTS / INSTRUMENTS

[Link] CATEGORY MONTHS PRESENT

1 2 3 4 5 6 & SO ON LOCATION

01 Welding Generators

02 Welding Transformer

03 TIG Welding sets

(air cooled)

04 Insulation Tester

a. Motorized Megger
1000 & 5000 V Grade
b. Hand operated
Megger
500 & 1000 V Grade

05 Earth resistance Megger

06 Transformer oil testing

kit

07 Torque wrench

08 Volt Meter/Ammeter/
Avometer/other
instrument

09 Multimeter/Test lamps/
Field telephone sets/
different gauges

10 High vac steam line filter

of 6000/4500 LPHfor
transformer dryout
 S.N CATEGORY MONTHS PRESENT
O
1 2 3 4 5 6 & SO ON LOCATION

11 3 phase/Single phase
Variac 15 Amps

12 Primary and Secondary

Injection testing kits.

13 HV test kit

14 Resistance measurement
unit

15 Oscilloscope

16 5 Amps DC Power Supply

unit

17 Crimping Tools with

various sizes of dyes.

NOTE

01. The list of Tools and other plants to be deployed for this project may be indicated
by the tenderers separately.

02. Above deployment plan shall be discussed with the site engineer and necessary
changes shall have to be made by the contractor as per discussions. If required, an
additional deployment during execution of work shall have to be made by the
contractor for meeting various schedules/targets set by BHEL without any
additional compensation.
 BHEL PS:SR Format No. CP: FEX
CALIBRATION RECORD OF SUB-CONTRACTOR'S INSTRUMENTS
Name of Site :
Name of Sub-contractor :

[Link]. NAME OF INSTRUMENT DATE OF PERIODICITY OF CALIBRATION

INSTRUMENT REGN. NO. ENTRY EXIT CALIBRATION DETAILS

DATE OF CAL.

CAL. AGENCY

NEXT DUE DATE

DATE OF CAL.

CAL. AGENCY

NEXT DUE DATE

DATE OF CAL.

CAL. AGENCY

NEXT DUE DATE

SIGN OF SITE CIC

 SECTION VII
NALCO CPP EXPANSION, ANGUL (2X120 MW)
TECHNICAL REQUIREMENTS AND GUIDELINES FOR
INSTALLATION, TESTING, COMMISSIONING AND SUPPLY ITEMS
OF HT/LT ELECTRICAL PACKAGES

7.1.0 INSTALLATION, TESTING & COMMISSIONING IN GENERAL:

The stages of completion of various works shall be as follows:

Completion

- Equipment shall considered to be completely erected when the following

activities have been completed.

- Moving of all equipment to the respective foundations.

- Fixing of anchor bolts or tack welding as required.

- Leveling and alignment of equipment.

- Assembling of all accessories such as relays, CTs, PTs, meters,

instruments
etc. as described in the job specification.

- Cable laying, termination with continuity check.

- Applying of finishing coat of paint.

All the equipment shall be tested at site to know their condition and
to prove suitability for required performance. The site tests and
acceptance tests to be performed by contractor are detailed below.

The contractor shall be responsible for satisfactorily working of

complete integrated system and guaranteed performance.
7.1.0 SITE TESTS AND CHECKS

a) General

All the equipment shall be tested at site to know their condition and to prove
suitability for required performance.

The test indicated in following pages shall be conducted after installation.

All tools, accessories and required instruments shall have to be arranged by
contractor. Any other test which is considered necessary by the
manufacturer of the equipment, contractor or mentioned in commissioning
manual has to be conducted at site.

In addition to tests on individual equipment some tests/checks are to be

conducted/observed from overall system point of view. Such checks are
highlighted under miscellaneous tests but these shall not be limited to as
indicated and shall be finalized with consultation of client before charging of
the system.

The contractor shall be responsible for satisfactory working of complete

integrated system and guaranteed performance.

All checks and tests shall be conducted in the presence of client’s

representative and test results shall be submitted in six copies to client and one
copy to Electrical Inspector. Test results shall be filled in proper proforma.

After clearance from Electrical Inspector system/equipment shall be charged in

step by step method.

Based on the test results clear cut observation shall be indicated by testing
engineer with regard to suitability for charging of the equipment or reasons
for not charging are to be brought by the contractor.

b) Trial Run Test

After the successful test of each equipment as per standard test procedure the
entire control system shall be put on trial run test on actual site conditions and
operation of the system.

c) Acceptance Test

The acceptance test on the system shall be carried out by the supplier as
per mutually agreed test procedures to establish satisfactorily functioning of
the system as a whole and each equipment as part of the system.
7.2.0 BUSDUCTS - ISOLATED/SEGREGATED PHASE BUSDUCTS

7.2.1 HANDLING AND STORAGE

General

Busduct form the main electrical connections between the Generator and
associated generator transformer and tap-off to UAT, VT & SP cubicle
and GCB. The ducts are made of aluminium sheet which house the busbar
conductors supported on post insulators. e duct assembled are suitably
supported on the structures in the station. The bus enclosure assembled
are despatched with the insulators assembled and the conductor are sent either
loose or assembled inside the duct, keeping in view the erection necessities
and transport limitations.

7.2.2 INSPECTION AT SITE :

When the packages are received at site, these must be checked for the following:

a. Completeness and correctness of the consignment. (Compare with delivery

documents)

b. Physical damage if any during transit.

7.2.3 HANDLING DURING ERECTION :

The busducts are in unpacked conditions, therefore, great care is necessary in handling.
Ensure that :

a. While lifting enclosure assemblies manila ropes are passed round the busduct
enclosure near the support channels.

b. All shipping steel clamps are to be tightened and busbars do not slip out while
handling, if the busbar is assembled in the enclosure.

c. While inserting and mounting the busbar in the enclosure care is taken that the
busbar does not hit and damage the insulators.

d. Eye bolts are used while lifting the cubicles.

On completion of 7.2.3 items must be returned to original packing cases

unless required for immediate erection.
7.2.3A Caution

1. When inspecting the enclosures assemblies etc. the wooden packings,

braces and polythene covers should be replaced, if removed, to prevent
damage and ingress of duct and moisture.

2. Aluminium being softer material, great care must be taken in handling

enclosures and other aluminum items.

3. If the site conditions make it impossible to return the items to the cases for storage:

a. Nothing must be laid direct on the ground.

b. All items must be protected against weather and damages.

7.2.4 HANDLING OF BUS DUCT.

Handling from delivery station to power station stores :

1. Use suitable slings to lift the packages

2. No impact should come on the packings while loading. Do not drop from height.

3. Do not stack busduct packings one above the other; also avoid stacking of heavier
items on busduct packings.

7.2.5 DURING UNPACKING, HANDLING AND STORAGE

DO's

1. Check all the packings for any damage during transit.

2. Open the packings carefully.

3. Verify material as per shipping list and report any shortage/damage immediately.

4. Keep material in original packings unless required for erection.

5. Ensure that Manila ropes are used for lifting the busduct.

6. Check the tightness of shipping steel clamps while lifting busduct assembly with
busbar in position.

7. Ensure that CTs, LAs, capacitors, N.G. transformer, grounding

resistor, fuses, insulators, wall bushings, moulded and rubber items and
flexibles are stored in well ventilated area.
 DON'Ts

1. Don't destroy any markings.

2. Don't drop packings from height.

3. Don't stack heavier items on busduct packings.

4. Don't keep door of cubicle open during storage.

5. Don't lay down unpacked material directly on the ground.

6. Don't cause damage or scratches by dropping, dragging etc. on fragile items such as
CTs, PTs, Insulators, rubber items etc.

7.2.6 DURING ERECTION & COMMISSIONING :

DO's

1. Carry out pre-lay survey to verify the position of various equipment to be

connected, levels of floors and positions of cutouts.

2. Keep the layout drawing etc. ready for reference.

3. Draw the material from stores as per erection sequence.

4. Ensure alignment and proper matching of various enclosures and busbars.

5. Ensure proper alignments of epoxy cast CTs and seal-off bushings before final
tightening of hardwares.

6. Make the busbar joints as per the instructions.

7. Ensure aluminium welding by qualified welder only.

8. Take care for proper sealing while joining the enclosure.

9. Ensure proper earthing of enclosure and structure as specified.

10. Check wiring as per relevant wiring diagram.

11. Ensure that CT secondaries are shorted and grounded before HV test on busduct.

DON'Ts

1. Don't allow accumulation of dirt or foreign material inside the enclosure during
erection.

2. Don't overtight the bolts.

 3. Don't hammer the bolts etc. while joining the busbars if holes are not matching.

4. Don't forget any foreign material inside the enclosure.

5. Don't allow aluminium welding by unqualified welder.

6. Don't subject IAS, capacitors, and PTs to HT test as these are pre-tested and test at
site is not required.

7. Don't subject NG transformers to over voltage as these are pre-tested.

8. Don't apply rated voltage unless pre commissioning checks are completed.

7.2.7 ERECTION INSTRUCTIONS

A. Packing and Shipping

Layout drawing and main bill of material (M.B.O.M) or shipping list should
be referred to for identification of various items. All the drawings necessary
for assembly and erection are furnished separately.

Busducts are usually despatched as single phase assemblies generally

assembled with busbars. The busbars are braced with steel clamps to avoid
any damage to insulators and displacement of busbars during transport.
Structures, hardwares, flexibles, and other miscellaneous items are packed
separately.

B. Marking :

Following markings are done with paint on busduct assemblies and cubicles for
identification :

a. Project name and unit number

b. Item no of main BOM this is encircled

c. Phase marking R, Y or B

d. Work order number

e. Drawing number and item/variant number

f. Arrow indicating direction towards transformers end. Direction of arrow shall be

decided from lay out.

C. Similarly loose items are also identified by suitable marking on tags.

7.2.8 PRE LAYOUT SURVEY

Before starting the erection work the centre lines of the complete busduct
installation, location of connected equipment such as main transformer, unit
auxiliary transformer, VT & SP cubicle, NG Cubicle etc. with respect to
generator central line should be established and marked clearly. The various
levels of floor, ceiling, terminal position of main transformer, unit
auxiliary transformer etc. should also be verified. Any deviations in this
regard should be recorded and necessary remedial measures should be
taken. In case of any substantial deviation which may effect the erection of
busduct installation, the same should be referred to the design engineer. The
remedial measures should be planned in advance, which may consist of
levelling by suitable packers chipping of the concrete floor or wall etc. or
rectification of the components with the concurrence of engineers.

7.2.9 PROVISION OF FOUNDATION BOLTS & EMBEDDED ITEM

In the power station, busduct is supported on various floors, halls, ceiling, etc.
and support structure is suitably attached to the building. For this foundation
bolts, embedded items are grouted on the number of locations as per
foundation drawing.

7.2.10 SEQUENCE OF ERECTION

Normally the following sequence of erection is recommended.

A. Erection of steel work :

First, all the vertical structures are to be installed, levelled and foundation
bolts grouted. Next, place all the longitudinal cross channels in position,
adjust the level and bolt/weld them.

Check up the correctness of levels and positions of various installed

structures. For installation of foundation bolts refer foundation details
drawing of the project.

B. Erection of Enclosures :

Before the installation of enclosures in position each assembly of enclosure

and conductor complete with insulator supports is to be checked for
correctness and cleaned on the working floor.

The various enclosures assembled are to be erected as per layout drawing.

After placing the assemblies in position the packing braces/steel clamps
inside the ducts are to be removed.

Some of the busduct assemblies will be self supporting only when they
are welded to adjacent enclosures, as such some temporary scaffolding is
necessary to support these enclosures during erection, levelling and welding.
C. Handling of Busducts :

For handling of busducts specified instructions should be followed.

D. Sequence of erection-enclosure assemblies :

In positioning the various enclosures assemblies the following sequence is recommended :

E. Indoor Portion :

(a) Neutral Side

Complete the assembly of top chamber/neutral shorting chamber at the

working floor as per the drawing. Connect copper flexibles on the generator
neutral terminals, and fix it the generator plate. Provide temporary support
as necessary. Complete the assembly of bottom chamber (if applicable)
alongwith CTs and wiring as per drawing at the working floor and match
with the top chamber (if applicable). Now fix the supporting structure.
Assemble N.G. Transformer and N.G. Reactor and complete the
terminal connections.

Note : Before fixing top chamber / bottom chamber, care should be taken that
shunts are welded on line side busduct as shown in lay out drawing :

(b) Line Side

Assemble copper flexibles and connections with generator line terminals.

Match each phase generator enclosure with generator plate and fix to the
support structure. Complete the generator terminal bolted connections.

Place P.T cubicle in position match and connect with the respective tap off.

F. Outdoor Portion :

Position the wall frame at the power house wall, place the wall duct and inset
the rubber sealing ring over the enclosure. Complete the wall frame assembly.

Place the remaining enclosures on the structure starting from the wall duct
and complete the main run to generator transformer. From main run tap-
off enclosures are to be connected to unit auxiliary transformers,
accommodating current transformers, flexible connection, disconnecting link
and rubber bellows.

The alignment and exact locations of ducts may be verified before proceeding
for making the assemblies of make-up piece rubber bellows, wall frame and
bolted/welded joints of conductor and enclosures.
 G. Busbar Joints :

Busbar joints may be bolted type or welded type as specified for the
installation. For making the busbar joints, it is essential that specified
procedures and precautions are followed.

H. Cleaning of Busduct

Before putting the split covers, enclosures make up pieces (welded to

enclosure) & covers of inspection windows, all the insulator should be
cleaned again. The busduct should also be cleaned and dried up for any
moisture/condensates. Thoroughly check the interior of every enclosures and
ensure that these are free from any foreign matter.

I. Inspection of windows, covers, etc.

Finally, the split covers, inspection windows and make-up piece may be
assembled. The assembly of split cover, inspection windows and make-up
pieces should be done as per recommended procedures and if should be
ensured that proper sealing is achieved.

7.2.11 BUSBAR BOLTED JOINTS

A. Aluminium to Aluminium Joints (Un plated)

Wipe the contact surfaces with dry clean cloth to remove any dirt, dust and
moisture and smear these with recommended jointing compound. Clean
the surfaces under the compound by breading with dry coarse emery cloth
or stainless steel wire brush. Wipe the surfaces with a clean dry cloth and
immediately make a light application of jointing compound. Close up the
joints and wipe off excess compound.

B. Aluminium to Copper Joints :

Cleaning of Aluminium surface (Unplated)

Follow Instructions given under 7.2.11A above and apply jointing

ompound. Cleaning of copper surfaces (unplated)

Clean the copper contact surface with emery cloth and wipe the surface
with clean dry cloth.

Cleaning of copper aluminium surfaces (unplated)

Clean the contact surface with dry cloth to remove dirt, dust and moisture.
Apply a light coating of jointing compound.
 C. Aluminium to Copper Joints using bimetallic strip

For cleaning of aluminium and copper surfaces follow instructions given

under 7.2.11 A&B above. Apply jointing compound to aluminium and copper
surfaces.

The contact faces of bimetallic strip should also be cleaned as per the above
practice and jointing compound applied.

Note : Bimetallic strip is inserted between the copper and aluminium

surfaces. Care should be taken that copper faces copper surface and
aluminium faces aluminium surface.

D. Cleaning of copper surfaces (plated)

Clean the contact surface with dry cloth to remove dirt, dust and moisture.

Note : Wire, brush, emery cloth or jointing compound containing metallic

particles or other abrasives should not be used on plated surfaces.

7.2.12 CONTACT PRESSURE

To obtain correct tightening pressure on contact surfaces following

torques are recommended for various bolt sizes.

Bolt Size Recommended Torque torque Spanner Capacity

M10 0.85 to 1.3 NM (20-30 Ft-lb) 0.85 to 1.3 NM (20-30 Ft-lb)

M12 1.3 NM to 1.7 NM (30-40 Ft-lb) 0.85 to 4.3 NM (20-100 Ft-lb)

M16 1.7 to 2.1 NM (40-50 Ft-lb) 0.85 to 4.3 NM (20-100 Ft-lb)

M20 2.1 to 2.5 NM (50-60 Ft-lb) 0.85 to 4.3 NM (20-100 Ft-lb)

Alternatively tighten the nut till belleville washer becomes flat. Then unscrew the nut by
about 1/8 th. turn.

7.2.13 RECOMMENDATION FOR WELDED JOINTS

A. Circumferential weld circular section :

A FULLY penetrated, fully fused welded with a 10%T (4mm max) reinforcement is
required.

Welding conditions M.I.G. Process

Filler wire : 1.6mm dia (NG 21 with 5% silicon)

Angle : 10° to 15° Forehand

Cleaning : Decrease and scratch brush

Setting : 250A to 320A, 28 to 30 Volts (Dependent on tk)

Process : 4 off 25mm long equispaced tack welds

Gas supply : 50 Cu. ft/hr argon

Shield : 5/8" dia

B. Tubular Conductors :

Tubular Conductors are used in tee-off connections.

Welding conditions M.I.G. Process

Filler wire : 1.6 mm dia (NG 21 with 5% silicon)

Angle : 10° to 15° Forehand

Cleaning : Degrease and scratch brush

Setting : 215A to 275A, 22 to 2 Volts

Gas supply : 50 Cu. ft/hr argon

Shield : 5/8" dia

C. Enclosures

Fillet weld for make up pieces/shunts. Tack weld at four places.

Welding conditions M.I.G. Process :

Filler wire : 1.6mm dia (NG 21 with 5% silicon)

Angle : 10° to 15° Forehand

Cleaning : Degrease and scratch brush

Setting : 200A to 300A, 25 to

30 Volts (Dependent
on thickness)

Gas supply : 50 Cu. ft/hr argon

Shield : 5/8" dia

 D. Drain valve and welding :

Owing to the dissimilar thickness used for this fillet weld, the arc must be
directed into the pad only and not allowed to melt away and enclosure.

7.2.14 WELDED BUS ENCLOSURE JOINTS

Bridge the gap between the bus enclosure by means of make up pieces and
clean the area by paint removed which is to be welded. Tack weld the make
up pieces before final filled weld all around.

7.2.15 WELDED JOINTS OF SHUNTS

Various locations of shunts to be welded to the enclosures are shown in layout drawing.

7.2.16 DRAIN VALVE WELDING (IF APPLICABLE)

Mark the location as per lay out and drill 10mm dia hole at the bottom
most point of enclosure. Tack weld the drain valve pad to enclosure ensuring
proper alignment of paid hole with enclosure hole. Weld continuously as per
jointing recommendations. Clean with wire brush and point for final finish.

7.2.17 FIXING OF NEOPRENE SEAL :

Enclosures are fitted with access covers. Each cover is fitted with four pieces
of neoprene seal and held in position by bolted clamps.

(Note : Only one cover should be removed from enclosure at any time to
minimise the air flow into the enclosure).

7.2.18 EARTHING OF ISOLATED /SEGREGATED PHASE BUSDUCT AND

CUBICLES

A. General

One end of the electrical continuous enclosure should be earthed to station

earth at the shunt location where all the three enclosures are shorted.
Location of earth points are shown in the layout drawing. For this purpose
two drillings are to be done on these shunt to suit at site and two separate
earth strap are to be connected to the station earth thus ensuring double
earthing.

In some assemblies (such as transformer hood etc) due to short length of

enclosures shunts are not provided. In such cases, each phase enclosure should
be separately earthed.

One point of the earth phase split cover, rubber bellow clamping strap
should be electrically connected to enclosures and in turn enclosures should
be earthed.
 B. Cubicle earthing :

Each cubicle is provided with two number of earthing terminals. These

terminals are generally located on side face of the cubicle. Both the
terminals are to be connected independently to the station earth by suitable
connectors.

For earthing the top and bottom C.T. chambers, station earth can be
connected to each chambers of two locations for double earthing.

7.2.19 SITE TESTS ON ISOLATED /SEGREGATED PHASE BUSDUCT

A. Physical Checks :

Design survey which include dimensional checking of electrical

clearances and cleanliness of the installation.

B. Cleanliness :

The inside of all enclosures, outside of conductors and insulators should be

free from dirt, all, grease, swaft and any deposits, special attention should be
paid to the insulators and seal off bushings and oil moisture is to be removed
and surfaces polished with a dry soft clutch. All panels/inspection windows
cover are to be replaced after cleaning operation.

C. Power Frequency High Voltage Test

Preparation :

Following equipment must be disconnected from busbars removing the bolted link and
grounded suitably prior to conducting this test :

a. Generator terminals

b. Unit auxiliary transformer terminals

c. Generator transformer terminals

d. Neutral grounding transformer HV terminal

e. Lightening arresters

f. Capacitors

g. Potential transformer.

It is important to ensure that secondaries of all the current transformers

mounted on busbars are shorted and grounded properly before conducting this
test.

Ensure that all insulators seal-off bushings are cleaned free from any dust,
grease and moisture etc before test.
 During the test, ensure the following

a. The generator rotor is kept stationary

b. H.V. Circuit breakers on system side are kept in the open position.

D. Test Voltage :

The test voltage shall be attenuating current on any frequency between 25

hertz to 100 Hz and approximately of sine-wave form. The r.m.s. value shall
be as given in table-1 below :

For A.C. voltage duration of test shall be one minute.

The test with D.C. at a voltage not in excess of the values given in Table-1,
Column-3 for the corresponding rated voltage may be substituted for the AC
test prescribed.

Table - 1

Rated Highest Test Voltage (A.C.) Test Voltage (D.C.)

System Voltage

Upto & Including KV

3.6 16.8

7.2 21.6

12 28

24 44

36 60

E. Meggar-Checks :

Before the application of high voltage, check the insulation of each bus,
conductors by means of 2.5 KV meggar. A value e. 100 mega ohms is
expected under normal conditions. However, during mainly season this value
may fall down considerably and drying up by hot air may be necessary
before the test. Minimum acceptable value is around 20 mega ohms. After
the application of high voltage the insulation value is checked gain.

F. Application of Test Voltage :

Corresponding test voltage as indicated in Table-1 shall be applied in turn

between each phase conductor and its enclosure which shall be kept at ground
potential. Remaining two phase conductors and their enclosure shall be
properly as in consistent with its value being indicated by the measuring
instrument. The full test voltage shall be then maintained for specified
duration. Each hus including tap-off must withstand the above test voltage.
7.2.20 SITE TEST RECORDS ON ISOLATED / SEGREGATED PHASE
BUSDUCTS :

Test conducted on date... ............ Site ...

Power Frequency high voltage test :

Instrument ...

Meggar Reading HV applied Leakage

Phase before after & duration current Remarks
HV test HV test A.C./D.C.

7.3.0 TRANSFORMER

7.3.1 INSTALLATION

To ensure that a Transformer will function satisfactorily, it is important

that handling, lifting, storing and assembling are carried out with great
care and cleanliness by experienced personnel who know the various
working operations very well.

7.3.2 INSPECTION

In connection with receiving and unloading at site, and at the final storing
place before
assembling, the transformers shall be inspected carefully. External visible
damages as
dents, paint damage etc. may imply that the transformer has been subjected to
careless
handling during transport and/or re-loading, and a careful investigation is
therefore
justified.

After the arrival of the material at receiving points, before unloading, the
condition of packing and of the visible parts should be checked and
possible traces of leaks verified (condenser bushing). If necessary,
appropriate statements and claims should be made.

Drums containing oil which have despatched separately should be examined

carefully for leaks or any sign of tampering,. All drums are despatched
filled upto their capacity and any shortage should be reported.
 Check immediately the gas pressure at the arrival. A positive indicates that
the tank and the transformer components respectively are tight, and that the
active part including the insulation materials is dry.

If there is no positive gas-pressure, transformer should be immediately filled

with dry Nitrogen gas at a pressure of 0.17 kg/Cm2 (2.5 psi) without loss of
time.

Otherwise, it should be checked if the core isolation is satisfactory and that

accessories packed separately have not been damaged during transportation .

7.3.3 UNLOADING

Whenever rollers/trolleys are supplied with transformer, movement of

transformer at site is carried out by mounting these rollers/trolleys.

Alternatively for movement of transformer from loading bay to actual

site of the equipment, skidding on greased rails etc can also be resorted to.

7.3.4 STORING

Dismantled equipment and components are packed to the protected against normal
handling and transport stresses. The instructions for lifting given on the packages,
must be complied with to avoid damages.

Goods stored outdoors must not be placed directly on the ground, and should be
covered carefully with tarpaulin or similar materials.

Oil drum should be stored in horizontal (lying) position with both the bungs also in
horizontal position.

7.3.5 LIFTING

Lifting devices on the transformer tank are dimensioned of lifting of

the complete transformer filled with oil. The positioning of the lifting
devices, permissible lifting angles, minimum height to crane hook and
transformer weight, appear from the OGA drawings. Check at lifting of
compete transformer that the lifting wires/ropes are not in contact with
bushing or other components on the cover.

For lifting with hydraulic jacks, the transformer is provided with

jacking pads dimensioned for lifting of complete transformer filled with oil.
The position of the pads appear on the OGA drawings.
7.3.6 CHECK POINTS BEFORE STARTING AND DURING ERECTION

a. Check points before starting erection.

1. Conditions of leads

2. Bracing, clamping of leads

3. Connections

4. Tap changer checks

5. General conditions of insulation

6. Core check that it has not moved in transit.

7. Core-ground; this is checked with the megger after removing earth connection

8. CTs, including the secondary leads and their passage through metal parts

9. Check that shipping frame for bushings have been removed.

10. Check that coil position has not moved in transit

11. Check for dirt, metal swarf, moisture

12. Check that the bushing leads set without being too close to ground or
other points of different potential.

b. Check-points during erection:

By means of the part list and the transformer/reactor OGA, the assembling of a fully
completed transformer is carried out according to the following instructions. The
following precautions are to be taken:

i. Fire-fighting equipment shall be available at the oil-treatment equipment as well as

at work on and adjacent to the transformer.

ii. Welding work on or adjacent to the transformer shall be avoided, but if this is not
possible, the work shall be supervised by fire-protection personnel.

iii. Smoking on or near the transformer shall not be allowed.

iv. Transformer tank, control cabinet etc, as well as assembling and oil-treatment
equipment shall be connected with the permanent earthing system of the station

v. Check that there is no overpressure in the transformer when blanking plates or

connection lids are to be opened.
 vi. All loose objects, tools, screws, nuts etc.. shall be removed from the transformer
cover before opening the connection and blanking lids.

vii. All loose objects (tools, pencils, spectacles etc..) shall be

removed from the boiler- suit pockets etc. before starting the
work through man holes.

viii. Tools to be used inside the transformer e.g. for tightening of screws-joint-shall
be fastened to the wrist or another fixed point by means of cotton tape or string.

ix. Tools with loose sleeves and tools with catches must not be used at work inside
the transformer.

x Greatest possible cleanliness shall be observed at work inside the transformer,

and at handling of part to be mounted inside the transformer.

xi. Fibrous cleaning materials should not be used as it can deteriorate oil when
mixed with it.

xii. All components despatched separately should be cleaned inside and outside
before being fitted.

xiii. A Transformer is best protected form damp hazard by circulating warm, dry, de-
aerated oil through it until it temperature is 5 C to 10 C above ambient. This
should be done before allowing external excess to the interior of the tank. The
warm oil should be circulated all the time transformer is open to atmosphere.

xiv. Oil pump & all joints in the oil pipe work should be air tight to avoid entrance of
air through leakage joints.

xv. The active part (core and winding) should be exposed to the surrounding air as
short time as possible. Open therefore only one blanking plate or connection lid at a
time for remounting of bushing, valves etc.

xvi. Objects which-despite all precaution are dropped inside transformer/reator, must
absolutely be brought up form the equipment.

xvii. Check that the oxygen content inside the transformer tank is minimum 20% if a
person is to enter the tank..

7.3.7 ASSEMBLY

Assembly of wheels Bushing Valves, cooling device, Oil conservator,

Pilol Flanges, Blanking plates and accessories like cooling fans, pumps,
OLTC and components for supervision and control oil level indicator, flow
indicators, gauges, Buchholz relay, PRV, thermometers etc. are assembled
according to leaflet/description valid for the components.
7.3.8 OIL FILLING

The following procedure is recommended.

(i) Close and blank the valve to isolate the conservator from main tank. Fill the oil in
transformer under vacuum upto Buchholz level as per instructions given else
where.

(ii) After filling the oil in transformer and breaking the vacuum, oil can be filled in
the conservator either through reactor or by drain valve.

(iii) Remove the inspection cover (ii) provided on the side of the conservator and
check the air cell assuring that it is inflated. The air must remain in
fully inflated condition during oil filling operation. If the air cell
is found deflated fit the inspection cover and inflate the air cell with
dry air/nitrogen gas to 0.035 kg/[Link] max . A gauge may be put by
removing plug . After filling close these connections.

(iv) Remove air release plugs provided on top of the conservator.

(v) Slowly pump the oil through main reactor/drain valve . Temporarily stop filling
operation when oil starts coming from opening after ensuring that no
air bubbles come out through these air release holes. Fit the two air
release plugs.

(vi) Continue oil filling till oil start coming from air release plug stop oil after
ensuring that no air bubbles come out. Fit the plug .

vii) Now release the air pressure held inside the air cell from point and continue oil
filling until magnetic oil gauge indicates 35 deg. C level.

(viii) Remove oil pump and connect air cell to breather from point . Also remove
pressure gauge and put plug .

(ix) The system is now properly filled. Air release plugs are fitted in normal operation.

7.3.9 EQUIPMENT FOR OIL-FILLING UNDER VACUUM

(i) High-vacuum 2 storage oil filtration plant provided with thermostat-controlled

oil heaters and vacuum-proof hoses with dependent vacuum pumping
system for tank evacuation. Capacity:6000 lph

(ii) Oil-storage tanks provided with silica-gel breathers and inlet/outlet valves for oil
circulation. Recommended capacity 20KL

(iii) Vacuum gauges provided in filtration plant.

(iv) Equipment for measurement of electric strength (BDV) of oil - 100 kv set.
 (v) Equipment for moisture content of oil.

vi) Equipment for measurement of Resistivity and Tan delta at 90 C.

vii) Transparent vacuum-proof tubes for checking of oil-level during oil filling.

ix) Valves, fitting, gaskets etc.

(x) Dry nitrogen cylinders.

7.3.10 COMMISSIONING

Testing after Assembly of the Transformer

After the transformer/has been assembled at site, it shall be tested in order to

check that it has not been damaged during transport and assembly to such
an extent that its future operation will be at risk. Regarding the performance
of the test, refer to the testing method as per standards. The results of the test
shall be documented.

COMMISSIONING CHECKS

SL NO DESCRIPTION

1. Breather Silica gel (Blue when dry)

2. Oil in the Breather housing cup.

3. All valves for their correct opening and closing sequence.

4. Oil level in conservator tank.

5. Oil in cooling system.

6. Oil level in bushings.

7. Release air, wherever necessary.

8. Cooling accessories (Pump motors, Fan motors etc.) for direction and O/L
setting.

9. Buchholz, oil level indicator, pressure gauges, thermometer, Temp. indicators

etc.

10. Neutral earthing.

11. Earth Resistance of Electrodes.

12. Earthing of bushing test tap.

13. Check oil leakage for 24 hrs.

 14. Check Auxiliary circuit voltage (415 V)

15. Calibration of OTI/WTI with hot oil.

16. Check Working of WTI/RTD repeaters at control room.

17. IR of core to earth.

18. Die electric strength of oil PPM & Chemical analysis, specific gravity test

19. IR tests on windings to earth and between winding

20. Phase sequence test & vector group check

21. Continuity test

22. No load voltage ratio on all tap position

23. Winding resistance in all taps

24. Tap changing at 415v 3 50 Hz supply in all three phases

25. TAN-DELTA test if quality check list calls for.

26. Dew point check for N2 Gas at the time of oil filling

INSULATION RESISTANCE TEST

[Link] Descriptio DateTime in Hrs Megger (not IR Value Temp Remarks less than 500 V)

1. Control wiring

2. Tap Changer

a) Motor

b) Control

[Link] system

a) Motor Fan

b) Motor pump

c) Control Wiring
[Link] Winding

a) HV/E+:V Not less

b) LV/E+HV+LV than 1000 V

c) HV/IV megger)

d) IV/LV

e) HV/L

Note :-

(1) While checking these values no external, lighting arrestors etc should be
in
circuit.

(2) Special care should always be taken while meggering the transformer
winding to ensure that there is no leakage in the leads.

Oil Characteristics.

Take necessary precaution (regarding rinsing the bottle, cleaning hand, air
bubble etc) while withdrawing the samples, Each sample should be free of air
bubbles and should not be tested when it is hot. The sample should satisfy
IS:1866.

1. Tank Top Sample Bottom Sample

2. Cooling system Top Sample Bottom Sample

3. OLTC Divertor (each phase)

Tests on CT

1.. Ratio

2. Polarity

3. Magnetising current

4. IR Value

Potential Transformer Tests

1. IR test of primary winding by HV megger between windings

2. IR test of secondary winding by LV megger between winding and winding to earth

3. Checking of voltage ratio

 4. Verification of terminal markings and polarity

5. Checking of oil level if applicable

6. Checking of continuity and IR values for cables from PT to M

7. Checking tightness of earthing connection.

8. Checking of insulator for cracks

9. Checking output on charging of the system with connected meter

On Load Tap changer

[Link] Description Date Observation Remarks

1. Visual Inspection of equipment.

2. Hand operation on II taps.

3. Complete wiring of the circuits.

4. Limit Switch

5. Over running device

6. Remote Panel Wiring.

7. Overload Device of Driving Motor.

8. Local Operation (Electrical)

9. Remote Operation (Electrical)

10. Tap Position Indicator.

11. Step by step contractor

12. Out of Step Relay.

Note

1) While operating the mechanism on Electrical Control, check once again limit switches,
step by step contractor, over running device etc. for their actual operation and prove that
they are functioning properly.

2) For More details Please refer Respective Manuals.

7.4.0 GUIDELINES FOR ERECTION OF HT SWITCHGEAR PANELS : (NOT
APPLICBALE)

7.4.1 Erection

The base frames will be supplied normally along with the boards. These will have to be
aligned, levelled and grouted in position as per approved drawings. Wherever the base
channels are not available, the same will have to be fabricated and painted at site. Base
frames shall be grouted on the openings which shall be made on the floor during the time
of casting. All necessary concrete chipping and finishing works are to be completed.

7.4.2 All the panels/board shall be placed on its foundation or supporting structures and shall be
assembled as required. All panels should be installed with parallel, horizontal and vertical
alignment by skilled craftsmen.

7.4.3 All the boards will be delivered in sections. Necessary interconnection of busbar, bolting
of panels, left out panel/interpanel wiring, etc. will have to be done after assembling the
panel.

7.4.4 THE FOLLOWING POINTS SHALL BE CHECKED UP DURING ERECTION

1. Layout of foundation channels.

2. Floor level covered by the panel with respect to main floor level.

3. Location and serial no. of panels.

4. Positioning of panels.

5. Verticality of switchgear panels within the limit specified.

6. Freeness of Breaker Truck and modules in housing and its manual operation.

7. Earthing of panels and breaker truck to station earth.

8. Lugs for termination of HT and LT cables.

9. Mounting and fixing arrangements of Bus bars.

10. Tightening of Busbar jointing bolts as specified.

11. Clearance between :

i. Phase to Phase

ii. Phase to earth

 12. Minimum clearance for :

i. Breaker, Truck and moduls withdrawal

ii. Distance required for maintenance work

13. Check the operation of :

i. Remote control

ii. Various required - closing / tripping / alarm / indications / interlocks

14. Installation position of insts and relays

Operation of relays and meters by secondary injection.

15. AC/DC supplies for panel

Final relay settings as per customer requirements.

16. Tightness of terminal connections for HT & LT connections.

17. Opening operation of breaker, manually and electrically.

18. Working of ammeters and voltmeters for their entire range and other panel
mounted insts
like recorder, indicator etc.

7.4.5 HT SWITCHGEAR TESTS

1. IR test

2. HV one minute P.F. test checking of oil level

3. Measurement of contact resistance for HT breakers

4. Test to prove inter changeability of similar parts (including breaker module)

5. Testing of relays as per supplier’s commissioning manual

6. Testing and calibration of all meters.

7. Operation of all relays by secondary injection method

8. Testing of CT polarities and CT ratio by primary injection test.

9. Measurement of kneepoint voltage and secondary resistance for CTs used for differential
protection.’

10. IR and voltage ratio test for PTs

 11. Functional test of all circuit components for each panel / feeder.

12. Test to prove closing/tripping operation at minimum and maximum specified voltage in
test and service position.

13. Check for drawout test and service position of breakers for all feeders.

14. Check for covering of all openings in the panel - check for continuity and
operation of
aux. contacts of breaker.

15. HV test on vacuum interrupters (for VCBs)

16. Check for pressure of SF6 gas and air (for SF6).

7.5.0 LT SWITCHGEAR PANELS

1. Erection
1.1 The base frames will be supplied normally along with the boards. These will have to be
aligned, levelled and grouted in position as per approved drawings. Wherever the base
channels are not available, the same will have to be fabricated and painted at site. Base
frames shall be grouted on the openings which shall be made on the floor during the time of
casting. All necessary concrete chipping and finishing works are to be completed.
1.2 All the panels/board shall be placed on its foundation or supporting structures and shall be
assembled as required. All panels should be installed with parallel, horizontal and vertical
alignment by skilled craftsmen
1.3 All the boards will be delivered in sections. Necessary interconnection of busbar, bolting of
panels, left out panel/interpanel wiring, etc. will have to be done after assembling the panel.

2. Checks during erection

12. Layout of foundation channels.
13. Floor level covered by the panel with respect to main floor level.
14. Location and serial no. of panels.
15. Positioning of panels.
16. Verticality of switchgear panels within the limit specified.
17. Freeness of Breaker Truck and modules in housing and its manual operation.
18. Earthing of panels and breaker truck to station earth.
19. Lugs for termination of LT cables.
20. Mounting and fixing arrangements of Bus bars.
21. Tightening of Busbar jointing bolts as specified.
22. Clearance between :
iii. Phase to Phase
iv. Phase to earth
12. Minimum clearance for :
i. Breaker, Truck and moduls withdrawal
ii. Distance required for maintenance work
13. Check the operation of :
i. Remote control
ii. Various required - closing / tripping / alarm / indications / interlocks
14. Installation position of insts and relays
Operation of relays and meters by secondary injection.
15. AC/DC supplies for panel
Final relay settings as per customer requirements.
16. Tightness of terminal connections for HT & LT connections.
17. Opening operation of breaker, manually and electrically.
18. Working of ammeters and voltmeters for their entire range and other panel
mounted insts
like recorder, indicator etc.

3 LT Switchgear tests
1. IR test
2. Measurement of contact resistance for LT breakers
3. Test to prove inter changeability of similar parts (including breaker module
4. Testing of relays as per supplier’s commissioning manual.
5. Testing and calibration of all meters.
6. Operation of all relays by secondary injection method.
7. Testing of CT polarities and CT ratio by primary injection test.
8. Measurement of kneepoint voltage and secondary resistance for CTs
used for
differential protection
9. IR and voltage ratio test for PTs
10. Functional test of all circuit components for each panel / feeder
11. Test to prove closing/tripping operation at minimum and maximum specified
voltage in test and service position
 12. Check for drawout test and service position of breakers for all feeders
13. Check for covering of all openings in the panel - check for continuity and
operation of
aux. contacts of breaker.

7.6.0 BATTERY AND BATTERY CHARGER

1 Battery Checks

1. Checking for completion of civil/ventilation requirement of battery room.

2. Checking of adequacy of charger output/requirement w.r.t. current required

battery charging as per the manual

3. Check availability of safety devices, water and first aid

4. Check polarity of connections between battery and charger

5. Visual inspection test for level and lekages

6. Checking of layout as per approved drawing

7. Checking of IR value from positive to earth and negative to earth

8. Checking of voltage per cell and total voltage between positive negative and
earth to positive/negative and also tap cell voltage (as applicable)

9. Checking of tightness of connectors on each cell

10. Checking of capacity test and hourly measurement of specific gravity and
voltage for each cell

2 Battery Charger

1. IR test.

2. HV test.

3. Checking voltage ratio of boost and float mode transformers.

4. Checking for charging mode of batteris, constant current and constant

voltage mode.

5. Load test on chargers by running of DC drives and by liquid resistance

system.

6. Checking of tightness of earthing connections.

7. Check for all alarm conditions.

8. Checking and clibration of all indicating meters.

 9. Check functional operation of charger, auto/manual change over from float
to boost and boost to float etc.

10. Checking and setting of all relays.

11. Check AC ripple in boost and float mode after charging.

12. Check polarity of cables connected to battery.

3. Additional tests

a. Insulation resistance and earth resistance checks.

b. Primary and secondary injection test.

c. Calibration of all instruments

d. Tests at normal voltage and when required at reduced voltage to prove

satisfactory closing and tripping from local and remote points, checking of
tripping from relay and protective gear, inter-tripping, interlocks etc.
Reduced voltage test at 70% rated voltage to prove tripping of each circuit
breaker.

e. Battery capacity test

7.7.0 GUIDELINES FOR CABLE LAYING

1 In the plant building, substations, switchgear rooms, control rooms etc. Power and
control cables shall generally be laid on cable trays installed in concrete trenches,
tunnels, cable basements, cable vaults, cable shafts or along building and
structures as the case may be.
2 In case of multicore cables of diameter upto 20 mm where not more than 3 cables
are taken in one run, these can be taken directly along structures, walkways,
platforms, galleries, walls, ceiling etc. by proper clamping at regular intervals of
more than 300 mm.
3 Power & control cables installed along buildings and structures, ceilings, walls, etc.
which are required to be protected against mechanical damage shall be taken in
G.I. conduits.
4 GI conduits shall also be used for flameproof installations, wherever required, with
sealing at both ends
5 In corrosive atmosphere, where 1100 V grade cables are required to be taken in
pipes, rigid heavy duty PVC pipes shall be provided.
6 Entry of cables through trenches/tunnels into buildings shall be by means of one of
the methods indicated in drawing as applicable for different buildings.
7 Cables laid exposed in racks/trays and routed through trenches/tunnels/basements
etc. to individual drive/control devices etc. shall be taken in embedded surface
exposed rigid GI conduits and or flexible conduits unless directly terminated to the
equipment in the panels located, above trenches, tunnels or basement.
8 All cables routed along walls or in equipment rooms shall be protected by means of
laying them through GI pipes or by providing sheet metal covers upto a height of
2000 mm from the working floor levels and platforms, for protection against
mechanical damage. All vertical risers shall be of enclosed type.
9 Tray covers shall not be provided for the cable trays within trenches, tunnels and
basements. Non-perforated type sheet steel covers shall be provided for the trays
in the areas susceptible to accumulation of coal dust/atmospheric abuses etc.
10 Cable trays shall be supported on ISA 50x50x6mm MS/Gi brackets. Brackets shall
be welded to steel plate inserts in the trenches/tunnels or supporting channel
angle/inserts in other areas.
11 Wherever direct heat radiation exists, heat isolating barriers (subject to customers
approval), for cabling system shall be adopted.
12 For 415V power wiring in ancillary buildings, offices and laboratories, cables shall
be taken through embedded/exposed GI conduits or rigid PVC pipes as applicable.
13 If required, a few number of cables in exceptional areas may be directly buried into
the earth.
14 Wherever cables are to be laid below roads and railway tracks, the same shall be
taken through ducts buried at a suitable depth as decided by Engineers.
15 At certain places where hazardous fumes/gases may cause fire to the cables,
cable trenches after installation of cables may be sand-filled.
16 In corrosive atmosphere, PVC conduits shall be used for cables.
17 Single core cables, when pulled individually shall be taken through PVC pipes only.
18 Laying and installation of power, control and special cables shall generally conform
to IS : 1255
19 The cables shall be laid-out in proper direction from the cable drums (opposite to
the normal direction of rotation for transportation).
20 In case of higher size cables, the laid out cables shall run over rollers placed at
close intervals and finally transferred carefully on the racks/trays. Care shall be
taken so that kinks and twists or any mechanical damage does not occur to cables.
Only approved cable pulling grips or other devices shall be used. Under no
circumstances cables shall be dragged on ground or along structure while paying
out from cable drums, carrying to site and straightening for laying purpose.
21 Suitable extra length of cables shall be provided for all feeders for any future
contingency, in consultation with Engineer.
22 Cable runs shall be uniformly spaced, properly supported and protected in an
approved manner. All bends in runs shall be well defined and made with due
consideration to avoid sharp bending and kinking of cable. The bending radius of
various types of cables shall not be less than those specified by cable
manufacturers and that specified in IS 1255.
23 All cables shall be provided with identification tags indicating the cable numbers in
accordance with the cable circuit schedule. Tags shall be fixed at both ends of
cables (both inside & outside of panel) both sides of floor/wall crossings, every
25m spacing for straight runs or as specified by Engineer for easy identification of
cable.
24 When a cable passes through a wall, cable number tags shall be fixed on both
sides of the wall.
25 Single core cables for AC Circuits shall form a complete circuit in trefoil formation
supported by means of trefoil clamps of non-magnetic material.
26 Multi-core cables above 1100 V grade shall be generally laid in ladder type trays in
one layer with spacing not less than one cable diameter of bigger diameter cable.
27 All 1100 V grade multicore power cables and single core DC cables shall be placed
in single layer, touching each other and clamped by means of single or multiple
galvanised MS saddles/aluminium strips/nylon cable ties. Cables above 35mm
diameter shall be clamped individually.
28 Control cables shall be laid touching each other and wherever required may be
taken in two layers. All control cables shall be clamped with a common clamp/tie.
29 Segregation of the cables on the basis of their types and their functions shall be as
under for horizontal formation:
30 HT cables shall be laid in the top tier(s)
31 LT power cables to be laid in the tray(s) below the HT cable trays.
32 LT control cables to be laid in the Tray(s) next below to the LT power cable (trays)
33 Special control cables including screened control cables to be laid in the bottom
most tray(s).
34 For vertical formations, the trays closest to the wall shall be considered as bottom
most tray and the order indicated in clause just above shall be followed. However,
where there is no clear distinction of bottom/top trays, the order convenient for
linking the horizontal and vertical formations shall be followed.
35 When it may not be possible to accommodate the cables as per the criteria
indicated in the two clauses indicated above, the following rules shall override the
criteria. However, prior approval of the Engineer will be required. In hierarchical
order:
36 Control cables are mixed up with the special control cables with clear minimum gap
of 100 mm between them.
37 LT power cables are mixed up with control cable with clear minimum gap of 150
mm between them.
38 LT power cables are mixed up with HT power cables with clear minimum gap of
200 mm between them.
39 LT power cables are mixed up with special control cables with clear minimum gap
of 200 mm between them.
40 Incase of duplicate feeders to essential loads, the respective cables shall be laid
through separate raceways. Alternatively, such cables shall be laid on the opposite
sides of a trench/tunnel/basement.
41 For laying cables along building steel structures and technological structures, the
cables shall be taken by clamping with MS saddles screwed to the MS flats welded
to the structure. MS saddles and flats shall be galvanised.
42 For laying cables along concrete walls, ceilings etc. The cables shall be taken by
clamping with MS saddles screwed to the MS flats welded on the inserts. Where
inserts are not available the saddles shall be directly fixed to the walls using raw
plus and MS flat spacers of minimum 6 mm thickness.
43 To facilitate pulling of cables in GI conduits, powdered soft stone, plastic scoop or
other dry inert lubricant may be used but grease or other material harmful to the
cable sheaths shall not be used.
44 No single core cable shall pass through a GI conduit or duct except DC single core
cables. AC single core cables shall pass through GT conduits/pipes in trefoil
formation only.
45 In case of a 3 phase, 4 wire system, more than one single phase circuit, unless
originating from the same phase shall not be taken in the same GI conduit.
46 Entry of cables from underground trenches to the buildings or tunnels shall be by
some approved method. Necessary precautions shall be taken to make the entry
point fully water tight by properly sealing the pipe sleeves wherever they enter
directly into the building at trench level. The sealing shall be by cold setting
compound. Any alternative sealing arrangement may be suggested with the offer
for consideration by BHEL.

47 Wherever specific cable routes are not shown in cable schedules cables shall be
laid as directed by Engineer.

48 SUPPORT SPACINGS & CLAMPINGS

Support spacing and clamping suitably provided and as required

49 LAYING OF CABLES DIRECTLY BURIED IN GROUND

Laying and installation of directly buried cables in ground shall conform to the
requirements of IS 1255.
50 SUPPORT SPACINGS & CLAMPINGS
Trefoil Clamps:
i. Horizontal run spacing 1000 mm (max)
:
: 1000 mm (max)
ii. Vertical run spacing iii
Double the diameter of larger cable or 150 mm
Axial spacing between
Whichever is less
adjacent trefoils

Other Clamps
A. Power Cables:
Above 35mm OD
Individually clamped at 3000 mm Interval
i) Horizontal runs :
(max)
ii) Vertical runs :
Individually clamped 3000mm intervals
Upto 35mm OD
(max).
i) Horizontal runs
: Collectively clamped at 3000 mm intervals
(max)
ii) Vertical runs : Collectively clamped at 2000 mm interval (max)

B. Control Cables:
i) Horizontal runs : Collectively clamped at 3000 mm interval (max)
ii) Vertical runs : Collectively clamped at 3000 mm interval (max)
 C. Spacing for cables supported along structure/ceiling
Clamping Spacing:
i) In horizontal runs : 750mm (max)
ii) In vertical runs : 750mm (max)
Spacing between cables : 30 mm (min)
Note:
a. Supports shall also be provided at each bend.
b. For any change in above spacing, prior approval of Engineer will be taken
51 CABLE TERMINATION AND JOINTING
1. When the equipment are provided with undrilled gland plates for cable/conduit entry into
the equipment, drilling and cutting on the gland plate and any minor modification work
required to complete the job shall be carried out at site and drawings shall be prepared and
take engineer's approval before drilling holes. Cutting shall not be allowed.
2. Termination of cables shall be done as per termination drawings & interconnection
diagrams furnished to the contractor. Looping of cores/wires at terminals as shown in
interconnection diagrams is to be done.
3. All cable entries in the equipment shall be sealed after glanding the cables..
4. Adequate length of cables shall be pulled inside the switch boards, control panels, terminal
boxes etc. as per near termination of each core/conductor.
5. Power cable terminations shall be carried out in such a manner as to avoid strain on the
terminals by providing suitable clamps near the terminals.
6. End sealing/termination of cables shall be done by means specified on the specification for
terminations. The system shall be suitable for types of cable specified and complete with
stress relief system.
7. Termination and jointing of aluminium/copper conductor power cables shall be done by
means of compression method using compression type aluminium/tinned copper lugs.
8. Copper conductor control cables shall be terminated directly into screwed type terminals
provided in the equipment. Wherever control cables are to be terminated by means of
terminal lugs, the same shall be of tinned copper compression type.
9. Cable joints shall normally be made at an intermediate point in the straight run of the cable
only when the length of the run is more than the standard drum length supplied by the cable
manufacturer. In such cases, when jointing is unavoidable, the same shall be made by
means of specified cable-jointing kit, subject to BHEL's approval of Engineer shall be taken
for deciding location of joint.
10. Termination and jointing shall generally conform to the requirements of IS : 1255 and shall
strictly conform to the recommendations of termination and jointing kit supplier.
 52 TESTING OF CABLES:
1 The contractor shall submit to the Engineer a checklist for testing and commissioning
and the activities shall be carried out in accordance with the checklist.
2 Testing and electrical measurement of cable installations shall conform to
IS : 1255 3 Prior to installation, cables shall be tested for :
a) Continuity of conductors
b) Insulation resistance between conductors & earth
c) Insulation resistance between conductors.

4 After installation cables shall be tested for :

a) Insulation resistance between conductors & iron
b) Insulation resistance between conductors & earth
c) Conductor resistance
e) Capacitance between conductors & earth (for cables above 7C.1.3KV
grade) f) DC high voltage test (for LT power cables of higher sizes
interconnecting
PCCs & MCC)
g) Absence of cross phasing
h) Firmness of terminations.
7.8.0 TESTS FOR THE EQUIPMENT ERECTED BY MECHANICAL CONTRACTOR

The tests to be carried out on the equipment at which are normally being
erected by Mechanical contractor.

a) Generator :

Generator set with all auxiliaries and controls shall be assembled and tested
to verify compliance with the guaranteed technical particulars and for
satisfactory performance. Relevant standards shall be followed as guideline
fo testing. All the tests shall be witnessed by customer or its representative.
The commissioning tests shall be carried out at site under normal service
conditions.
 Following tests shall be carried out on the generators :

1. Insulation resistance test and determination of polarization index value of:

- Generator

- Exciter

- Resistance temperature detectors

2. Dielectric test

3. No load characteristics

4. Short circuit characteristics

5. Temperature rise at rated voltage, current, power factor and frequency.

6. Over-speed test

7. Calculation of efficiency

8. Phase sequence/voltage balance/current balance checks.

Note :

1. Vibration tests in the factory to be taken at 100% of synchronous speed

and at 120% during overspeed test.

2. Vibration test at site to be taken at 100% of synchronous speed of the

complete generator with its driver.

9. Instantaneous short circuit test (Optional).

10. Noise measurement test.

11. Response of voltage and frequency with sudden shedding of 25%, 50%, 75%
and 100% of rated load respectively.

12. Temperature detector test

13. Measurement of DC resistance of winding

14. Inter turn insulation test of stator winding with induced voltage 130% of
rated value for 5 minutes (if applicable).

15. Measurement of shaft voltage.

16 Tan Delta test for generator bushing. (if required).

b) AC Motors

1. IR test of stator and rotor windings.

2. Heating of both windings upto the permissible temp.

3. Checking/testing of associated switchboard, cables, relays/meter interlockings as

mentioned in relevant chapters are completed.

4. Tightness of cable connection.

5. Winding resistance measurement of stator and rotor.

6. Checking continuity of winding.

7. Checking tightness of earth connections.

8. Checking space heaters and carryout heating of winding (if required)

9. Checking direction of rotation in decoupled condition during kick start

10. Measurement of no load current for all phases

11. Measurement of temperature of body during no load and load conditions.

12. Check for tripping of motor from local/remote switches and from.

13. Checking of vibration (if required).

14. Checking of noise level (if required)

15. Measurement of stator and bearing temperatures during load running (if applicable)
for every half an hour interval till saturation comes.

16. Checking operation of speed switch (if there)

17. Checking of polarisation index of stator winding, R10/R1 by motorised megger

(The value should not be less than 2.0) R60/10 absorption coefficient shall not be
less than 1.5.

18. Dielectric test.

B ) DC Motors
1. IR measurement and heating the winding as per heating curve.
2. Check for earth connection
3. Winding resistance for field and armature.
4. Check running of drive at minimum and maximum specified.
 5. Check auto start of drive on failure of AC supply (if applicable)
6. Check operation of overload relay.
7. Measure vibration.
8. Check temperature rise on body of drive after required period of continuous
running.
9. Measure load currents and no load currents (if possible)
10. Check direction of rotation.
11. Check continuity of winding.
12. Measurement of RPM.

7.9.0 PAINTING

The surface shall be free from rust, foreign adhering matters, grease etc. Two
coats of rust preventing red-oxide primer and final painting of two coats as per
the colour decided by the site engineer. (More details please refer Section VI
scope of works). After cleaning the surface is painted with one coat of Red oxide
zinc chromate primer confirming to IS 2074 and allowed to dry completely.
The primer coated surface is painted with two coat of final painting of desired
colour which shall be selected from IS-5.

The contractor shall paint steel fabrications at site with two (2) coats of primer
followed by two (2) final coats of epoxy paint of shade 631 of IS:5 as detailed in
section VI.

7.10.0 CODES AD STANDARDS

7.10.1 All equNipment and materials shall be designed, manufactures and tested in accordance
with the latest applicable Indian Standards (IS) except where modified and/or
supplimented by this specification.

7.10.2 Equipment and materials conforming to any other standard which ensures equal or better
quality may be accepted. In such case, copies of the English version of the standard
adopted shall be submitted along with the bid.

IS The electrical installation shall meet the requirement of Indian Electricity

Rules as amended upto dates, relevant IS codes of Practice and
Indian Electricity Act. In addition, other rules or regulations
applicable to the work shall be followed. In case of any discrepancy,
the more restrictive rule shall be binding. A list of applicable
standards is given below for reference.
 IS 3043 Code of practice for earthing

IS 3072 Installation and maintenance of switchgear

IS 5133 Box for enclosure of electrical equipment

IS 5216 Guide for safety procedure and practice in electrical work

IS 13947 Degree of protection provided by enclosures for low voltage

switchgear and control gear.

IS 5216 Guide for safety procedures and practices in electrical works.

IS 800 Code of practice for use of structural steel

In addition to the standards mentioned above, all works shall conform to the requirements
of the following rules and regulations.

a) Indian Electricity Act and Rules framed thereunder

b) Fire insurance regulations

c) Regulations laid down by the Chief Electrical Inspector of State and CEA

d) Regulations laid down by the Factory Inspector of State

e) Any other regulations laid down by the authorities.

In case any clause of contradictory nature arises between standards and this
specification, the latter shall prevail.

7.11.0 TECHNICAL REQUIREMENT FOR ITEMS SUPPLIED BY THE

CONTRACTOR.

1. GENERAL
Equipment and material supplied shall comply with description, rating, type and
size as detailed in this specification, drawings and annexures.
Equipment and materials furnished shall be complete and operative in add details.
All the accessories, fittings, supports, anchor bolts etc., which form part of the
equipment or which are necessary for safe and satisfactory installation and
operation of the equipment shall be furnished.
All parts shall be made accurately to standard gauges so as to facilitate
replacement and repair. All corresponding parts of similar equipment shall be
interchangeable.
Samples of all items shall be made available for purchaser's approval prior to
supply of item to site.
 2 FERRULES
a) Ferrules shall be required for individual core of cable hence they shall be suitable
for the insulated conductor diameter.
b) Ferrules shall be of plastic material.
c) Numbering on the ferrules shall be engraved type with contrast colour to the base.
Engrave colouring shall be of durable quality to match the entire life of the plant.
Engraving shall be legible from a distance of 600 mm.
d) Ferrules shall be interlocking type in such a way that the interlocked ferrules take
the shape of tube with complete ferrule number appearing in a straight line.

3 TAGS
a) Cables shall be provided with cable number tags for identification.
b) Cable tags shall be of durable fibre, aluminium or stainless steel sheets.
c) Cable number shall be engraved type in case of aluminium or stainless steel tags,
and printed type in case of fibre sheet.
d) Tags shall be durable quality of size 60mm x 12mm with holes at both ends.
e) Samples of tags shall be approved by BHEL Engineer before delivery.
f) Tags shall be provided with non-corrosive wire of sufficient strength for
taggings.
4 FIRE STOP CABLE SEALING SYSTEM (AS APPLICABLE)
Fire stop cable sealing system shall have two (2) hours fire protection rating
suitable for sealing both vertical & horizontal cable penetrations. The
sealing compound in conjunction with mineral wool shall form effective fire
seals. The sealing compound shall have special property to allow for short
circuit conditions. GPG fire stop sealing compo or equivalent sealing
compound shall be used.

7,12,0 GUIDELINES FOR ERECTION OF GI PIPES , SUPPORTS AND ACCESSORIES

7.12.1 For installation of cables in GI conduits the conduits shall be installed first without cables
but having suitable pull wires laid in conduits.

7.12.2 For equipment and devices having GI conduit entry arrangement other than standard GI
conduit adopter, adopters shall be provided as required to enable the GI conduit to be
properly terminated, between conduit end and motor T.B.

7.12.3 GI conduits shall run without moisture or water traps and shall be made drawing
arrangement towards the end.

7.12.4 The entire GI conduit system shall be firmly fastened in position. All boxes and fittings
shall generally be secured independently from the GI pipes entering them.
7.12.5 Bends of GI pipes/conduits shall be made without causing damage to the pipes/conduits.

7.12.6 Occupancy of conduits shall not be greater than 40%.

7.12.7 The adopter for coupling rigid GI pipe/conduits and flexible conduit shall be of
aluminium or galvanised steel.

7.12.8 Transportation and storage of cable drums

Transportation and storage of cable drums shall generally conform to the

requirements of IS : 1255

7.12.9 All the cables shall be supplied to the contractor free of cost from BHEL/Customer's
store/storage area. Transportation of cables from storage area to the work site shall be the
responsibility of the contractor.

7.12.10 The cable drums shall be transported on wheels to the place of work.

Note : The test specified above for all the electrical equipment are not
exhaustive. Any other pre-commissioning and field tests not included in
the above list but necessary as per relevant standards, Electricity
rules, code of practice and instructed by the manufacturer of
the equipment shall also have to be carried if deemed necessary
shall be carried out as per requirement either at free of cost or at
additional cost. Decision of Engineer in charge will be the final
regarding additional cost for [Link] contractor shall take the
full responsibility of testing, commissioning, trial run and successful
operation of the equipment under overall guidance of BHEL
engineer
 SECTION VIII
APPENDIX - I DATA SHEET

SPECIFIC TECHNICAL REQUIREMENTS

SUPPLY ITEMS

1. Clamps

a. Material & Type : Nylon self locking ties aluminium strips

clamps as per Section VI

b. Sizes : To meet the requirements of :

2. Ferrules : Section VI : As per Section VI

3. Tag

a. Material : Aluminum/Fibre/Stainless Steel

b. Markings : Engraving/Embossing/Printing

c. Size : As required.

4. Cable lugs : Copper/Aluminium (crimping type)

5. Clamp Spacing:

a. Trefoil Clamps:

i. Horizontal run : 1000 mm (max)

spacing
: 1000 mm (max)
ii. Vertical run spacing
: Double the diameter of larger cable or : :
iii. Axial spacing :150mm
between
Whichever is less
adjacent trefoils

Other Clamps

A. Power Cables:

Above 35mm OD
: Individually clamped at 3000 mm Interval
i) Horizontal runs
(max)

: Individually clamped 3000mm intervals (max).

ii) Vertical runs
 Upto 35 mm OD

i) Horizontal runs : Collectively clamped at 3000 mm intervals

(max)

ii) Vertical runs : Collectively clamped at 2000 mm interval (max)

B. Control

Cables: : Collectively clamped at 3000 mm interval

i) Horizontal (max)

runs : Collectively clamped at 3000 mm interval

ii) Vertical runs (max)

C. Spacing for cables supported along structure/ceiling

Clamping Spacing:

i) In horizontal runs : 750mm (max)

ii) In vertical runs : 750mm (max)

Spacing between cables : 30 mm (min)

Note:

a. Supports shall also be provided at each bend.

b. For any change in above spacing, prior approval of Engineer will be taken
6. Cable termination:

Type of Lugs:

a. Power Cables : Copper/Aluminium/Both crimping type

b. Control Cables : Copper pin type, copper screw type,

Direct termination

c. Special Cables : Pin type, maxi-termi type.

7. Wastage Allowance:

a. HT cables : 1%

b. LT cables above 70mm : 1%

c. LT cables upto 70mm : 1%

d. Control & Special cables : 1%

e. Fire Survival cables : 1%

f. Steel materials (for cable : 1% by weight

trays/tray support
installation)
 SECTION VIII

APPENDIX - II

DECLARATION SHEET

I, hereby certify that, all

the information and data furnished by me with regard to this Tender
Specification [Link]:PSSR:SCT:1308 are true and complete to the best of
my knowledge. I have gone through the specifications, conditions, stipulations
in detail and agree to comply which the requirements and intent specifications.

I further certify that I am duly authorized representative of the under

mentioned tenderer and a valid power of Attorney to this effect is also enclosed.

TENDERER’S NAME & ADDRESS

AUTHORISED REPRESENTATIVE’S
SIGNATURE WITH NAME & ADDRESS
 SECTION VIII

APPENDIX - III

TENDER SPECIFICATION NO BHEL:PSSR:SCT:1308

CERTIFICATE OF DECLARATION FOR CONFIRMING

KNOWLEDGE ON SITE CONDITIONS

We,

hereby declare and confirm that we have visited the project site under subject,

namely and acquired full knowledge and information about the site

conditions. We further confirm that the above information is true and correct

and we will not raise any claim of any nature due to lack of knowledge of site

conditions.

TENDERER’S NAME AND ADDRESS

Place:

Date :
SIGNATURE OF AUTHORISED
REPRESENTATIVE WITH NAME & ADDRESS:

OFFICE SEAL
 BHARAT HEAVY ELECTRICALS LIMITED
(A Government of India Undertaking)
Power Sector: Southern Region
474, Anna Salai, Nandanam, Chennai - 600 035.

SECTION VIII
APPENDIX - IV
CHECK LIST
TENDER SPECTFICATION NO, BHEL: PSSR : SCT : 1308

Tenderers are required to fill in the following details:

1. a) Name of the Tenderer with address : YES/NO

b) Telegraphic/Telex address : YES/NO

c) Phone (Office/Residence) : YES/NO

d) Management Structure of firm (Pvt.

Ltd/Public Ltd./Partnership/Sole
Proprietorship) Documentary proof
For the same enclosed) : YES/NO

2. Whether EMD submitted as per

Tender specifications terms and : YES/NO
Conditions

3. Validity of offer (offer shall be

kept open for acceptance for : YES/NO
minimum six months)

4. Whether tenderer visited the

erection site and acquainted with : YES/NO
the site conditions before quoting

SIGNATURE OF THE TENDERER

5. Whether the following details are : YES/NO
furnished

a) Previous Experience : YES/NO

b) Present assignments : YES/NO

c) organization chart of the : YES/NO

company

d) Company financial status : YES/NO

e) Incase of company, proof of

Registration of the company : YES/NO

f) Memorandum & Articles of

Association of company/copy of
Partnership deed : YES/NO

g) Profit & Loss account for the

Last 3 years : YES/NO

h) Audited Balance sheet for the

Last 3 years : YES/NO

i) Income Tax clearance certificate

(latest) : YES/NO

j) Solvency Certificate from a

Nationalised Bank : YES/NO

k) Power of Attorney of the person

Signing the tender duly attested
By a Notary Public : YES/NO

l) Manpower organization chart

With deployment plan
at site For posting of
Engineers/super
Visitors and workers/labourers : YES/NO
For satisfactory
completion of Work
under this
specification

SIGNATURE OF THE TENDERER

6. Whether the Tenderer is conversant
with local labour laws & conditions : YES/NO

7. Whether the tenderer is aware of

all safety rules and codes : YES/NO

8. Whether the Declaration sheet (as

per appendix enclosed : YES/NO

9. Time required for mobilization of

of site organization and start of work : YES/NO

10. Whether list of tools and Plants

available with the contractor and
proposed to be deployed for this
work enclosed : YES/NO

11. Whether all the Pages are read

understood and signed. : YES/NO

12. Deviations, if any Pointed out :

13. Whether PF exemption No. is

allotted by RPFC of your area if
so, indicate number : YES/NO

SIGNATURE OF THE TENDERER

 NALCO ANGUL CPP EXPANSION -UNIT 10 (1 x 120 MW)

ELECTRICAL (HT & LT) PACKAGE

BILL OF MATERIALS WITH RELEVANT CLAUSE REFERENCE
Bill of Materials (BOM) contains detailed specification of various Equipments and items supplied by
various BHEL Unit-wise. Scope of work specific for each item is indicated in the last column of BOM. In
addition to these clauses, other common clauses like painting, calibration, Civil Work etc. (under 6.3.0)
related to the work also to be referred.

SL. Qty Clause

DESCRIPTION
NO. Unit 10 Ref No:

A.1 BHEL-JHANSI SCOPE

A.1.0 GENERATOR TRANSFORMER
A.1.1
150 MVA GENERATOR TRANSFORMER 1 set* 6.3.1
Description
150 MVA, 10.5kV/235 kV, Three phase, OFAF cooled, YNd1,
Generator Transformer complete loose accessories like 2 Nos. of
Radiator banks, on load tap changers, HV/LV/HVN bushings,
bushing CTs, Turrets, conservators, cooler control cabinet,
marshalling box, pipings, common KIOSK etc.
Loose items like raise/lower [Link], tap changer indicators, facia
windows, W.T.I. repeaters, buzzers, signal lamps, [Link] be
mounted and wired in control panel.

BOM/1
SL. Qty Clause
DESCRIPTION
NO. Unit 10 Ref No:

A.1 BHEL-JHANSI SCOPE

Complete erection and integration of all accessories and
components, grounding, brazing of joints, painting of supports, ,
connection to earth grid etc., shall also be part of transformer
erection.
Approximate Dimensions and weight of transformer

Max. dimension 15,000 x 10,500 x 7000 mm

Shipping. dimension 7170 x 3450 x 3450 mm
Approximate weights in kg
Tank & fittings 43,000
Total wt of transformer 1,83,000
Untanking Weight 10,000
Shipping weight (gas filled) 1,20,000
Total oil (49,440 lts) 44,000

Ref: OGA of Trf drg. 04590050036; Rev:00.

* Lump sum rate shall be quoted including final painting

BOM/2
SL. Qty Clause
DESCRIPTION
NO. Unit 10 Ref No:

A.1 BHEL-JHANSI SCOPE

A.1.2
UNIT AUXILIARY TRANSFORMER
1 set* 6.3.1
16 MVA, 10.5/6.9 kV, ONAN Unit Auxiliary Transformer
complete with radiators, conservators, control panels, marshalling
box [Link] NGR.
Loose items like raise/lower [Link], tap changer indicators, facia
windows, W.T.I. repeaters, buzzers, signal lamps, [Link] be
mounted and wired in control panel
Approximate Dimensions and weight of transformer

Overall dimension: 7700 x 6800 x 5000 mm

Shipping. dimension 4400 x 2900 x 3250 mm
Approximate weights in kg
Tank & fittings 14800
Total wt of transformer 46,600
Untanking Weight 17800
Shipping weight (gas filled) 25,000

Total oil (15700 lts) 14,000

Ref: OGA of Trf drg. 04590050036; Rev:00.

BOM/3
SL. Qty Clause Ref
DESCRIPTION
NO. Unit 10 No:

A.1 BHEL-JHANSI SCOPE

NGR for UAT
6.9 kV, 9.95 ohm, 400 A for 30 sec Neutral Grounding Resistor
with connected accessories
Approximate dimension: 1200 x 1200
Approximate weight: 600 kg
A.2.0 HT BUSDUCT
A.2.1 10.5 KV IP Busduct along with support structures, LAVT
Cubicle, NG Cubicle and other loose supplied items such as Seal
1 set* 6.3.2
off Bushings, CTs, Hot air blowing equipment, flexible hoses
from HAB System unit to Bus Duct, Control cabinet for HAB,
Conduiting and wiring for space heaters, illumination, etc.
CT/PT wiring & conduiting ,erection works includes making
welded joints and flexible joint connection and fixing of rubber
bellows & shunts etc comprising of the following
a) Main Busduct: 10000 A IP Bus Duct from 120 MW
Generator to 150 MVA Three phase generator
transformers, with 10000 A main run bus duct
Size: 6.35 TK x 1000 O/D Aluminium Alloy enclosure
and 450 O/D x 15 TK. Round Aluminium Alloy
conductor.
Approximate length of all phases: 110 Meters per set

BOM/4
SL. Qty Clause Ref
DESCRIPTION
NO. Unit 10 No:

A.1 BHEL-JHANSI SCOPE

b) Tap off Busduct: 1000A- to 1 x 16 MVA Unit
Auxiliary transformers, LAVT Cubicle, NG Cubicle etc.

Size: 4.78 TK.x 780 O/D Aluminium Alloy enclosure

and 152.4 Box conductor 8.1 TK
Approximate length of all phases: 16 Meters per set
Other Details of Busduct:
a) App Weight of Bus duct- : 200kg/ Mtr (approx.)
b) Hot Air Blower : Size 1500 x 1200 x 1500 mm.
Capacity: 6000 cubicmeter / hour ,
c) 1 No: NG Cubicle: Size 2000 x 1250 x 1690 mm;
Weight: 1400 kg approx.
d) 3 Nos: LAVT Cubicle: size 900 x 2250 x 2400 mm
Weight : 1000 kg per cubicle.
e) Weight of Support Structure: 3.5 MT (approx.)
Reference:
a) Layout of IPB Drg No. 0 541 00 51 434, rev 01
b) Hot Air Blower Ref Drg 35410051380, rev 00.
c) NG Cubicle Ref Drg 3 542 10 51 198, rev 00
d) LAVT Cubicle Ref Drg :2 542 20 51 129, rev 00
* Lump sum rate shall be quoted including final painting.

BOM/5
SL
Qty Clause Ref
NO. DESCRIPTION
Unit 10 No:

B.1 BHEL-PEM SCOPE

B.1.0 LT MCC’s
B.1.1 415 V TURBINE MCC [10KA]
1 No 6.3.3
13 panels of total dimension 10460 x 900/600 x 2,430 mm in
suitable shipping sections.
Total Weight: 5400 kg (Approximate)
B.1.2 415 V TURBINE VALVE MCC [10KB]
1 No 6.3.3
18 panels of total dimension 14460 x 600 x 2,430 mm in
suitable shipping sections.
Total Weight: 6300 kg(Approximate)
B.1.3 415 V MISCELLANEOUS MCC [9SB]
1 No 6.3.3
13 panels of total dimension 10460 x 900/600 x 2,430 mm in
suitable shipping sections.
Total Weight: 6500 kg(Approximate)

BOM/6
SL. Qty Clause
DESCRIPTION
NO. Unit 10 Ref No:

B.1 BHEL-PEM SCOPE

B.1.4 415 V WELDING PDB [PDB-10]
6 panels of total dimension: 4860 x 600 x 2430 mm; 1 No 6.3.3
Weight : 2100 kg.
B.1.5 VENTILATION MCC [10TA]
1 No 6.3.3
15 panels of total dimension 12060 x 900/600 x 2430 mm in
suitable shipping sections.
Total Weight: 5700 kg(Approximate)
B.1.6 AC MCC [10TB]
1 No 6.3.3
10 panels of total dimension 8060 x 600 x 2430 mm in suitable
shipping sections.
Total Weight: 3900 kg(Approximate)
B.1.7 ESP, AC & VENTILATION MCC [10TC]
1 No 6.3.3
12 panels of total dimension 9660 x 600 x 2430 mm in suitable
shipping sections.
Total Weight: 3900 kg(Approximate)

BOM/7
SL. Qty Clause
DESCRIPTION
NO. Unit 10 Ref No:

B.1 BHEL-PEM SCOPE

B.2.0 BATTERY & BATTERY CHARGERS:
B.2.1 220 V DC Battery & Battery Charger consisting of the
following: 6.3.5
a) Battery banks:
1500 AH, 220V, VRLA Type, 108 Cells housed in single row
single tier racks, along with inter cell connectors, inter row
connector, inter bank connectors, rack insulators etc.
2 Sets*
Size of each battery bank: 9776 x 2836 x 935 mm
b) Battery Charger:
Each charger of Rating- 300A, consists float & boost charger
panels, dispatched in suitable shipping sections.
Size of Float Charger (FC) : 2200 x 1675 x 1100 mm
Size of Float cum Boost Charger (FCB) : 2200 x 1675 x 1100
mm
Approximate Weight of charger: 2000 kg / Charger
* Lump sum rate shall be quoted

BOM/8
SL. DESCRIPTION Qty Clause
NO. Unit 10 Ref No:
B.1 BHEL-PEM SCOPE
B.3.0 LOCAL PUSH BUTTON STATIONS
B.3.1 Type – A - For Unidirectional drives 62 Nos. 6.3.12

B.3.2 Type – B - For Bi directional drives 75 Nos. 6.3.12

B.3.3 Type – C - With Ammeters 9 Nos. 6.3.12

B.4.0 6.6 KV UNEARTHED XLPE CABLE TERMINATIONS

KITS
B.4.1 1 C x 500 sq. mm 38 Nos. 6.3.10

B.4.2 3 C x 185 sq. mm 26 Nos. 6.3.10

BOM/9
SL. DESCRIPTION Qty Clause
NO. Unit 10 Ref No:
B.1 BHEL-PEM SCOPE
B.5.0 CABLE TRAYS AND ACCESSORIES
along with bends, reducers, tees, cross etc.
B.5.1 600 mm wide, Ladder Type Tray 10800 Mtrs 6.3.11

B.5.2 450 mm wide, Ladder Type Tray 2200 Mtrs 6.3.11

B.5.3 300 mm wide, Ladder Type Tray 2450 Mtrs 6.3.11

B.5.4 150 mm wide, Ladder Type Tray 1200 Mtrs 6.3.11

B.5.5 600 mm wide, Perforated Type Tray 2200 Mtrs 6.3.11

B.5.6 450 mm wide, Perforated Type Tray 800 Mtrs 6.3.11

B.5.7 300 mm wide, Perforated Type Tray 800 Mtrs 6.3.11

B.5.8 150 mm wide, Perforated Type Tray 8500 Mtrs 6.3.11

BOM/10
SL. Qty Clause
DESCRIPTION
NO. Unit 10 Ref No:

B.1 BHEL-PEM SCOPE

B.6.0 STRUCTURAL STEEL FOR SUPPORT
B.6.1 Structural Steel for fabrication of supports (ISA - 60X60X6, ISMC – 112 MT 6.3.13
100, ISMC - 160 etc.)

B.7.0 ABOVE GROUND EARTHING

B.7.1 65 x 8 mm GS Flat 60 Mtrs 6.3.14

B.7.2 50 x 6 mm GS Flat 3400 Mtrs 6.3.14

B.7.3 25 x 6 mm GS Flat 3000 Mtrs 6.3.14

B.7.4 25 x 3 mm GS Flat 300 Mtrs 6.3.14

B.7.5 6 sq. mm wire 1200 Mtrs 6.3.14

B.7.6 Treated Earth Pit 64 Sets* 6.3.14

B.8.0 LIGHTNING PROTECTION

B.8.1 Vertical Air Termination of size 20 mm dia, 1000 mm long 38 Nos. 6.3.14
Galvanised Steel Rod with conical end
B.8.2 Test Links for lightning protection 38 Nos. 6.3.14

B.8.3 25 x 6 mm GI Flat Strips for lightning protection 2625 Mtrs 6.3.14

BOM/11
SL. Qty Clause
DESCRIPTION
NO. Unit 10 Ref No:

C. 1 BHEL-RANIPET SCOPE

C.1.0 ESP

C.1.1 ESP LT MAIN SWITCH BOARD 1 No. 6.3.3

Dimension: 11600 x 1700 x 2400 mm
Weight: 8000kg (approx).
C.1.2 AUXILIARY CONTROL PANEL 02 Nos. 6.3.3

Dimension : 10800 x 1000 x 2400 mm

Weight : 6000 kg (approx)
C.1.3 STARTER BOX FOR DC AIR HEATER MOTOR 02 Nos. 6.3.3

Dimension: 750 x 375 x 1000 mm

Weight : 200 kg each (approx.)
C.1.4 ELECTRONIC CONTROLLER with only one loose supplied 14 Sets* 6.3.3
BAPCON Controller
Dimension : 700 x 660 x 2000 mm
Weight : 400 kg

BOM/12
SL. Qty Clause
DESCRIPTION
NO. Unit 10 Ref No:

C. 1 BHEL-RANIPET SCOPE

C.1.5 RAPPER CONTROL PANEL, with 2 Nos of LOOSE 1 Set* 6.3.3

SUPPLIED RAPCON Controller .
Size : 1000 x 660 x 2000 mm
Approximate Weight : 400 kg
C.1.6 IOS-PC, DC logger PC & Printer 1 set* 6.3.3
C.1.7 Ash Level Indicator 28 Sets* 6.3.7

C.2.0 TESTING of HEATING ELEMENTS & THERMOSTAT

C.2.1 HEATING ELEMENTS FOR HOPPER 446 Nos. 6.3.8

C.2.2 HEATING ELEMENTS FOR SHAFT INSULATOR 14 Nos. 6.3.8

C.2.3 HEATING ELEMENTS FOR SUPPORT INSULATORS 66 Nos. 6.3.8

C.2.4 THERMOSTAT FOR SUPPORT INSULATORS 2 Nos. 6.3.8

C.2.5 THERMOSTAT FOR HOPPER HEATER 14 Nos 6.3.8

C.3.0 LOCAL START STOP PUSH BUTTON STATION 40 Nos. 6.3.12

BOM/13
SL. DESCRIPTION Qty Clause
NO. Unit 10 Ref No:
C. 1 BHEL-RANIPET SCOPE
C.4.0 JUNCTION BOXES (POWER AND CONTROL) 40 Nos. 6.3.12

Approximate weight: 12 kg each

C.5.0 CABLES
FRLS, PVC, Al conductor cable
C.5.1 4 C x 1.5 sq. mm FRLS Cu, Screened Armoured Cable 3000 Mtrs 6.3.10

C.6.0 CABLE TRAYS

C.6.1 450 mm, Ladder type Tray 676 Mtrs 6.3.11

C.7.0 EARTHING MATERIALS

C.7.1 50 x 6 mm GI Flat 550 Mtrs 6.3.14

C.7.2 30 x 5 mm GI Flat 350 Mtrs 6.3.14

C.7.3 Dia 3.15 mm GI Wire 2400 Mtrs 6.3.14

BOM/14
SL. DESCRIPTION Clause
NO.
Qty Ref No:
Unit 10

C. 1 BHEL-RANIPET SCOPE
C.8.0 SUPPORT MATERIALS
C.8.1 Structural steel for fabrication of supports (Angles, Channels 6 Tonnes 6.3.13
etc.)
C.9.0 COMMISSIONING
C.9.1 HIGH VOLTAGE TR. RECTIFIER 14 Nos. 6.3.18

The scope of work includes oil filteration, sample testing for

dielectric strength, PPM etc., calibration of WTI, temperature
gauges, Bucholz relay etc.
Approximate Oil Weight: 760 kg/ trf
C.9.2 L.T. GEARED MOTOR (Rapping motors) 40 Nos. 6.3.18

D.1 BHEL-PIPING CENTRE SCOPE

D.1.0 COMMISSIONING
D.1.1 BIIDIRECTIONAL MOTORS (L.T.) 5 6.3.18
Nos.

BOM/15
SL. Qty Clause
DESCRIPTION
NO. Unit 10 Ref No:

E.1 BHEL-TRICHY SCOPE

E.1.1 DC SCANNER AIR FAN MOTOR STARTER BOX 1 No. 6.3.3

Dimension: 900 x 1120 x 476 mm
Approximate weight: 200 kg
E.1.2 FURNACE TEMPERATURE PROBE STARTER BOX 1 No. 6.3.3
Dimension: 900 x 1120 x 476 mm
Weight: 260 kg
E.2.0 LT POWER CABLES
E.2.1 3C x 2.5 sqmm, Cu, Armoured, PVC insulated 21000 Mtrs 6.3.10
E.3.0 CONTROL CABLES
E.3.1 4C x 2.5 sqmm, Cu, Armoured, PVC insulated 1500 Mtrs 6.3.10

BOM/16
SL. DESCRIPTION Qty Clause
NO. Unit 10 Ref No:
E. 1 BHEL-TRICHY SCOPE

E.4.0 CABLE TRAYS

E.4.1 Perforated Type, 100mm wide 2375 Mtrs 6.3.11

E.4.2 Perforated Type, 150mm wide 1000 Mtrs 6.3.11
E.4.3 Perforated Type, 50mm wide 500 Mtrs 6.3.11
E.5.0 JUNCTION BOXES 150 Nos 6.3.12
E.6.0 COMMISSIONING
E.6.1 Hoist 1 No 6.3.18
E.6.2 UNIDIRECTIONAL MOTORS (L.T.) 109 Nos. 6.3.18
(Includes Soot Blower Motors also)
E.6.3 BIDIRECTIONAL DRIVES (L.T.) 108 Nos. 6.3.18
(Includes Soot Blower Motors also)
E.6.4 6.6kV , HT Motors 16 Nos 6.3.18
(PA FAN-2 Nos , FD FAN-2 Nos, CEP-2 Nos, MILL MOTOR-6
Nos, BFP-2 Nos & ID FAN-2 Nos; per Unit)

BOM/17
SL. DESCRIPTION Qty Clause
NO. Unit 10 Ref No:
F.1 BHEL-EDN SCOPE
F.1.1 AVR 1 set* 6.3.4

Digital AVR comprising of Regulation Cubicle, Thyristor

Cubicle, Field Suppression Cubicle along with loose supplied
items.
Overall dimension : 4060 x 760 x 2296 mm
Total Weight : 1000 kg
F.1.2 UNIT ELECTRICAL CONTROL PANEL (UECP) 1 No 6.3.4
Approx Overall dimensions: 1500 x 800 x 2415 mm
Approx weight: 800kg.
F.1.3 TRANSDUCER & AVT PANEL (AVT) 1 No 6.3.4
Approx Overall dimensions: 1000 x 800 x 2415 mm
Approx weight: 700kg.
F.1.4 GENERATOR RELAY PANEL (GRP) 1 No 6.3.4
Approx Overall dimensions: 4000 x 800 x 2415 mm
Approx weight: 2000kg.

BOM/18
G.1 BHEL-BHOPAL SCOPE
G.1.1 GENERATOR, GT & UAT PROTECTION PANELS 6.3.4
1 set*
4 Nos. panels having each Panel Dimension : 2600 x 1200 x
1200 mm dispatched in 4 shipping sections.
Approximate weight: 600 kg
H.1 BHEL-HYDERABAD SCOPE
H.1.0 COMMISSIONING
H.1.1 UNIDIRECTIONAL MOTORS (L.T.) 11 Nos. 6.3.18
H.1.2 BIDIRECTIONAL DRIVES (L.T.) 18 Nos. 6.3.18
H.1.3 Commissioning of GENERATOR 1 No. 6.3.18

The scope of work includes measuring IR Value, HV Test for

Generator Bushing, improving IR value, measuring winding
resistance etc.

BOM/19
SL. DESCRIPTION Qty Clause Ref
NO. No:
Unit 10
I.1 CUSTOMER SCOPE OF SUPPLY
I.1.0 HT CABLES

6.6 KV, Armoured FRLS Cable, Al Conductor

I.1.1 1 C x 500 sq. mm (Al) 900 Mtrs. 6.3.10

I.1.2 3 C x 185 sq. mm (Al) 6.3.10
1900 Mtrs
I.2.0 LT POWER CABLES, FRLS, PVC, Armoured

I.2.1 4 C x 16 sq. mm , Al 5000 Mtrs 6.3.10

I.2.2 4 C x 10 sq. mm, Al 1500 Mtrs 6.3.10
I.2.3 4 C x 6 sq. mm , Al 2500 Mtrs 6.3.10
I.2.4 3.5 C x 240 sq. mm , Al 2000 Mtrs 6.3.10
I.2.5 3.5 C x 120 sq. mm , Al 2500 Mtrs 6.3.10
I.2.6 3.5 C x 95 sq. mm , Al 825 Mtrs 6.3.10
I.2.7 3.5 C x 70 sq. mm , Al 1875 Mtrs 6.3.10
I.2.8 3.5 C x 50 sq. mm , Al 8500 Mtrs 6.3.10
I.2.9 3.5 C x 25 sq. mm , Al 4500 Mtrs 6.3.10
I.2.10 3 C x 70 sq. mm , Al 2385 Mtrs 6.3.10

BOM/20
SL. DESCRIPTION Qty Clause Ref
NO. No:
Unit 10
I.1 CUSTOMER SCOPE OF SUPPLY
I.2.11 3 C x 50 sq. mm , Al 1750 Mtrs 6.3.10
I.2.12 3 C x 35 sq. mm , Al 235 Mtrs 6.3.10
I.2.13 3 C x 25 sq. mm , Al 750 Mtrs 6.3.10
I.2.14 3 C x 16 sq. mm, Al 2750 Mtrs 6.3.10
I.2.15 3 C x 10 sq. mm , Al 3675 Mtrs 6.3.10
I.2.16 3 C x 6 sq. mm , Al 6575 Mtrs 6.3.10
I.2.17 2 C x 240 sq. mm , Al 250 Mtrs 6.3.10
I.2.18 2 C x 120 sq. mm , Al 3000 Mtrs 6.3.10
I.2.19 2 C x 50 sq. mm , Al 2250 Mtrs 6.3.10
I.2.20 2 C x 25 sq. mm , Al 2250 Mtrs 6.3.10
I.2.21 2 C x 16 sq. mm , Al 1710 Mtrs 6.3.10
I.2.22 2 C x 6 sq. mm , Al 4010 Mtrs 6.3.10
I.2.23 2 C x 35 sq. mm , Al 660 Mtrs 6.3.10
I.2.24 3 C x 150 sq. mm , Al 550 Mtrs 6.3.10
I.2.25 2 C x 70 sq. mm , Al 135 Mtrs 6.3.10
I.2.26 3.5 C x 4 sq. mm , Al 2000 Mtrs 6.3.10
I.2.27 1 C x 10 sq. mm , Cu 750 Mtrs 6.3.10

BOM/21
SL. DESCRIPTION Qty Clause Ref
NO. No:
Unit 10
I.1 CUSTOMER SCOPE OF SUPPLY
I.2.28 1 C x 16 sq. mm , Cu 750 Mtrs 6.3.10
I.3.0 LT CONTROL CABLES, Armoured
I.3.1 19 C x 2.5 sq. mm, Cu 1500 Mtrs 6.3.10
I.3.2 14 C x 2.5 sq. mm, Cu 3250 Mtrs 6.3.10
I.3.3 10 C x 2.5 sq. mm , Cu 37725 Mtrs 6.3.10
I.3.4 7 C x 2.5 sq. mm, Cu 5550 Mtrs 6.3.10
I.3.5 5 C x 2.5 sq. mm, Cu 56000Mtrs 6.3.10
I.3.6 4 C x 2.5 sq. mm , Cu 750 Mtrs 6.3.10
I.3.7 3 C x 2.5 sq. mm , Cu 29775Mtrs 6.3.10
I.3.8 10 C x 1.5 sq. mm , Cu 6600 Mtrs 6.3.10
I.3.9 4 C x 1.5 sq. mm , Cu 3250 Mtrs 6.3.10
I.3.10 7 C x 1.5 sq. mm , Cu 2500 Mtrs 6.3.10
I.3.11 2C x 1.5 sq. mm , Cu 375 Mtrs 6.3.10
I.3.12 24C x 2.5 sq. mm , Cu 500 Mtrs 6.3.10
I.3.13 2 C x 2.5 sq. mm, Cu 67350 Mtrs 6.3.10
I.3.14 3 C x 1.5 sq. mm, Cu 100 Mtrs 6.3.10

BOM/22
SL. DESCRIPTION Qty Clause Ref
NO. No:
Unit 10
I.1 CUSTOMER SCOPE OF SUPPLY
I.4.0 LT POWER CABLE TERMINATIONS
I.4.1 3.5 C x 240 sq. mm , Al 26 Nos. 6.3.10
I.4.2 3.5 C x 120 sq. mm , Al 34 Nos 6.3.10
I.4.3 3.5 C x 95 sq. mm , Al 12 Nos 6.3.10
I.4.4 3.5 C x 70 sq. mm , Al 26 Nos 6.3.10
I.4.5 3.5 C x 50 sq. mm , Al 114 Nos 6.3.10
I.4.6 3.5 C x 25 sq. mm , Al 60 Nos 6.3.10
I.4.7 3 C x 70 sq. mm , Al 32 Nos 6.3.10
I.4.8 3 C x 50 sq. mm , Al 24 Nos 6.3.10
I.4.9 3 C x 35 sq. mm , Al 4 Nos 6.3.10
I.4.10 3 C x 25 sq. mm , Al 10 Nos 6.3.10
I.4.11 3 C x 16 sq. mm, Al 36 Nos 6.3.10
I.4.12 3 C x 10 sq. mm , Al 50 Nos 6.3.10
I.4.13 3 C x 6 sq. mm , Al 88 Nos 6.3.10
I.4.14 4 C x 16 sq. mm , Al 66 Nos 6.3.10
I.4.15 4 C x 10 sq. mm, Al 20 Nos 6.3.10
I.4.16 4 C x 6 sq. mm , Al 33 Nos 6.3.10

BOM/23
SL. DESCRIPTION Qty Clause Ref
NO. No:
Unit 10
I.1 CUSTOMER SCOPE OF SUPPLY
I.4.17 2 C x 240 sq. mm , Al 4 Nos 6.3.10
I.4.18 2 C x 120 sq. mm , Al 40 Nos 6.3.10
I.4.19 2 C x 50 sq. mm , Al 30 Nos 6.3.10
I.4.20 2 C x 25 sq. mm , Al 6.3.10
30 Nos
I.4.21 2 C x 16 sq. mm , Al 24 Nos 6.3.10
I.4.22 2 C x 6 sq. mm , Al 6.3.10
54 Nos
I.4.23 2 C x 35 sq. mm , Al 8 Nos 6.3.10
I.4.24 3 C x 150 sq. mm , Al 8 Nos 6.3.10
I.4.25 2 C x 70 sq. mm , Al 2 Nos 6.3.10
I.4.26 3.5 C x 4 sq. mm , Al 26 Nos 6.3.10
I.4.27 1 C x 10 sq. mm , Cu 10 Nos 6.3.10
I.4.28 1 C x 16 sq. mm , Cu 10 Nos 6.3.10

BOM/24