Uploaded on 03.06.

2021

AN ISO 9001 & 14001 COMPANY

TENDER DOCUMENT

e-TENDER No: SRO/CON/ETS/090

Tender For “Design, Engineering, Supply, Commissioning and Supervision of Erection of CEMS
for Stack Flue Gas & Absorber Inlet Gas analysers package of FGD Plant of Ramagundam STPP
(Unit #7)"-PACKAGE-G”

VOLUME – II

Technical Specification, Drawings and Client documents

ENGINEERING PROJECTS (INDIA) LIMITED

(A GOVT. OF INDIA ENTERPRISE)
Southern Regional Office, Chennai
 INDEX

Sl. Page No. No. of

Description
No. Pages

203
1. Technical Specification and drawings 3-205
 CEMS FOR CHIMNEY & INLET GAS
RSTPP ANALYSERS PACKAGE FOR FGD (Supply, SCOPE OF
STAGE - III Commissioning and Supervision of Erection) SUPPLY & SERVICES
– FGD System

SECTION–I

SCOPE OF

SUPPLY & SERVICES

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS &
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

1. PREAMBLE:

1.1. EPC contract of Flue Gas Desulphurisation (FGD) system package for
RAMAGUNDAM SUPER THERMAL POWER STATION - Stage III (Unit # 7) of NTPC
Ltd (OWNER) is being executed by ENGINEERING PROJECTS (INDIA) Ltd (EPIL-
Client) in technical association with M/s WUHAN KAIDI ELECTRIC POWER
ENVIRONMENAL, CO, LTD – CHINA (KDPE).

1.2. EPIL has appointed M/s POWERTEC Engineering Pvt Ltd (PEPL) as their Associate
Engineering Consultant for the pre-and Post award engineering activities of FGD
package.

1.3. EPIL has split the entire FGD scope of supply, erection and commissioning into a
number packages for ease of procurement and for fulfilling the provenness/qualifying
criteria of NTPC's Tender requirement. Powertec the Associate Consultant will be
supporting EPIL in the Pre-award and preparation of tender documents for various
packages and evaluation and post award review engineering activities.

1.4. EPIL shall tender and award the packages to reputed, qualified, technically competent,
Vendors / Suppliers / Manufacturers / Sub-contractor as the case may be.

1.5. The Vendors/ Suppliers / Manufacturers Sub-contractors shall supply /execute the
work / as per the requirements spelt out in the Technical Specifications.

2. PROJECT INFORMATION

NTPC Ramagundam (RSTPS) is a pit-head thermal power station operating with

seven coal fired units having a total installed capacity of 2600 MW consisting of 3 units
of 200 MW capacity in stage-I, three units of 500 MW in stage-II and one unit of 500
MW capacity in stage-III.

The station is located in the Karimnagar district of Andhra Pradesh about 60 kms from
Karimnagar town and 100 kms from Warangal. The coordinates of plant are 18.7519°
N, 79.5134° E. Ramagundam Railway station is on the Delhi - Chennai main line.
Ramagundam is well connected to Hyderabad by Rajiv Rahadari state highway. The
plant site is approximately at a height of 156m from the mean sea level.

3. INTENT OF SPECIFICATION

3.1. The scope of the proposal covered in this tender document shall be on the basis of a
single point responsibility, completely covering the following activities and services in
respect of all the equipment specified and covered under the specifications and read in
conjunction with Section- II of this Technical Specification.

a) Detailed design, Engineering & Supply of all the equipment and system(s) included
under Bidder’s scope.
b) Providing engineering drawings, equipment sizing & performance data, instruction
manuals, as built drawings and other information;

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

c) Compliance with statutory requirements and obtaining clearances from statutory

authorities, wherever required;
d) Finalization of sub-vendors, manufacturing quality plans and Field quality plans;
e) Complete manufacturing including shop testing/type testing;
f) Packing and transportation from the manufacturer’s works to the site including all
expenses & charges, if any.
g) Receipt, storage, preservation, handling and conservation of equipment at the site;
h) Commissioning & Supervision of Erection and any other related Services.
i) Supply of spares on FOR site basis.
j) Insurance and other requirements for the complete package in accordance with the
provisions of General (GCC) Conditions of Contract enclosed in Volume-I of Bid
Document.
k) The contractor shall be responsible for supplying any necessary jointing material,
connectors, nuts, bolts (including anchor/foundation bolts, accessories), etc.
l) All the first fill and one year's topping requirement of consumables such as oil,
lubricants, greases etc. which will be required to put the equipment covered under
the scope of specifications, into successful commissioning/ initial operation and to
establish completion of facilities shall be furnished by the contractor.
m) Suitable standard lubricants as available in India are desired. Effort should be made
to limit the variety of lubricants to minimum.
n) Special tools and tackles if any required for maintenance Equipment(s) included in
Bidder’s scope.

3.2. The Bidder shall be responsible for providing all materials, equipment and services,
specified or otherwise which are required to fulfill the intent of ensuring operability,
maintainability and the reliability of the equipments/system covered under this
specification.

3.3. In the event of conflict between the Technical Specifications and the GCC, the
requirements as indicated in the Technical Specification shall govern, unless confirmed
otherwise by the Client (EPIL) in writing before the award of this contract, based on a
written request from the Bidder for such a clarification.

3.4. Technical Deviations

a) Any deviation or variation from the scope, requirement and/or intent of this
specification shall be clearly brought out under Deviation Schedules of the relevant
Bid forms.

b) No other deviation whatsoever from this specification, except for the declared
deviations submitted by the bidder with his proposal under “Deviations Schedule”
shall be considered for Evaluation. Bids not complying with this requirement shall
be treated as non-responsive and hence liable for rejection.

c) The interpretation of the Client (EPIL) in respect of the scope, details and services to
be performed by the Bidder shall be binding unless specifically clarified otherwise
by the Client (EPIL) in writing before the Award of the Contract.

3.5. Additional Requirements

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

a) In addition to the specifications of equipment / system indicated in various

sections, General Technical (Section-VII) Requirements and Erection Conditions
of (Section-VII) Contract shall also form part of this Technical specification and
shall be referred by the Bidder.

4. TENDER DRAWINGS

4.1. The tender drawings listed in the Technical Specification shall form part of the
specification and shall supplement the requirements specified in these Technical
specifications. The scope and terminal points of the equipment to be furnished under
this Package shall be as identified in these drawings read in conjunction with text of
the specification.

4.2. These drawings are preliminary drawings for bidding purpose only and subject to
changes that may be necessary during the detailed engineering keeping the basic
parameters as specified. Various parameters for building and other equipment
specified in the tender drawing are the minimum required & any increase in these
parameters if required to meet the system requirement shall be made by the Bidder
without any additional cost implication to Client (EPIL).

5 SCOPE OF SUPPLY & SERVICES

a. The scope of work for the equipment and accessories to be furnished in accordance
with this specification shall include design, manufacture, engineering, supply,
inspection and testing at supplier’s works, packing, forwarding to site, unloading,
commissioning and supervision of erection of the equipment /system and works as
indicated below and in the Technical specification for CEMS at Section II and any item
or work though not specifically mentioned in this specification but needed to complete
the equipment & system to meet the Intent of the Specification shall also be considered
as covered in the scope of the Bidder.

b. In addition to CEMS detailed at 5.1 below, Bidder shall offer other Analysers for the
measurement of SO2 in Raw flue gas to Absorber and shall fully meet the requirements
of the Tender diagram Drg.No. 3140-1095-PVE-W-302 R0 attached with this
specification.

c. Bidder shall furnish the requirement of Power supply, Instrument air and Cooling
water if any at Tapping point and at Porta Cabin along with complete details. The
same will be provided by the Client at two points. Further distribution to various
consumers shall be in the scope of the bidder.

d. One 240V AC UPS & Normal Power supply will be made available to the Bidder at
respective Porta cabin. Supply of Cables & Cabling from Porta cabin to field
instruments will be in the scope of the Client. Bidder to provide the details &
specification of all types of cables used for successful commissioning of their system.

e. All tapping points will be provided by EPI at an elevation of 257M and the FGL is
155M, as per the installation drawings furnished by Bidder. The Porta cabin will be
located at FGL. All erection materials required for the provision of tapping points
along with all erection hardwares, impulse lines etc., shall be in the scope of the

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

Bidder. Erection work only shall be carried out by the EPI based on the guidelines and
supervision by Bidder.

5.1 CONTINUOUS EMISSION MONITORING SYSTEM (CEMS)

CEMS comprising of analysers and associated items for measurement of SO2, NOx,
CO, CO2, Mercury, Particulate Matter (dust density), Humidity and Stack Flue Gas
Flow in Stack emission shall be provided for each unit by the Contractor for stack
emission monitoring
.
A. LIST OF FLUE GAS EMISSION ANALYSERS FOR CONTINUOUS EMISSION
MONITORING SYSTEM (CEMS)

S. No. KKS CODE DESCRIPTION RANGE ZONE REMARK

SO2 in stack 0-250 /0-1500
1 HNE10CQ005 CHIMNEY
emission mg/Nm3 (SELECTABLE)
0-250 /0-1500
NOX in stack Refer
2 HNE10CQ001 mg/Nm3 CHIMNEY
emission note-2
(SELECTABLE)
CO2 in stack
3 HNE10CQ002 0-25% (Selectable) CHIMNEY
emission
0-100/ 0-1000
CO in stack
4 HNE10CQ004 mg/Nm3 CHIMNEY
emission
(SELECTABLE)
Particulate Matter 0-50 mg/Nm3 /
5 HNE10CQ003 (Dust Density) in 0–300 mg/Nm3 CHIMNEY
stack emission (PROGRAMMABL E)
Mercury (Hg) in 0 – 35
6 HNE10CQ006 CHIMNEY
stack emission microgram/Nm3

Flue Gas flow at To be Decided during

7 HNE10CQ007 CHIMNEY
stack Detail Engineering.

O2 in stack To be Decided during

8 HNE10CQ008 CHIMNEY
emission Detail Engineering.

Humidity in stack
9 HNE10CQ009 During Detail Engineering CHIMNEY
emission

LIST OF ANALYSERS FOR INLET FLUE GAS

0-500 /0-1500
SO2 in Raw Inlet to
1 mg/Nm3
Flue gas inlet Absorber
(SELECTABLE)
O2 in Raw 0-5%/0-1% Inlet to
2
Flue gas inlet (selectable) Absorber

Flow of gas to To be Decided during Inlet to

3
Aborber Detail Engineering. Absorber

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

NOTES: 1. SO2, NOX, CO2 and CO analyzer are shown separately for the purpose
of input only otherwise SO2, NOX, CO2 and CO analyser may be
supplied as a single unit/ Combined Unit (s) meeting specification
requirement.

2. Direct measurement of NO and NO2 shall be done. Total NOx values

shall be reported as NO2 i.e. NOx = NO + NO2 = NO X 1.53 + NO2 =
NOx as NO2.

3. Oxygen (O2) measurement in stack emission based on Paramagnetic/

Zirconia type instrument shall be provided by the Contractor for
correction of SO2, NOx and Particulate matter value corresponding to
the standard/reference O2.

4. CEMS Parameters shall be normalized for temperature, pressure,

moisture (applicable in case of wet measurement techniques), etc. This
facility shall be available in the respective analyzers. Necessary
measurement shall be provided by the Contractor for these parameters.
All the CEMS parameters shall be reported on dry basis.

5. CO2 Measurement at stack and at instrument end shall be provided in

case dilution techniques are used.

6. Offered CEMS should comply with latest CPCB/regulatory

requirement prevailing at the time of award of the contract even if same
is not explicitly indicated in the technical specification, without any cost
implication to the Employer.

7. Offered CEMS shall be fully proven for the actual flue gas parameters
at stack. Reference list and user feedback of offered CEMS in similar
applications shall be furnished to NTPC for review during detailed
engineering stage.

8. These are per unit quantities.

2. CEMS analysers/instruments shall be provided with single point bidirectional

connectivity over RS-232/RS-485 Modbus Protocol/ Ethernet TCP/IP protocol
with Employer’s central cloud server for real time data monitoring, remote
diagnostics & remote calibration checks, etc., complying with CPCB IT Division
document “Protocol for real time (Emission & Effluent) data management from
industries version 1.2 (10.6.2015),CPCB Guidelines July-2017 on CEMS or the
latest regulatory requirement prevailing at the time of award of the contract. All
necessary hardware and software required at instrument end shall be provided
by the Contractor. Bidder shall connect analysers instruments of his scope and
provide single point/port in FGD Control room for connection with Employer's
cloud server. Further connection to Employer's cloud server shall be in the scope
of Employer. Necessary details like scheme, register addresses of analyzer, etc.
shall also be provided by the Contractor for implementation of above. The
Contractor shall fully assist NTPC’s agency involved in implementation of

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

above connectivity. Successful Bidder to confirm the Data logger models,

software, updation availabilities, per year data connectivity charges, parameters
of CEMS incrypted for each data loggers), Latest data connectivity protocol to be
applied, to add any parameter in future, vendor should provide extra port
(minimum 02 nos.).

For CEMS - In addition to above requirement, 4-20 mA connectivity to DDCMIS shall

be provided by the Contractor. Contractor shall provide one no. of Hand held HART
calibrator per FGD

Comprehensive Annual Maintenance Contract (AMC) for three (03) years after
warranty period shall be provided by the contractor for CEMS and Analysers of FGD
System

B. SERVICES DURING DEFECT LIABILITY PERIOD FOR CEMS AND ANALYSER

INSTRUMENTS OF FGD

1. The Contractor shall provide an unlimited warranty on all equipments

during the Defect liability period. This warranty shall include repair,
replacement, replenishment of consumables (for e.g. reagents, calibration
gases etc. as applicable) and correction of identified discrepancies including
Analysers, Sample Handling System, Transmitters, (as applicable) etc. at no
cost to Employer.

2. The Contractor shall provide warranty spares including components for each
system based on (and keeping adequate over margin) normally experienced
failure rate. Exhaustive list of all such items shall be submitted along with
Datasheet for Employer's review and approval during details Engg stage
regarding adequacy of the same. The warranty spares as per the list
mentioned above will be dispatched by the Contractor along with the main
equipment consignment. However for items which have a limited shelf life
shall be dispatched in a phased manner during the warranty period. Unused
spares/consumables shall be Contractor’s property after expiry of warranty
period and shall be taken back.

C. SERVICES DURING ANNUAL MAINTENANCE CONTRACT (AMC) PERIOD

FOR CEMS AND ANALYSER INSTRUMENTS OF FGD

1. The Contractor shall provide complete maintenance services for each System
under comprehensive Annual Maintenance Contract (AMC) for period of
three years after the Warranty period.

2. The AMC shall cover total maintenance of all Analysers, Sample Handling
System, Transmitters etc. coming under the scope of each system and shall
include free repair/replacement of each items, replenishment of consumables,
correction of problems (if any) and supply of expendable items.

3. Further, Contractor may note that during the AMC he will be allowed to use
Employer's mandatory spares, but has to replenish the same within three
months’ time or before completion of AMC period whichever is earlier.

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

4. The Contractor shall prepare detailed list of faults corrected and parts,
expendables utilized during AMC period and shall furnish the same to
Employer, properly documented at the end of AMC period. Further, during
AMC period the details as required by Employer/ Project Manager shall be
made available by Contractor's personnel.

5. Contractor shall also provide a list of all required AMC spares which shall be
finalized along with datasheet during detail Engineering stage. These spares
will be dispatched by the Contractor at the beginning of AMC on yearly
requirement basis. However for items which have a limited shelf life shall be
dispatched in a phased manner during the AMC period. Unused
spare/consumable shall be Contractor’s property after expiry of AMC period
and shall be taken back.

D. DEPUTATION OF ENGINEER/ TECHNICAL EXPERT FOR CEMS AND

ANALYSER INSTRUMENTS OF FGD

1. Contractor shall depute Technical Experts of the OAM /OEM/OES/ (Original

Analyser Manufacturer/Original Equipment Manufacturer/Original
Equipment supplier) for each of the above system at Site, who will be fully
qualified to perform the required duties, supervision of maintenance, repair
etc. for a period of six month. Employer will intimate the contractor two
weeks advance notice for start of deputation period.

2. After expiry of above six month period, Technical expert for each system shall
visit site on monthly basis for monitoring the performance and rectify the
problem (if any) for each system for the remaining warranty period and
during entire AMC period. In the event of any malfunction/fault/failure in
the system or any component thereof contractor shall depute Technical expert
of respective system to reach site within 48hrs of call raised by site during the
remaining warranty period and entire AMC period

E. Material Codification of C&I items in NTPC SAP system:

1. Contractor to provide detailed catalogue with complete part number of all the
instruments, Electronic cards, accessories, JBs, Panels, etc. to Site Erection
Incharge within one month of supply of item at site for material codification of
Main supply and mandatory spares items.

2. Contractor to depute his representative for 30 mandays at site for codification

of materials in NTPC SAP system in phased manner. The detail schedule of
the program shall be finalized during commissioning stage at site.

3. The material codification of all the C&I items shall be completed before
completion of commissioning and handover of system to site.

5.4 Spares
Scope of supply of the Bidder includes Mandatory spares, Start-up and
Commissioning spares including general spares. The list of Mandatory Spares is given
in Section - II of Technical specification.

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

5.5 Not used

5.6 Scope of the Bidder also includes all shop tests, type tests, site tests, and Routine
tests etc for fulfillment of complete quality assurance & inspection requirements for
the equipment included in the scope of Bidder as per the stipulations of Technical
Specifications.

5.7 Paints / Painting

Bidder to comply with the requirements specified in Section-II, Technical

specification

5.8 Pre-commissioning and Commissioning Activities

a) The bidder's scope shall include all supervision of installation/ erection, pre-
commissioning and commissioning activities, provision of materials and services
as detailed in Section- VII of Technical Specifications (Erection Conditions of
Contract) including supply of all consumables temporary equipments and pipings,
instruments, labour/ skilled manpower etc.

b) Contractor's scope shall also include supply of any special materials and services
including the following for successful conductance of pre-commissioning and
commissioning activities:

c) Complete pre-commissioning work including tests of facilities and all other tests as
mutually agreed in the Contractor’s quality assurance program as well as those
identified in the specification.

d) Commissioning & 30 days of operation of the CEMS after establishing

communication with CPCB.

e) Supply of all consumables as may be required for above pre-

commissioning/commissioning activities.

5.9 First Fill of Consumables, Oils & Lubricants, chemicals

All the first fill and One year's topping requirements of consumable such as greases,
oil, lubricants, servo fluids etc. which will be required to put the equipments covered
under the scope of specifications, into successful commissioning/ initial operation and
to establish completion of facilities shall be furnished by the bidder, unless specifically
excluded under the Exclusions in these specifications and documents.

5.10 Guarantee Tests

The guarantee tests for various equipment and systems shall be carried out as
specified in SECTION –II (Functional guarantee and LD) and in Section – VII (GTR)
of Technical Specification. All special equipment, tools and tackles instruments,
measuring devices required for the successful conductance of Guarantee Tests shall be

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

provided by the bidder, free of cost. All costs associated with the tests shall be
included in bid price.

5.11 Special Tools & Tackles and Test/ Measuring Equipments

One set of all special tools and tackles including testing, calibrating and measuring
instruments required for erection, assembly, disassembly and maintenance of all
equipments/ systems covered under the scope of the Bidder shall be supplied by the
Bidder if any, as per relevant clauses of SECTION III and SECTION-VII of Technical
Specifications.

5.12 Detailed Engineering, Documentation and Technical co-ordination

i) Scope of the bidder includes complete design and engineering, technical

coordination (including participation and arranging technical co-ordination
meetings), finalization of drawings/ documents, submission of engineering
drawing / documents and processing of their approvals by NTPC/Owner as per
relevant clauses of Section – VII (GTR) of Technical Specification and other
relevant clauses given elsewhere in the Technical Specifications.

ii) The Contractor shall furnish all relevant data required by the Client / NTPC, at
interface points within schedule as agreed to prior to award of contract.

5.13 Type Tests and Type test Charges

a) Bidder shall include under his scope all type tests to be conducted on various
equipments as envisaged in Technical Specifications. Bidder shall include in the
total Bid Price the cost of carrying out all such type tests.

b) Further in relevant price Schedule(s), of the bid documents, bidder shall furnish
the breakup of the type test charges indicating charges of each type and rating of
various equipments. Client (EPIL) at his discretion during the execution of the
work may delete any or all type tests from the Bidder’s scope and the contract
price shall be adjusted as per the breakup of type test charges indicated in the
schedule for such type tests.

5.14 Noise Level

5.15 The noise level to be maintained by all the equipment & systems supplied and erected
by the bidder as per relevant clause of General Technical Requirements (GTR) in
Section VII

6 QUALIFYING REQUIREMENTS FOR EQUIPMENTS / SYSTEMS

The Bidder is required to meet the provenness criteria and/or qualification

requirement for the items/ as per the stipulated criteria indicated in the respective
clauses. For the purpose of qualification of Bidders experience shall be reckoned as on
the date of consideration for approval but not later than six months to award date of
contract to the Main bidder unless otherwise specified in the respective clauses.

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

7 PROVENNESS CRITERIA FOR CEMS

The Bidder is required to meet the provenness criteria and/ or qualification

requirement for CEMS and other Analytical instruments, systems and brought out
items as per criteria stipulated below:

7.1 CEMS

i. Bidder should be an NTPC approved sub-vendor as on date of bid opening for

the items under this tender
And
ii. CEMS and other analysers offered shall be same or of same series which should
have been in successful operation for a period of not less than one (1) year in
atleast one (1) FGD unit or above in a Power Station

The Bidder at his option can source other associated items not covered in clause above.
However for such balance child parts, the Client (EPIL)/NTPC reserves the rights to
satisfy himself on the provenness of the equipment and capability and capacity of the
manufacturers.

Notwithstanding anything stated above, the Client (EPIL) reserves the right to assess
the capabilities and capacity of the Bidder/his collaborators/ licenser/ his
subcontractors to perform the contract, should the circumstances warrant such
assessment in the overall interest of the Client (EPIL).

To enable the approval of sub-vendors, the Bidder shall provide all necessary data
such as type, design, make, capacity, duty conditions, date of commissioning /
operation etc.

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS &
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

SECTION – II

TECHNICAL REQUIREMENTS

AND SPECIFICATIONS

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS &
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

1 GENERAL REQUIREMENTS

1.1 The Contractor shall provide instruments and equipments for monitoring of flue gas
pollutants in inlet to the Absorber and in Chimney in all regimes of operation in
compliance with CPCB Guidelines in safe and most efficient manner including
Primary and Secondary Instruments, Process Connection and Piping, associated
Instrumentation Cables etc. as identified in the specification.

1.2 The Contractor shall provide all material, equipment and services so as to make a
totally integrated Instrumentation together with all accessories, auxiliaries and
associated equipments ensuring operability, maintainability and reliability. This work
shall be consistent with modern power plant practices and shall be in compliance with
all applicable codes, standards, guides, statutory regulations and safety requirements
in force.

1.3 Further Bidder shall also include in his proposal and shall furnish all equipment,
devices and services which may not be specifically stated in the specification but are
needed for completeness of the equipment/systems furnished by the Bidder and for
meeting the intent and requirements of the specification.

1.4 Bidder shall include in his bid a detailed Bill of Material (BOM) for each of the
systems.

1.5 In addition to requirements specified under this Section, all C&I systems/ sub-
systems/ equipment/ devices shall also meet other requirements stipulated under
other Sub-sections/ parts/ sections of specification.

2 RELIABILITY AND AVAILABILITY

1.1 Each component and system offered by the Bidder shall be of established reliability.
The minimum target reliability of each piece of equipment like each electronic
module/card, Power supply, Peripheral etc. shall be established by the Bidder,
considering its failure rate/mean time between failures (MTBF), meantime to repair
(MTTR), such that the availability of the complete C&I system is assured .

1.2 When more than one device uses the same measurement or control signal, the
transmitter and other components/ module shall be fully equipped to provide all
signal requirements. All the 4-20 mA output signals from transmitters/other control
system shall be able to drive minimum 500 Ohms load resistance. The system shall be
arranged so that the failure of any monitoring device or control components or
spurious intermediate grounding in the signal path shall not open the signal loop nor
Cause the loss or malfunction of signal to other devices using the same signal.

1.3 To ensure availability, adequate redundancy in system design shall be provided at

hardware, software and sensor level to satisfy the availability criteria mentioned
above. For the protection system, independent sensing device shall be provided to
ensure adequate safety of plant equipment.

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

3 OPERABILITY & MAINTAINABILITY

3.1 The design of the control systems and related equipments shall adhere to the principle
of ‘Fail Safe’ Operation wherever safety of personnel / plant equipment is involved.
‘Fail Safe’ operation signifies that the loss of signal, loss of excitation or failure of any
component shall not cause a hazardous condition. However, it shall also be ensured
that occurrence of false trips are avoided / minimized.

3.2 The types of failure that shall be taken into account for ensuring operability of the
plant shall include but not be limited to:

 Failure of sensor or transmitter.

 Failure of main and/or redundant controller/other modules.
 Loss of motive power to final control element.
 Loss of control power.
 Loss of instrument air.

3.3 The choice of hardware shall also take into account sound maintainability principle
and techniques. The same shall include but shall not be limited to the following:

 Standardization of parts.
 Minimum use of special tools.
 Grouping of functions.
 Interchange ability.
 Malfunction identification facility/self surveillance facility.
 Easy modular replacement.
 Fool proof design providing proper identification and other features to preclude
improper mounting and installation.
 Appropriate de-rating of electronic components and parts.

3.4 The equipment shall employ latest state of the art technology to guard against
obsolescence. In any case, Bidder shall be required to ensure supply of spare parts for
lifetime of the plant. In case, the Bidder feels that certain equipment/component is
likely to become obsolete, the Bidder shall clearly bring out the same in his Bid and
indicate steps proposed to deal with such obsolescence. The bidder shall clearly state
the availability of bidded items for the next 10 years

3.5 Control & Monitoring

3.6 The control, monitoring & operation of flue gas desulphurization system and other
system being supplied under the contract, is envisaged from DDCMIS Based Control
system being supplied by the contractor under this package.

4 ENVIRONMENTAL CONDITIONS

4.1 Instruments, devices and equipments for location in outdoors/indoor/air-conditioned

areas shall be designed to suit the environmental conditions indicated below and shall
be suitable for continuous operation in the operating environment of a coal fired utility
station and also during periods of air conditioning failure without any loss of function,
or departure from the specification requirements covered under this specification.

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

Required protection
Ambient Class of panels/
Relative
Temperature Pressure Atmosphere cabinets/ desks to be
humidity
(outside cabinets) provided by
contractor.
Outdoor Location
55 degree C max. Atmosphere 100 % Max. Air (dirty) IP 55
4 degree C min. Atmosphere 5 % min. Air (dirty) IP 55
Indoor Location
55 degree C max. Atmosphere 95 % Max Air IP 54**
4 degree C min. Atmosphere 5 % Max Air IP 54**
Air Conditioned Areas
24 +/- 5 degree C Atmosphere 95 % Max Air IP 22***
normal
50 degree C max. * Atmosphere 5 % Max Air IP 22***
* During air conditioning failure.
** For non-ventilated enclosures. For ventilated enclosures, protection class shall be IP 42.
*** With a suitable canopy at the top to prevent ingress of dripping water.

For PCs, OWS, EWS, Servers, Printers and other peripherals, maximum temperature limit
shall be 35 Deg.C. For mini-UPS, the same shall be 40 Deg.C.

5 DATA FOR ANALYSER SELECTION

5.1 Basic data of FGD inlet flue gas

5.1.1 Requirements for measurement parameter of FGD inlet flue gas analyzers
Flue gas analyzers measure the following flue gas parameters: SO2, O2, flow.

5.1.2 Flue gas duct design parameters

FGD inlet flue gas analyzers measure at FGD inlet flue gas duct (horizontal
arranged steel flue gas duct), the flue gas duct sized
11600mm×5800mm×7mm (Width×Height×Wall thickness), with horizontal
straight duct section length of 3000mm, EL.166.0m bottom elevation of
horizontal straight duct, about 100mm thickness of insulation.

Item Unit / Status Data

Analyzer Probe Installation Location Refer to Attached Drawing（By EPIL）
Flue gas duct Dimension: (W×H) mm 11600W x 5800H
Flue gas duct Wall thickness mm 7 minimum
Straight duct section length mm 3000
bottom elevation of horizontal
m EL.166.00
straight duct
Material Carbon steel
Liner material Yes/No No
Insulation Yes/No Yes
thickness of insulation mm 100

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
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FGD System SPECIFICATIONS

5.1.3 Flue gas components design parameters

Design point @ worst coal
Item Unit Value
Total Flow (Wet) m3/hr 3,595,704
Total Flow (Dry) m3/hr 3,063,559
Total Flow (Wet) Nm3/hr 2,311,200
Total Flow (Dry) Nm3/hr 1,969,155
Pressure Pa 2,187
Temp oC 153
Total Flow (Wet) kg/hr 2,930,733
Total Flow (Dry) kg/hr 2,655,813
Flue Gas Density kg/m3 0.815
CO2 kg/hr 461,003
H2O kg/hr 274,920
SO2 kg/hr 4,646
N2 kg/hr 1,996,819
O2 kg/hr 192,586
HCl kg/hr 169
HF kg/hr 25
H2SO4 kg/hr 103
Ash kg/hr 462
SO2 mg/Nm3 2010
SO2 mg/DNm3 2,359
SO2 @ 6% O2 dry volume mg/DNm3 2,502
HCl mg/DNm3 86
HF mg/DNm3 13
H2SO4 mg/DNm3 52
Ash + Carryover Solids mg/DNm3 234.74
O2 wet vol % 5.8
O2 dry vol % 6.9

5.2 Basic data for Chimney CEMS

5.2.1 Requirements for measurement parameter of chimney CEMS Chimney CEMS

measure the following flue gas parameters: SO2, NOx, CO, CO2, O2,
Mercury, Particulate Matter, temperature, pressure, moisture, flow.

5.2.2 Chimney design parameters

Item Unit / Status Data

Chimney general arrangement Refer to Chimney Drawing
Chimney diameter mm 7240see note
Chimney wall thickness mm Refer to Chimney Drawing
Chimney Material Carbon Steel
The bottom elevation of chimney m Refer to Chimney Drawing
The top elevation of chimney m Refer to Chimney Drawing

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
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FGD System SPECIFICATIONS

Center elevation of FGD outlet into

m Refer to Chimney Drawing
chimney level flue
Elevation of each platform m Refer to Chimney Drawing
Borosilicate Glass Block
Liner material Lining of minimum 38 mm
thickness
Insulation Yes/No No

Note: The internal flue diameter is after applying/considering liner at inner surface of
can (liner to liner clearance distance).

5.3 Chimney flue gas components design parameters

Design point @ worst coal

Item Unit Value
Total Flow (Wet) m3/hr 2,703,961
Total Flow (Dry) m3/hr 2,253,002
Total Flow (Wet) Nm3/hr 2,207,209
Total Flow (Dry) Nm3/hr 1,839,097
Pressure Pa 250
Temp oC 56
Total Flow (Wet) kg/hr 2,774,120
Total Flow (Dry) kg/hr 2,478,248
Flue Gas Density kg/m3 1.026
CO2 kg/hr 432,091
H2O kg/hr 295872
SO2 kg/hr 207
N2 kg/hr 1,865,554
O2 kg/hr 180,274
HCl kg/hr 15
HF kg/hr 2
H2SO4 kg/hr 67
Ash kg/hr 38
SO2 mg/Nm3 94
SO2 mg/DNm3 113
SO2 @ 6% O2 dry volume mg/DNm3 119.5
HCl mg/DNm3 8
HF mg/DNm3 1
H2SO4 mg/DNm3 36
Ash + Carryover Solids mg/DNm3 20.66
O2 wet vol % 5.7
O2 dry vol % 6.9
Mercury mg/DNm3 See note
CO mg/DNm3 See note
NO2 mg/DNm3 See note
NO mg/DNm3 See note

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
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FGD System SPECIFICATIONS

Note:

As per NTPC’s specification, mercury, NO (nitrogen monoxide), NO2 (nitrogen dioxide) and
CO (carbon monoxide) in the gas shall be measured on chimney, while the detailed emission
value has not been provided in specification.

The emission concentration of the pollutants such as NO, NO2, CO cannot be removed by FGD
process, the data from boiler supplier shall be provided to the supplier prior to Award of
contract

The following emission limit for power plant is indicated for reference:

Mercury and mercury chemical compound : 0.03 mg/m3

NOx (for NO and NO2) : 50 mg/m3
CO : 100 mg/m3 (only applicable to waste
incineration)

6 CONTINUOUS EMISSION MONITORING SYSTEM (CEMS):-

i. CEMS comprising of analysers and associated items for measurement of SO2,

NOx,CO, CO2, Mercury, Particulate Matter (dust density) monitor, moisture and
Stack Flue Gas Flow in Stack emission shall be provided by the Contractor.

ii. Direct measurement of NO and NO2 shall be done. Total NOx values shall be
reported as NO2 i.e. NOx = NO + NO2 = NO X 1.53 + NO2 = NOx as NO2.

iii. Oxygen (O2) measurement in stack emission based on Paramagnetic/ Zirconia type
instrument shall be provided by the Contractor for correction of SO2, NOx and
Particulate matter value corresponding to the standard/reference O2.

iv. CEMS Parameters shall be normalized for temperature, pressure, moisture

(applicable in case wet measurement techniques), etc. This facility shall be available
in the respective analysers. Necessary measurement shall be provided by the
Contractor for these parameters. All the CEMS parameters shall be reported on dry
basis.

v. CO2 Measurement at stack and at instrument end shall be provided in case dilution
techniques are used.

vi. CEMS analysers for which dual ranges are specified shall be calibrated for range
near to operating process value.

vii. Offered CEMS should be capable of operating unattended over the prolonged
period of time, as per PG test terms & conditions

viii. Analyzers shall be placed inside Air conditioned CONTAINERISED ROOM

(PORTABLE CABIN) or Air conditioned analyzer room provided by the contactor.
For detailed specification of CONTAINERISED ROOM (PORTABLE CABIN),
Contractor to refer Clause No. 17 below

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
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FGD System SPECIFICATIONS

The common requirements to be met for all types of analysers are as below. The
specific requirements to be met by each type of analyser are detailed in the
subsequent clauses.

7 Common Requirements for all Analysers

1 Type Microprocessor based with self-indicating type

diagnostic feature.
Output signal: 4-20 mA DC galvanically isolated.
Digital signal transmission: RS232/ RS485 Modbus
Protocol/ Ethernet TCP/IP protocol shall be provided in
CEMS analysers for bidirectional communication of stack
emission data to Employer’s cloud server.
2 Display Digital display with reading in engineering units.
Display of the measurement values as well as all the
information required for checking/maintenance of the
analyzer
3 Zero & Span
To be provided for all selectable ranges.
Adjustment
4 Ambient temp. 0-50°C unless defined otherwise.
5 Analyser enclosure Weather protection for analyser mounted inside analyser
Type/Material panel shall be IP-22 or better. For all other analysers,
weather protection class shall be IP-55.
6 Calibration Auto & Manual (from Remote). CEMS analyser should
have inbuilt zero and calibration check capability.
7 Power Supply To be arranged by Contractor subject to Employer’s
approval.
8 Others i. All interconnection tubing and cabling between probe
and analyser / analyser panel and cabling from
analyser/ analyser panel to DCS (in respective unit
control room) are to be provided by Contractor.

ii. All the calibration gases (certified cylinder, cylinder

validity certificate to be provided by the successful
bidder) required for one year continuous operation
shall be provided. The calibration gas container
material shall not contaminate the calibration gas.
9 Location of SO2/NOx/CO/CO2/O2-On stack at approximate
probe elevation as per tender sketch from ground level
Particulate Matter (Dust Density) & Flow measurement -
On stack at approximate elevation as per tender sketch
from ground level.
Mercury:- On stack at approximate elevation of 88 Mtrs
from ground level
Location of sample point given above is indicative.
Actual sample point location shall comply with latest
CPCB norms and shall be accessible for maintenance.
10 Location of the AT 0’ Mtrs near stack for CEMS analysers except

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
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FGD System SPECIFICATIONS

analysers (other particulate matter analyser. For particulate matter

than insitu type) / preferred location is ‘0’ meter near stack. Remote display
Analyser Panel. cum configuration unit for particulate matter analyser
should be provided at ‘0’ meter near stack in the analyser
panel in case particulate matter analyser is kept near the
sample point due to technical limitation.
11 Compliance to USEPA, TUV, MCERTS or equivalent standards
standards

12 Type of Technology SO2/NOx :- Hot-extractive sampling type/ Dilution

Extractive/ Insitu (Path) type

CO: - Hot-extractive sampling type/ Dilution Extractive/

In-situ (Cross-duct) type. (can be combined with
SO2/NOx)

CO2:- Hot-extractive sampling type/ Dilution

Extractive/ In-situ (Cross-duct) type (can be combined
with CO or SO2/NOx above).

Particulate Matter (Dust Density):- Extractive type with

reheating or dilution.

Mercury (Hg) :- Extractive type

Note: - For Hot extractive sampling type and Dilution

extractive sampling type system – The components
involved in sample handling system shall be imported &
further, Sample handling system design shall be vetted
by Original Analyzer Manufacturer (OAM). Necessary
documents shall be furnished during detailed
engineering in order to establish the above requirement.
Technical expert of OAM shall witness testing of sample
handling system and validate it. Alternatively sample
handling system assembled at Original Analyzer
manufacturer (OAM) works shall also be accepted.
13 Contractual Warranty:- As defined elsewhere in the Contract.
conditions for Comprehensive Annual Maintenance Contract:-. Refer
CEMS system subsection- IIC-C&I/ Section-VI/ Part-A. This shall
cover total maintenance of all hardware and software
related to CEMS and shall include free
repair/replacement of all
components/cables/equipment etc and supply of
expendable items.

Availability of valid data:-AT least 90% of time during

warranty and CAMC period. For this purpose, contractor
may take necessary steps to ensure availability.

Services to be provided during Warranty and CAMC

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
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FGD System SPECIFICATIONS

period shall be as per clause no. 3.04.00, 3.05.00 and

3.06.00, Sub-Section- III-C, SECTION-VI, PART-A.

8 Specific requirements for Hot-extractive sampling type SO2, NOx, CO2 & CO analysers

SO2 Analyser and

Nox
Specification CO2 ANALYZER
Analyser cum CO Analyser
Requirements
monitor
(combined)
Type of Sampling type - Hot Hot-Extractive Hot-extractive type
Instrument Extractive type
Principle of Radiation absorption NDIR absorption NDIR absorption
Measurement
Measurement 0-250 / 0-1500 0 to 25% 0-100/ 0-1000
Range mg/Nm3 (selectable) mg/Nm3
(selectable) (selectable)
Accuracy +/- 1% of lowest +/- 1% of Span or +/- 1% of lowest
measurement range better measurement
or better range or better
Linearity < +/-1% of lowest < +/-1% of lowest < +/-1% of lowest
measurement range measurement measurement
range range
Repeatability < 1% of lowest < 1% of lowest < 1% of lowest
measurement range measurement measurement
range range
Minimum < 0.5% of lowest < 0.5% of lowest < 0.5% of lowest
detection measurement range measurement measurement
limit range range
Temperature Drift < +/- 2%/10 Deg.C < +/- 2% / 10 < +/- 2%/10 Deg.C
Deg.C
Zero Drift < +/-1% of lowest < +/-1% of lowest < +/-1% of lowest
measurement range measurement measurement range
/week range /week
/week
Span Drift < +/-1% of lowest < +/-1% of lowest < +/-1% of lowest
measurement range measurement measurement range
/week range /week
/week
Analyser < 5 secs < 5 secs < 5 secs
Response time (up
to 90% of full
scale)
Operating 0-300 deg.C 0-300 deg.C 0-300 deg.C
Temperature
Range for probe
Filter Ceramic 3.5 Micron Ceramic 3.5 Ceramic 3.5 Micron
Micron
Accessories for Purging system Purging system Purging system
purging system including including including

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
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FGD System SPECIFICATIONS

Auto Scavenging Auto Scavenging Auto Scavenging

facility facility facility
shall be provided shall be provided shall be provided
Sample gas inlet Temperature of the Temperature of the Temperature of the
temperature to sample gas inlet to sample gas inlet to sample gas inlet to
analyser analyser shall be analyser shall be analyser shall be
controlled before controlled before controlled before
analyser as per analyser as per analyser as per
manufacturer manufacturer manufacturer
standards. standards. standards.

9 Specific requirements for Dilution Extractive type SO2, NOx, CO2 & CO Analsyers

The design of the Dilution Extractive type system shall be satisfying the following
requirements. The sampling system shall consist of In-situ dilution probe, dilution probe
controller, sample conditioning system like air drier and filters etc and other accessories
meeting the following requirements as a minimum. All system components and accessories
required for completion of this system shall be furnished although these may not be
individually specified herein. Following are the minimum requirements:

a) Modular Electronic Design.

b) Heatless Air dryer with inlet filter, chemical scrubbers to remove traces of
NOx/CO2/SO2 from air and accumulator.

c) Self test facility with screen display at the ground level at CEMS PORTA
cabin

d) Protection of instrument in case ambient or surrounding temp going high

beyond stipulated limit.

e) The following are the minimum requirement for the probe:-

 Flange and counter flange for inserting probe

 Flange and counter flange for inserting probe
 Coarse and Fine Filters
 Critical orifice
 Automatic blow back or purging facility
 SS316L probe material

f) Further dilution probe controller shall be provided with the ability to control
dilution ratio.

g) Unheated umbilical chord to be provided for transportation of the diluted

sample, zero air, vacuum pressure, and calibration gas. This chord has to be a
single bundle in FRLS PVC outer sheath. The sample line has to be of PTFE.

h) Any dilution extractive system must have CO2 measurement facility at

source/stack and measuring point/instrument end to prove the correctness
of the selected dilution ratio.

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
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REQUIREMENTS AND
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FGD System SPECIFICATIONS

Specification
SO2 Analsyer NOx Analsyer CO2 Analsyer CO Analsyer
Requirements
Principle of Pulsed/UV Chemiluminesc Gas Filter Gas Filter
measurement Fluorescence ence correlation Correlation
technology. technology. technology
Measurement 0-250 / 0-1500 0-250 / 0-1500 0 to 25% 0-100/ 0-
Range mg/Nm3 mg/Nm3 (selectable) 1000
(selectable) (selectable) mg/Nm3
(selectable)
Probe 0-300 deg C 0-300 deg C 0-300 deg C 0-300 deg C
operating
temp
Accuracy +/- 1% of +/- 1% of +/- 1% of +/- 1% of
lowest lowest lowest lowest
measurement measurement measurement measurement
range or better range or better range or better range or better
Linearity < 1% of lowest < 1% of lowest < 1% of lowest < 1% of lowest
measurement measurement measurement measurement
range range range range
Repeatability < 1% of lowest < 1% of lowest < 1% of lowest < 1% of lowest
measurement measurement measurement measurement
range range range range
Minimum < 0.5% of < 0.5% of < 0.5% of < 0.5% of
detection lowest lowest lowest lowest
limit measurement measurement measurement measurement
range range range range
Zero drift < +/-1% of < +/-1% of < +/-1% of < +/-1% of
lowest lowest lowest lowest
measurement measurement measurement measurement
range/week range/week range/week range/week
span drift < +/-1% of < +/-1% of < +/-1% of < +/-1% of
lowest lowest lowest lowest
measurement measurement measurement measurement
range/week range/week range/week range/week
Response time 100 sec 60 sec 90 sec 60 sec
(upto 95% of
full scale)
Sample gas 5 deg.C - 40 5 deg.C - 40 5 deg.C - 40 5 deg.C - 40
inlet deg.C deg.C deg.C deg.C
temperature to
analyser

10 Specific requirements for In-situ (Path) type SO2, NOx, CO2 & CO analysers

Specification SO2/NOx Analyser CO2 Analyser cum CO Analyser cum

Requirements cum monitor monitor monitor
Principle of Differential Optical Differential Optical IR absorption
Measurement Absorption Absorption
Spectroscopy Spectroscopy

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

Measurement 0-250 / 0-1500 0-25% (selectable) 0-100/ 0-1000

Range mg/Nm3 mg/Nm3
(selectable) (selectable)
Accuracy +/- 1% of lowest +/- 1% of lowest +/- 1% of lowest
measurement measurement measurement
range or better range or better range or better
Linearity < +/-1% of lowest < +/-1% of lowest < +/-1% of lowest
measurement measurement measurement
range range range
Repeatability < 1% of lowest < 1% of lowest < 1% of lowest
measurement measurement measurement
range range range
Minimum < 0.5% of lowest < 0.5% of lowest < 0.5% of lowest
detection measurement measurement measurement
limit range range range
Temperature < +/- 2%/10 Deg.C < +/- 2%/10 Deg.C < +/- 2%/10 Deg.C
Drift
Zero Drift < +/-1% of lowest < +/-1% of lowest < +/-1% of lowest
measurement measurement measurement
range/week range/week range/week
Span Drift < +/-1% of lowest < +/-1% of lowest < +/-1% of lowest
measurement measurement measurement
range/week range/week range/week
Response < 5 sec < 5 sec < 5 sec
time(up
to 90% of full
scale)
Probe 0 to 300 deg C 0 to 300 deg C 0 to 300 deg C
Operating
Temperature
Range
Accessories for Purging system to Purging system to Purging system to
purging system be provided with be provided with be provided with
heavy duty blowers heavy duty blowers heavy duty blowers
and shutter and shutter and shutter
mechanism for mechanism for mechanism for
automatic isolation automatic isolation automatic isolation
of lens during purge of lens during purge of lens during purge
air failure. air failure. air failure.
Temperature Automatic Automatic Automatic
compensation temperature temperature temperature
compensation to compensation to compensation to
be provided be provided be provided

11 Specific requirements for Particulate Matter (Dust density) monitor

Specification Requirements PARTICULATE EMISSION (Dust density

Stack Opacity) monitor
Type of Instrument Extractive type with reheating or dilution.
Principle of Measurement Scattered Light measurement

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
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FGD System SPECIFICATIONS

Measurement Range 0-50 mg/Nm3 / 0 - 300 mg/Nm3

(Programmable)
Accuracy +/- 2% of lowest measurement range or
better
Linearity < +/- 1% of lowest measurement range
Repeatability < 1% of lowest measurement range
Minimum detection limit < 1% of lowest measurement range
Temperature Drift < +/- 2%/10 Deg.C
Zero Drift < +/-1% of lowest measurement range/week
Span Drift < +/-1% of lowest measurement range/week
Analyser Response time(up to 90% < 5 sec
of full scale)
Operating Temperature Range for 0-300 deg.C
probe
Filter To be provided
Accessories purging system Purging system to be provided.
Temperature Temperature compensation to be provided, if
compensation/measurement applicable.
First site Calibration of the instrument should
be done based on the results of an extractive
IsoKinetic Test by the Contractor.

12 Specific requirements for Continuous On-line Mercury Analyser

S. No Parameter Details
1 Measurement Atomic Absorption Spectrometry/
Principle Atomic Fluorescence spectrometry.
Cold vapour Absorption Spectrometry
2 Range 0 - 35 microgram/Nm3
3 Accuracy +/- 1% of Span or better
4 Minimum detection 1 microgram/Nm3
limit

13 ULTRASONIC FLOW METER FOR FLUE GAS FLOW IN STACK

Type Microprocessor based with self-indicating type

diagnostic feature.

Output signal: 4-20 mA DC galvanically

isolated.

Digital signal transmission: RS232/ RS485

Modbus Protocol/ Ethernet TCP/IP protocol for
bidirectional communication of stack emission
data to Employer’s cloud server.
Mounting Style Transducers on the duct/stack
Transducer type and material Single pair of Corrosion resistant material to be
provided
Zero and Span adjustment To be provided

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
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FGD System SPECIFICATIONS

Flow measurement Instantaneous Flow rate as well as totalized

flow
Power supply Distribution To be arranged by the Contractor from
Employer’s terminal point.
Display/Indication Flow meter with LCD screen backlight based
local display and keypad . If required,
transmitter shall be suitably located away from
the sensor for better access and visibility.
Recording/Totalizing/Logging To be provided
Facilities
Diagnostics False signal tolerance , power supply failure etc
Protection class IP-65 or better
Ambient temperature -20 deg to +60 deg C
Accuracy +/- 2% of span or better
Electrical connection Plug and socket
Accessories All mounting hardware required like clamping
fixtures, mechanism to remove the transducers
online, interconnecting cables to DDCMIS, cables,
flexible conduits, junction boxes etc

Purging arrangement for Cleaning sensors to be

provided. Material of all fittings shall be SS316.
Software features Compensation for temperature and pressure and
any cross path errors. Programming,
configuration, shall be possible from front panel.

NOTES:-

1. Hot extractive sampling type/ Dilution extractive type SO2/NOx/CO/CO2

systems shall be provided with dual sample probes along with all required
accessories such as redundant heavy duty pumps with continuous rated
motors, moisture detection instruments/facility as per vendors proven
practice, pre-fabricated heated (for sampling type only) sample lines from
probes to analyser panel, solenoid valves, filters, coolers along with level
switch in gas coolers for auto draining purpose and flow meter etc as
applicable. Alternatively, permeation based dryer (located near the tapping
point) along with necessary sample conditioning devices to ensure full
protection, to avoid clogging & long life of permeation tubes may also be
provided in place of sample cooler. Also, healthiness status/alarm/indication
of permeation based dryer shall be provided in analyser panel.

2. In case IR based technique is used for SO2/NOx measurement, correction for

H2O cross interference shall be available in the analyser.

3. For O2 Analyser, the construction of the sensor shall be such that joints
between dissimilar materials are avoided to prevent formation of cracks.

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
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FGD System SPECIFICATIONS

14 Connectivity with DDCMIS and provision for bidirectional communication with

Employer’s Cloud Server

1. 4-20mA signals from all the above analysers, flow meters, stack gas
temperature, stack pressure, stack gas moisture, stack gas O2 shall be wired
to DCS of respective unit.

2. RS232/ RS485 Modbus protocol/ Ethernet TCIP/IP based bidirectional

communication with Employer’s Cloud Server as defined in Sub-section-
IIICC& I/ Section-VI/ Part-A.

All necessary hardware and software required at instrument end shall be provided by
the Contractor. Bidder shall connect analysers/instruments of his scope and provide
single point/port for connection with Employer’s cloud server. Further connection to
Employer’s cloud server shall be in the scope of Employer. Necessary details like
scheme, register addresses of analyzer, etc. shall also be provided by the Contractor for
implementation of above. The Contractor shall fully assist NTPC’s agency involved in
implementation of above connectivity.

All the accessories and cables required for connecting Analysers outputs to DCS and
provision of bidirectional communication as defined above shall be provided by
Contractor on as required basis.

Pressure Transmitter & Flow Transmitter

S No. Features Essential/Minimum Requirements

1 Type of FOUNDATION Fieldbus/PROFIBUS PA based output
Transmitter
2 Accuracy ± 0.060 % of calibrated range (minimum) for calibrated
range greater than 400 mmwc.

+0.065% of calibrated range (minimum) for calibrated

range greater than 250 kg/cm2.

± 0.10 % of calibrated range (minimum) for calibrated

range less than 400 mmwc.
3 Stability 0.25 % of calibrated range for 10 years for calibrated
range greater than equal to 400 mmwc on standard
conditions of manufacturer.

0.2 % of calibrated range for 1 years for calibrated range

less than 400 mmwc on standard conditions of
manufacturer.

0.15% of calibrated range for 5 years for DPT with static

pressure greater than 250 kg/cm2.
4 Turn down 50:1 for greater than or equal to span of 400mmwcl.

20:1 for span below 400mmwcl.

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
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REQUIREMENTS AND
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

10:1 for span greater than 250 kg/cm2

(Above mentioned (2, 3, 4) parameters/features of offered models shall be strictly as
defined in standard published catalogue of the manufacturer only).
5 Housing Weather proof as per IP-67, metallic housing with
durable corrosion resistant coating
6 Electrical ½” NPT(F) FOUNDATION Fieldbus/PROFIBUS PA
connection compatible
7 Process connection ½” NPT (F)
8 Operating Ambient 85 deg C without display.
temperature 70 deg C with display.
Overpressure 150% of max operating pressure
9 Accessories -Diaphragm seal, pulsation dampeners, syphon etc. as
required by service and operating condition.

-2 valve manifold for absolute & gauge pressure

transmitters, -3-valve for DP and 5 valve manifold for
level/flow applications.

-The valve manifold shall be non-integral type.

-For hazardous area, enclosure as described in NEC

article 5.
10 Mounting 2 inch pipe mounting with Enclosure/Rack/Canopy.
11 Diagnostics & Self-Indicating feature and digital display on transmitter
display
12 Certificates Successful bidder shall give test certificates complying to
NABL norms
Notes
- For primary air/ secondary air/flue gas/ furnace pressure applications, DP type
transmitters shall be provided for pressure measurement below 2000 mmwc.
- LVDT type is not acceptable.
- Where the process fluids are corrosive, viscous, solid bearing or slurry type,
diaphragm seals shall be provided. Parts below the diaphragm shall be removable for
cleaning. The entire volume above the diaphragm shall be completely filled with an
inert liquid suitable for the application.

Temperature Transmitter

15 Single Input /Dual Input Temperature transmitter

Temperature transmitter shall be provided which shall be fully compatible with

thermocouples and RTDs being provided by the contractor. Temperature
compensation for thermocouples shall be performed in the temperature transmitter
itself. Transmitters shall be capable of withstanding ambient temperature up to 85
deg C.

Following specifications are applicable for dual input/single input temperature

transmitter.

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
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FGD System SPECIFICATIONS

S No. Features Essential/Minimum Requirements

1 Output FOUNDATION fieldbus /PROFIBUS PA
Same transmitter shall be capable to handle
2 Input
Pt-100 RTD, Thermocouples –K, R & ,S types
Weather proof as per IP-67, metallic housing
3 Housing
with durable corrosion resistant coating
½” NPT(F) FOUNDATION
4 Electrical connection Fieldbus/PROFIBUS PA
compatible
Self-Indicating feature and digital display on
5 Diagnostics & display
transmitter
Operating Ambient 85 deg C without display.
6
temperature 70 deg C with display.
7 Mounting 2 inch pipe mounting with Canopy.
As required by service and operating
8 Accessories
condition.
9 Composite Accuracy (Refer note 2 )
RTD =<0.25% of 0-250 deg C span
T/C-K
=<0.2% of 0-600 deg C span
type
CJC accuracy (for thermocouples) shall be =<
1 deg C
Notes:
1. In case of failure (open or burn-out) of RTD/thermocouple, transmitter shall
provide low temperature output.
2. Dual input temperature transmitter shall have bump less changeover facility to
second sensor in case first sensor fails. This changeover is to be alarmed.
3. Composite accuracy is to be calculated as summation of all applicable accuracies
of temperature transmitter for converting sensor input to output (e.g., basic
accuracy, digital accuracy, etc.) and temperature effect on these accuracies at
ambient temperature of 50 deg C, based on the figure/ formula given in the
standard product catalogue for span as specified above for various types of
temperature elements specified. All such accuracy/ temperature effect figures in
catalogue shall be first converted to deg C, and then percentage of this converted
accuracy in specified span shall be calculated to compare with the specified
composite accuracy figures. All temperature transmitters shall be interchangeable
(i.e. can be used for either RTD or thermocouple) and composite accuracy shall be
met for each type of input as specified above.
4. Above mentioned parameters/features of offered models shall be strictly as
defined in standard published catalogue of the manufacturer only.
5. Dual input temperature transmitters can also be accepted in place of single input
TT.

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
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FGD System SPECIFICATIONS

16 ANALYSER INSTRUMENTS (OTHER THAN CEMS)

16.1 Common requirements:-

Microprocessor based with self-indicating type

1 Type diagnostic feature. Output signal: 4-20 mA DC
galvanically isolated. Binary Signal: 2NO+2NC
Digital display with reading in engineering units.
Display of the measurement values as well as all the
2 Display
information required for checking/maintenance of the
analyzer.
Zero & span
3 To be provided for all selectable ranges.
Adjustment
4 Ambient temp. 0-50°C unless defined otherwise.
Weather protection for analyser mounted inside
Analyser enclosure
5 analyser panel shall be IP-22 or better. For all other
Type/Material
analysers, weather protection class shall be IP-55.
6 Calibration Auto & Manual (from Remote).
To be arranged by Contractor subject to Employer’s
7 Power Supply
approval.
i) All interconnection tubing and cabling between
probe and analyser / analyser panel and cabling
from analyser/ analyser panel to FGD Control
system are to be provided by Contractor.
8 Others
ii) All the calibration gases (certified cylinder)
required for one year continuous operation shall be
provided. The calibration gas container material
shall not contaminate the calibration gas.
Compliance to
9 USEPA, TUV, MCERTS or equivalent standards
standards
SO2/NOx :- Hot-extractive sampling type/ Dilution
Extractive/ Insitu (Path) type

Note:- For Hot extractive sampling type and Dilution

extractive sampling type system – The components
involved in sample handling system shall be imported
& further, Sample handling system design shall be
10 Type of Technology vetted by Original Analyzer Manufacturer (OAM).
Necessary documents shall be furnished during
detailed engineering in order to establish the above
requirement. Technical expert of OAM shall witness
testing of sample handling system and validate it.
Alternatively sampling handling system assembled at
Original Analyzer manufacturer (OAM) works shall
also be accepted.
Measurement range,
11 As per FGD system design and process parameters.
tapping point

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
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FGD System SPECIFICATIONS

Note: Analyzers shall be placed inside Air conditioned CONTAINERISED ROOM

(PORTABLE CABIN) or Air conditioned analyzer room provided by the contactor.
For detailed specification of CONTAINERISED ROOM (PORTABLE CABIN),
Contractor to refer Sub section IIIC-11, Part-B, Section-VI of technical specification.

16.02 Specific requirements for Hot-extractive sampling type SO2 analysers

Specification Requirements SO2 Analyser

Type of Instrument Sampling type - Hot Extractive type
Principle of Measurement Radiation absorption
Accuracy +/- 1% of lowest measurement range or
better
Linearity < +/-1% of lowest measurement range
Repeatability < 1% of lowest measurement range
Minimum detection limit < 0.5% of lowest measurement range
Temperature Drift < +/- 2%/10 Deg.C
Zero Drift < +/-1% of lowest measurement range
/week
Span Drift < +/-1% of lowest measurement range
/week
Analyser Response time (up to 90% of < 5 secs
full scale)
Operating Temperature Range for 0-300 deg.C
probe
Filter Ceramic 3.5 Micron
Accessories for purging system Purging system including Auto Scavenging
facility shall be provided
Sample gas inlet temperature to Temperature of the sample gas inlet to
analyser analyser shall be controlled before analyser
as per manufacturer standards.

16.03 Specific requirements for Dilution Extractive type SO2 Analsyers

The design of the Dilution Extractive type system shall be satisfying the following
requirements. The sampling system shall consist of In-situ dilution probe, dilution
probe controller, sample conditioning system like air drier and filters etc and other
accessories meeting the following requirements as a minimum. All system
components and accessories required for completion of this system shall be
furnished although these may not be individually specified herein. Following are the
minimum requirements:

a) Modular Electronic Design.

b) Heatless Air dryer with inlet filter, chemical scrubbers to remove traces of
NOx/CO2/SO2 from air and accumulator.

c) Self test facility with screen display.

d) Protection of instrument in case ambient or surrounding temp going high beyond

stipulated limit.

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
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FGD System SPECIFICATIONS

e) The following are the minimum requirement for the probe:-

 Flange and counter flange for inserting probe

 Flange and counter flange for inserting probe
 Coarse and Fine Filters
 Critical orifice
 Automatic blow back or purging facility
 SS316L probe material

f) Further dilution probe controller shall be provided with the ability to control
dilution ratio.

g) Unheated umbilical chord to be provided for transportation of the diluted

sample, zero air, vacuum pressure, and calibration gas. This chord has to be a
single bundle in FRLS PVC outer sheath. The sample line has to be of PTFE.

Specification Requirements SO2 Analyser

Principle of measurement Pulsed/UV Fluorescence technology.
Probe operating temp 0-300 deg C
Accuracy +/- 1% of lowest measurement range or
better
Linearity < +/-1% of lowest measurement range
Repeatability < 1% of lowest measurement range
Minimum detection limit < 0.5% of lowest measurement range
Zero drift < +/-1% of lowest measurement
range/week
span drift < +/-1% of lowest measurement
range/week
Response time (up to 95% of full scale) 100 sec
Sample gas inlet temperature to 5 deg.C - 40 deg.C
analyser

16.4 Specific requirements for In-situ (Path) type SO2 analysers

Specification Requirements SO2 Analyser cum monitor

Principle of measurement Differential Optical Absorption
Spectroscopy
Accuracy +/- 1% of lowest measurement range or
better
Linearity < +/-1% of lowest measurement range
Repeatability < 1% of lowest measurement range
Minimum detection limit < 0.5% of lowest measurement range
Temperature Drift < +/- 2%/10 Deg.C
Zero Drift < +/-1% of lowest measurement
range/week
Span Drift < +/-1% of lowest measurement
range/week

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

Response time(up to 90% of full scale) < 5 sec

Probe Operating Temperature Range 0 to 300 deg C
Accessories for purging system Purging system to be provided with heavy
duty blowers and shutter mechanism for
automatic isolation of lens during purge air
failure.
Temperature compensation Automatic temperature compensation to be
provided

16.5 pH Analyser

Sl.No. Specification Requirements : pH Analyser

a) Type : Cell – flow through
b) Accuracy : < ± 1% of reading
Range : 0 – 14 pH freely programmable (For
c)
others)
d) No. of steams : Single
e) Temp. compensation : Automatic
f) Successful bidder to confirm validity of the consumable probe of pH
Analyser, it should start from the date of installation for max.6-8 months
g) Successful bidder has to give guarantee of Two point calibration

16.6 Moisture Analyser

Specification Requirements Moisture Analyser

Sl.No.
a) Sensor Type Aluminium Oxide sensor
b) Measurement Accuracy ± 2 deg C dew point
c) Measurement Range 0-100ppm ………0-3000ppm
c) Repeatability 0.5 deg C dew point
d) Response time 5 min (dry to wet)
e) Operating Humidity 0 to 100 % RH
f) Sensor Operating Temp 0 to 60 deg C
g) Temp. compensation Across operating temperature range

17 CONTAINERISED ROOM (PORTABLE CABIN)

17.1 Enclosure rating & Design

 For the purpose of design of equipment/systems, an ambient temperature of 50

deg. Centigrade and relative humidity of 95% shall be considered. The
equipment shall operate in a highly polluted environment.

 CONTAINERISED ROOM (PORTABLE CABIN) shall be designed for outdoor

application.

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
STAGE - III Supervision of Erection & Commissioning) –
FGD System SPECIFICATIONS

18 General Description

The Containerized room shall meet all requirements of analyzers and analyser
panels.

 Containerized room would be closed type, weather proof and made of CRCA
steel construction.
 It shall withstand heavy monsoon, heavy rain and heavy wind condition.
 Doors would be equipped with hydraulic door closer.
 Each door shall be fitted internally with "panic” bar exit handles and externally
with key lockable handles. Exterior handles will be of stainless steel.
 Door will be provided with heavy-duty latches, hinges, door stop and pad lock.
 Personnel doors would be provided with canopy with necessary rubber
gaskets to prevent the entry of water.
 The Containerized room shall be air-conditioned to maintain an air
temperature less than 24°C. Redundancy/Standby AC of suitable ratings
should be considered for porta cabins
 The Containerized room shall be designed as multiple modular transportable
units; they shall be modularized for ease of separation for transport and quick
re-assembly at site.
 Split Modules shall be designed for lifting as single piece along with
equipment’s.
 Lifting lugs should be designed to carry the weight of the Containerized room
including all the Electrical panel boards.
 Suitable lifting provisions and accessories shall be provided along with
Containerized room.

19 Structural Arrangements

19.1 Frame

The pre-fabricated enclosure(s) frame shall be constructed as a rigid, self-supporting

steel structure. Structural steel design and fabrication shall be in accordance with
AISC Manual of Steel Construction.
Construction Materials

* Steel: load bearing members: : IS 10748; Grade IV

* Structural Steel : IS 2062.
* Side-end walls & roof panels : IS 2062.
* Square/Rectangular hollow sections: JIS STKR-41 / IS 1161

The roof framing and the columns shall be designed to support any additional dead
load suspended from the roof such as air conditioning duct, false ceiling, cable trays,
light fixtures, and piping.

The pre-fabricated enclosure(s) floor framing (skid) shall be fabricated from ASTM
A36/ JIS 3101 or Equivalent steel members to form a rigid rectangular frame. The
frame shall be braced with cross members as required to support the equipment
installed in the building.

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
REQUIREMENTS AND
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FGD System SPECIFICATIONS

The pre-fabricated enclosure(s) shall be analyzed to resist both dead and live loads
expected during construction, transportation, installation, and operation.

The pre-fabricated enclosure(s) shall be designed for the maximum in-place

Structural loading consisting of the structure, equipment dead weight, all operating
loads, and the maximum environmental loads

19.2 Shell and Base frame

The outer shell of the Containerised room shall be manufactured with 1.6mm sheet.
The main load bearing members such as posts, base members, bottom and top side
rails, end rails headers are selected based on approved structural analysis. Lifting
hooks shall be provided at minimum at corners. The adequacy of the same shall be
verified by structural analysis.

Adequate number of doors with reinforced framework and locking device shall be
provided as per requirement. The door has to be effectively sealed against water
ingress in closed condition. The shell structure is to be rigid enough to withstand
rough handling rigorous transportation hazards etc. and able to stand
flexing/distortion even when placed on uneven ground.
Base members are to be made from press formed steel sections of appropriate
Geometry of required thickness. Base frame design shall be accommodating the
panels provided inside the room.

Panel mounting structure shall be fabricated and drilled with holes for fixing bolts
for the site erection panel during site erection. 16 gauge galvanized sheet for cable
protection at the bottom sheeting plate.

19.3 Side & End Walls

External walls are to be vertically corrugated 1.6 mm thick GI/CRCA conforming to

IS 2062/IS 513.
The corrugated panels shall form entire side wall and the assembled side wall shall be
assembled with the peripheral frame members.

19.4 Roof

The roof has to be manufactured from 1.6 mm thick GI/CRCA conforming to IS 2062.
The roof will have sloping arrangement for effective drainage.Sloping edge should
be considered with extra sheet of minimum 5-10 inches from all sides.

19.5 Flooring System

Floor plating shall be covered with a non-skid surface. The exposed floor shall be
covered with a insulating material as per statutory requirement.

19.6 Insulation

Containerised room will be insulated on sides, end walls, roof & doors with 50mm
thick Glass Wool/Rockwool insulation. Densities should be 48 kg/m3

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
RSTPP ANALYSERS PACKAGE FOR FGD (Supply and
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FGD System SPECIFICATIONS

19.7 Inner Paneling

Interiors of the Containerised room shall be aesthetically finished so as to give a

pleasing appearance with high quality workmanship. All joints shall be neatly
finished. For side, roof and end walls paneling will be done with 1.6mm thick
Galvanized sheet.

19.8 Doors

All exterior doors shall be of weather-proof construction with four sided frames. All
exterior hardware shall be stainless steel, including, but not limited to hinges. Hinges
shall be concealed type. If non concealed type then the hinge should be tamper proof
arrangement.

Doors shall be fabricated from aluminum with SS panic hardware. Doors shall be
lockable with one key for all doors. Provide four keys total.

Two doors of Aluminum shall be provided unless otherwise specified. One

equipment door and one personnel door shall be provided. The size of equipment
door shall be as per equipment sizing. One personnel door minimum 1.2M x 2.5M
shall be provided. Doors shall be of 4 hours fire rated.

19.9 Protective Coating Procedure

All steel structure members shall be cleaned prior to finishing. Standard interior
finish shall be white. After welding do abrasive blast – SA 2 ½ thereafter below
process to be adapted

A) Internal Panels Painting (Walls & Roof) :-

Powder Paint Sheet

 Surface Preparation/Primer :Intercure 200HS Min 150 um

 Finish : Interthane 990 Min 50 um
 Total Minimum DFT shall be 200 um

B) Exterior Panels Painting (Walls, Roof & Base structure) :

Powder Paint Sheet

 Surface Preparation/Primer : Interzinc 52 Min 75 um

 Coating : Interguard 475HS Min 200 um
 Finish : Interthane 990 Min 50 um
 Total Minimum DFT shall be 325 um

Both Interior and exterior panels, roof and base frame will be painted in colour shade
of RAL5012.

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
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FGD System SPECIFICATIONS

19.10 Grounding

Internal Earthing inside enclosure with suitable cross sectional GI flats. The building
shall be furnished complete with ground pads which shall bond of electrical
equipment enclosure frames and ground buses to the building frame at the exterior
base in two locations and at opposite ends of the building so as to provide a
continuous path to ground. The Grounding system shall connect to each end of the
ground bus in each assembly of installed equipment.

19.11 Lighting

The lighting system shall maintain minimum levels as given below:

Lux level shall be 200 inside the Containerised room and outside platforms/ stairs
shall be 100 Lux.

All luminaries shall be suitable for industrial duty and provided with IP65 housings
for outdoor enclosures and IP54 for indoor enclosures. All fittings shall be
weatherproof and able to withstand direct hosing. The wiring for lighting shall be
routed through GI conduits either concealed or the wall of the enclosure External
light around Containerised room only shall be considered. All Light Fixtures shall be
high efficiency LED type only.

19.12 Lifting Tools and Tackles

Suitable lifting system shall be designed and furnished. The system will consist of a
spreader bar, slings, shackles and other tools to lift the equipment building in one
piece A lifting system installation & operational diagram shall accompany all
shipping documents.

19.13 DIMENSIONS

Bidder to consider at least clear space of 4x3x3.5 (LxBxH) for locating all the
analysers and their accessories including UPS and Calibration equipments etc.,

20 List of Mandatory Spares

REFER SECTION – VI

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 CEMS FOR CHIMNEY & INLET GAS TECHNICAL
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FGD System SPECIFICATIONS

21 TENDER DRAWINGS

The drawings listed below and forming part of Specifications shall supplement the
requirements specified herein. The scope and terminal points of the equipment to be
furnished under this package shall be as identified in these drawings and read in
conjunction with text of the specification

1 CHIMNEY –GENERAL ARRANGEMENT Drg.No. 3140-1095-PVC-A-002 Rev R0

Indicating tapping point locations

2 Extract of FGD Layout indicating SKETCH-1 OF F-044

Tentative location of Porta cabin

3. P&ID of Flue gas system 3140-1095-PVM-F-079 Sh.No4 R04

4. CPCB DATA POLICY FOR REFERENCE -

5. Indicative VENDOR LIST & QAP -

SECTION – III…………………………VOID

SECTION – IV…………………………VOID

SECTION – V…………………………..VOID

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 CEMS FOR CHIMNEY & INLET GAS
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STAGE - III Commissioning & supervision of Erection) –
FGD System

SECTION – VI

MANDATORY SPARES

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 CEMS FOR CHIMNEY & INLET GAS
RSTPP ANALYSERS PACKAGE FOR FGD (Supply, MANDATORY SPARES
STAGE - III Commissioning & supervision of Erection) –
FGD System

1. GENERAL

The Bidder shall include in his scope of supply all the necessary Mandatory spares,
Start-up and commissioning spares and recommended spares. These shall be
indicated in the relevant schedules of the Bid Forms & Price Schedules. The
general requirements pertaining to Mandatory spares, Start-up and commissioning
spares and Recommended spares is given in this Section.

2. DESCRIPTION OF VARIOUS TYPE OF SPARES

2.1. MANDATORY SPARES

a) The list of mandatory spares considered essential by the

Client(EPIL)/NTPC is indicated in the list enclosed to this Section.

b) The bidder shall indicate the prices for each and every item (except for
items not applicable to the bidders design) in the „Price Schedule of
Mandatory Spares‟ whether or not he considers it necessary for the
Client(EPIL)/NTPC to procure such spares.

c) If the bidder fails to comply with the above or fails to quote the price of any
spare item, the cost of such spares shall be deemed to be included in the
contract price. The bidder shall furnish total population of each item in the
Bid Forms & Price Schedules. Whenever the quantity is mentioned in “sets”
the bidder has to give the item details and prices of each item.

d) Whenever the quantity is indicated as a percentage, it shall mean

percentage of total population of that item in the station (project),
unless specified otherwise, and the fraction will be rounded off to the next
higher whole number.

e) Wherever the requirement has been specified as a „set‟ (marked by **) it

will include the total requirement of the item for a unit, module or the
station as specified.

f) Where it is specified as „set‟ (marked by*) it would mean the requirement for
the single equipment / system as the case may be. Also one set for the
particular equipment. e.g. „set‟ of bearings for a pump would include the total
number of bearings in a pump. Also the „set‟ would include all components

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required to replace the item; for example, a set of bearings shall include all
hardware normally required while replacing the bearings.

g) The assembly / sub assembly which have different orientation (like left hand,
right hand, top or bottom), different direction of rotation or mirror
image positioning or any other regions which result in maintaining two
different sets of spares to be used for subject assembly / sub-
assembly shall be considered as different type of assembly/sub-assembly.

h) The Client (EPIL)/NTPC reserves the right to buy any or all the mandatory
spare parts.

i) The prices of mandatory spares indicated by the Bidder in the Bid

Proposal/ Bid forms sheets shall be used for bid evaluation purposes.

j) All mandatory spares shall be delivered at site at least two months before
scheduled date of initial operation of the first unit. However, spares shall not
be dispatched before dispatch of corresponding main equipments.

k) Wherever quantity is specified both as a percentage and a value, the Bidder

has to supply the higher quantity until & unless specified otherwise.

2.2. RECOMMENDED SPARES

a) In addition to the spare parts mentioned above, the Contractor shall

also provide a list of recommended spares for 3 years of normal operation of
the plant/equipment and indicate the list and total prices in relevant
schedule of the Bid Forms / Price Schedules.

b) This list shall take into consideration the mandatory spares specified
in this Section and should be independent of the list of the mandatory spares.
The Client(EPIL)/NTPC reserves the right to buy any or all of the
recommended spares.

c) The recommended spares shall be delivered at project site at least two

months before the scheduled date of initial operation of first unit.
However, the spares shall not be dispatched before the dispatch of the main
equipment.

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d) Prices of recommended spares will not be used for evaluation of the bids.

e) The price of these spares will remain valid up to 6 months after placement of
Notification of Award for the main equipment. However, the Contractor shall
be liable to provide necessary justification for the quoted prices for
these spares as desired by the Client(EPIL)/NTPC.

2.3. START-UP & COMMISSIONING SPARES

a) Start-up & commissioning spares are those spares which may be required
during the start-up and commissioning of the equipment/system. All spares
used till the Plant is handed over to the Client(EPIL)/NTPC shall come
under this category.

b) The Contractor shall provide for an adequate stock of such start up and
commissioning spares to be brought by him to the site for the plant erection
and commissioning. They must be available at site before the equipments are
energized. The unused spares, if any, should be removed from site only after
the issue of "Taking Over certificate” by Client(EPIL)/NTPC. All start up spares
which remain unused at the time shall remain the property of the Contractor.

c) In case the equipment erection / installation and commissioning is carried

out by Client (EPIL)/NTPC through an another agency / contractor, the
equipment supplier shall be intimated about the time schedule of erection /
commissioning and the equipment supplier shall ensure timely availability of
these commissioning/start-up Spares at site.

2.4. The Bidder shall include in his scope of supply all the necessary Mandatory spares,
Start-up and commissioning spares and indicate these in the relevant schedules of
the Bid forms/Price Schedules.

2.5. The general requirements pertaining to supply of these spares is given below.

a) The Contractor shall indicate the service expectancy period for the
spare parts (both mandatory and recommended) under normal operating
conditions before replacement is necessary.

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b) All spares supplied under this contract shall be strictly inter-changeable

with the parts for which they are intended for replacements. The spares shall
be treated and packed for long storage under the climatic conditions
prevailing at the site e.g. small items shall be packed in sealed
transparent plastic with desiccators packs as necessary.

c) All the spares (both recommended and mandatory) shall be

manufactured along with the main equipment components as a
continuous operation as per same specification and quality plan.

d) The Contractor will provide Client (EPIL) with cross-sectional drawings,

catalogues, assembly drawings and other relevant documents so as to enable
the Client to identify and finalize order for recommended spares.

e) Each spare part shall be clearly marked or labelled on the outside of the
packing with its description. When more than one spare part is packed in a
single case, a general description of the content shall be shown on the outside
of such case and a detailed list enclosed. All cases, containers and other
packages must be suitably marked and numbered for the purposes of
identification.

f) All cases, containers or other packages are to be opened for such examination
as may be considered necessary by the Client (EPIL)/NTPC.

g) The Contractor will provide the Client (EPIL)/NTPC with all the addresses and
particulars of his sub-suppliers while placing the order on vendors
for items/components/ equipments covered under the Contract and will
further ensure with his vendors that the Client (EPIL)/NTPC, if so desires, will
have the right to place order for spares directly on them on mutually agreed
terms based on offers of such vendors.

h) The Contractor shall warrant that all spares supplied will be new and in
accordance with the Contract Documents and will be free from defects in
design, material and workmanship.

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i) In addition to the recommended spares listed by the Contractor, if the

Client (EPIL)/NTPC further identifies certain particular items of spares, the
Contractor shall submit the prices and delivery quotation for such spares
within 30 days of receipt of such request with a validity period of 6
months for consideration by the Client (EPIL)/NTPC and placement of
order for additional spares if the Client (EPIL)/NTPC so desires.

j) Long term Availability:

i) The Contractor shall guarantee the long term availability of spares to the
Client (EPIL)/NTPC for the full life of the equipment covered under the
Contract.

ii) The Contractor shall guarantee that before going out of production
of spare parts of the equipment covered under the Contract, he shall
give the Client (EPIL)/NTPC at least 2 years advance notice so that the
latter may order his bulk requirement of spares, if he so desires. The
same provision will also be applicable to Sub-contractors.

iii) Further, in case of discontinuance of manufacture of any spares by

the Contractor and/or his Sub- Contractors, Contractor will provide
the Client (EPIL)/NTPC, two years in advance, with full manufacturing
drawings, material specifications and technical information including
information on alternative equivalent makes required by the Client
(EPIL)/NTPC for the purpose of manufacture/procurement of such
items.

3. LIST OF MANDATORY SPARES

S. No Description Quantity

Continuous Emission Monitoring System

a)
(CEMS)
1 no. complete analyser of each
1 Analyzer for SO2, NOx, CO2, CO
type and model.
1 no. complete instrument along
2 Flue gas flow measurement instrument
with sender/receiver unit.
3 Analyser for Particulate Matter 1 no. complete analyser

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4 Analyser for Mercury 1 no. complete analyser

5 O2 Analyser 1 no. complete analyser
Electronic card assembly/ PCBs
10% of each type, model and
6 Moisture/condensate monitor, power supply
rating
Modules
20% of each type, model, rating
7 Set of gaskets/O-rings/ seals
and size
20% of each type, model, rating
8 Temp. Sensor
and size
Heater assembly, Coolers/dryers, Pumps, 200% of each type, model, rating
9
and etc. size
Complete Probe with shield assembly (Not
10 1 no. of each type and model
applicable for In situ- path)
2 nos. of each type, model and
11 Solenoids
rating
100% of each type, model and
12 Filters, light source, sensor, detector, etc
rating
Calibration gases, Calibration cell and other One year supply of all types and
13
consumables for calibration: - ranges
14 Blower assembly . 1 no. of each type, size and rating
b) Other FGD Analysers
1 no. complete analyser of each
14 Analyzer for SO2, pH
type and model.
200% of each type, model, rating
15 Set of gaskets/O-rings/ seals
and size
20% of each type, model, rating
16 Temp. Sensor
and size
Heater assembly, Coolers/dryers, Pumps, 20% of each type, model, rating
17
and etc.. size
100% of each type, model and
18 Filters, light source, sensor, detector, etc.
rating
Complete Probe with shield assembly (Not
19 1 no. of each type and model
applicable for In situ- path)
2 nos. of each type, model and
20 Solenoids
rating
Electronic card assembly/ PCBs
10% of each type, model and
21 Moisture/condensate monitor, power supply
rating
Modules
Calibration gases, Calibration cell and other One year supply of all types and
22
consumables for calibration: - ranges

NOTE:

1. Wherever set is mentioned, one set of the spares of that item shall be for
complete replacement of that particular item for one equipment.

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2. Any fraction of an item shall mean the next higher integer.

3. Wherever quantity has been specified as percentage (%), the quantity of

mandatory spares to be provided by contractor shall be the specified
percentage (%) of the total population of the plant. In case the quantity so
calculated happens to be fraction, the same shall be rounded off to next
higher whole number.

4. Wherever the quantities have been indicated for each type, size, thickness,
material, radius, range etc., these shall cover all the items supplied and
installed and the breakup for these shall be furnished in the bid.

5. In case spares indicated in the list are not applicable to the particular design
offered by the bidder, the bidder should offer spares applicable to offered
design with quantities generally in line with the approach followed in the
above list

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SECTION – VII -- INDEX

GENERAL TECHNICAL REQUIREMENTS
1.00.00 INTRODUCTION ............................................................................................................ 3
2.00.00 BRAND NAME ................................................................................................................ 3
3.00.00 BASE OFFER & ALTERNATE PROPOSALS ............................................................... 3
4.00.00 COMPLETENESS OF FACILITIES ................................................................................ 3
5.00.00 RULES, REGULATIONS, CODES & STANDARDS ................................................... 4
6.00.00 EQUIPMENT FUNCTIONAL GUARANTEE ............................................................. 7
7.00.00 DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITY
CONSIDERATIONS........................................................................................................ 7
8.00.00 DOCUMENTS, DATA AND DRAWINGS TO BE FURNISHED BY
CONTRACTOR ............................................................................................................... 8
9.00.00 TECHNICAL CO-ORDINATION MEETING............................................................ 25
10.00.00 DESIGN IMPROVEMENTS .......................................................................................... 26
11.00.00 EQUIPMENT BASES ..................................................................................................... 26
12.00.00 PROTECTIVE GUARDS ............................................................................................... 27
13.00.00 LUBRICANTS, SERVO FLUIDS AND CHEMICALS ............................................... 27
14.00.00 LUBRICATION .............................................................................................................. 27
15.00.00 TERIAL OF CONSTRUCTION .................................................................................... 27
16.00.00 RATING PLATES, NAME PLATES & LABELS ........................................................ 28
17.00.00 TOOLS AND TACKLES................................................................................................ 29
18.00.00 WELDING ........................................................................................................................ 29
19.00.00 COLOUR CODE FOR ALL EQUIPMENTS/ PIPINGS/ PIPE SERVICES ............ 29
20.00.00 PROTECTION AND PRESERVATIVE SHOP COATING ....................................... 30
21.00.00 QUALITY ASSURANCE PROGRAMME ................................................................... 31
22.00.00 GENERAL REQUIREMENTS - QUALITY ASSURANCE ....................................... 32
23.00.00 QUALITY ASSURANCE DOCUMENTS ................................................................... 38
24.00.00 PROJECT MANAGER‟S SUPERVISION ..................................................................... 40
25.00.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES ............................. 40
26.00.00 PRE-COMMISSIONING AND COMMISSIONING FACILITIES........................... 44
27.00.00 TAKING OVER .............................................................................................................. 47
28.00.00 TRAINING OF NTPC'S PERSONNEL ....................................................................... 47
29.00.00 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION ....................... 48

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30.00.00 NOISE LEVEL................................................................................................................. 48

31.00.00 PACKAGING AND TRANSPORTATION ................................................................ 48
32.00.00 ELECTRICAL EQUIPMENTS/ENCLOSURES ......................................................... 49
33.00.00 INSTRUMENTATION AND CONTROL ................................................................... 49
34.00.00 ELECTRICAL NOISE CONTROL ................................................................................ 50
35.00.00 SURGE PROTECTION FOR SOLID STATE EQUIPMENT ..................................... 50
36.00.00 INSTRUMENT AIR SYSTEM ....................................................................................... 50
37.00.00 TAPPING POINTS FOR MEASUREMENTS ............................................................. 51
38.00.00 SYSTEM DOCUMENTATION..................................................................................... 51
39.00.00 MAINTENANCE MANUALS OF ELECTRONIC MODULES ................................. 52
ANNEXURE- I .................................................................................................................................... 79
ANNEXURE- II .................................................................................................................................. 80
ANNEXURE- III ................................................................................................................................. 81
ANNEXURE- IV ................................................................................................................................. 82
ANNEXURE- V .................................................................................................................................. 83
ANNEXURE- VI ................................................................................................................................. 84
ANNEXURE- VII................................................................................................................................ 86

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1.00.00 INTRODUCTION

This part covers technical requirements which will form an integral part of the
Contract. The following provisions shall supplement all the detailed
technical specifications and requirements brought out in the Technical
Specification and the Technical Data Sheets.

2.00.00 BRAND NAME

Whenever a material or article is specified or described by the name of a particular

brand, manufacturer or vendor, the specific item mentioned shall be understood to be
indicative of the function and quality desired, and not restrictive; other
manufacturer's products may be considered provided sufficient information
is furnished to enable the Client (EPIL) / NTPC to determine that the products
proposed are equivalent to those named.

3.00.00 BASE OFFER & ALTERNATE PROPOSALS

The Bidder's proposal shall be based upon the use of equipment and material
complying fully with the requirements specified herein. It is recognised that the
Contractor may have standardized on the use of certain components, materials,
processes or procedures different than those specified herein. Alternate proposals
offering similar equipment based on the manufacturer's standard practice will also be
considered, provided the base offer is in line with technical specifications and such
proposals meet the specified design standards and performance requirement and
are acceptable to the Client (EPIL) / NTPC. Sufficient amount of information for
justifying such proposals shall be furnished to Client (EPIL) / NTPC along with the
bid to enable the Client (EPIL) / NTPC to determine the acceptability of these
proposals.

4.00.00 COMPLETENESS OF FACILITIES

4.01.00 Bidders may note that this is a contract inclusive of the scope as indicated
elsewhere in the specification. Each of the plant shall be engineered and designed in
accordance with the specification requirement. All engineering and associated
services are required to ensure a completely engineered plant shall be provided.

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4.02.00 All equipments furnished by the Contractor shall be complete in every respect, with all
mountings, fittings, fixtures and standard accessories normally provided with such
equipment and/or those needed for erection, completion and safe operation of
the equipment and for the safety of the operating personnel, as required by applicable
codes, though they may not have been specifically detailed in the respective
specifications, unless included in the list of exclusions.

All same standard components/ parts of same equipment provided, shall

be interchangeable with one another.

For the C&I systems, the Contractor shall be required to provide regular information
about future upgrades and migration paths to the Client (EPIL) / NTPC.

5.00.00 RULES, REGULATIONS, CODES & STANDARDS

5.01.00 In addition to the codes and standards specifically mentioned in the relevant
technical specifications for the equipment / plant / system, all equipment parts,
systems and works covered under this specification shall comply with all
currently applicable statutory regulations and safety codes of the Republic of
India, NTPC rules/codes of practices as well as of the locality where they will
be installed, including the following:

a) Indian Electricity Act

b) Indian Electricity Rules

c) Indian Explosives Act

d) Indian Factories Act and State Factories Act

e) Indian Boiler Regulations (IBR)

f) Regulations of the Central Pollution Control Board, India

g) Regulations of the Ministry of Environment & Forest (MoEF), Government of

India

h) Pollution Control Regulations of Department of Environment, Government of

India

i) State Pollution Control Board.

(j.) Rules for Electrical installation by Tariff Advisory Committee (TAC).

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(k.) Building and other construction workers (Regulation of Employment and

Conditions of services) Act, 1996

(l.) Building and other construction workers (Regulation of Employment and

Conditions of services) Central Rules, 1998 (m.) Explosive Rules, 1983

(n.) Petroleum Act, 1984

(o.) Petroleum Rules, 1976,

(p.) Gas Cylinder Rules, 1981

(q.) Static and Mobile Pressure Vessels (Unified) Rules, 1981

(r.) Workmen's Compensation Act, 1923

(s.) Workmen's Compensation Rules, 1924

(t.) NTPC Safety Rules for Construction and Erection

(u.) NTPC Safety Policy

(v.) Any other statutory codes / standards / regulations, as may be applicable.

5.02.00 Unless covered otherwise in the specifications, the latest editions (as applicable as on
date of bid opening), of the codes and standards given below shall also apply:

a) Bureau of Indian standards (BIS)

b) Japanese Industrial Standards (JIS)

c) American National Standards Institute (ANSI)

d) American Society of Testing and Materials (ASTM)

e) American Society of Mechanical Engineers (ASME)

f) American Petroleum Institute (API)

g) Standards of the Hydraulic Institute, U.S.A.

h) International Organisation for Standardisation (ISO)

i) Tubular Exchanger Manufacturer's Association (TEMA)

j) American Welding Society (AWS)

k) National Electrical Manufacturers Association (NEMA)

l) National Fire Protection Association (NFPA)

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m) International Electro-Technical Commission (IEC)/European Norm (EN)

n) Expansion Joint Manufacturers Association (EJMA)

o) Heat Exchange Institute (HEI)

p) IEEE standard

q) JEC standard

5.03.00 Other International/ National standards such as DIN, JIS, VDI, EN, BS, GOST etc. shall
also be accepted for only material codes and manufacturing standards, subject to the
Client (EPIL) / NTPC's approval, for which the Bidder shall furnish, adequate
information to justify that these standards are equivalent or superior to the standards
mentioned above. In all such cases the Bidder shall furnish specifically the
variations and deviations from the standards mentioned elsewhere in the specification
together with the complete word to word translation of the standard that is normally
not published in English.

5.04.00 Not used.

5.05.00 In the event of any conflict between the codes and standards referred to in the
above clauses and the requirement of this specification, the requirement of
Technical Specification shall govern.

5.06.00 Two (2) English language copies of all national and international codes and/or
standards used in the design of the plant, equipment, civil, structural and
architectural works shall be provided by the Contractor to the Client (EPIL) / NTPC
within two calendar months from the date of the Notification of Award.

5.07.00 In case of any change in codes, standards & regulations between the date of bid
opening and the date when vendors proceed with fabrication, the Client (EPIL) /
NTPC shall have the option to incorporate the changed requirements or to retain
the original standard. It shall be the responsibility of the Contractor to bring to the
notice of the Client (EPIL) / NTPC such changes and advise Client (EPIL) / NTPC of
the resulting effect.

5.08.00 A detailed list of standards apart from those mentioned in the respective
detailed specifications in other parts of Section-VI to which all
equipment/systems/civil works should conform as indicated in this Part C and
elsewhere in the specification.

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6.00.00 EQUIPMENT FUNCTIONAL GUARANTEE

6.01.00 The functional guarantees of the equipment under the scope of the Contract is given in
Section-V of Technical Specifications. These guarantees shall supplement the
general functional guarantee provisions covered under Defect liabilities Section-IV,
General Conditions of Contract.

6.02.00 Liquidated damages for shortfall in meeting functional guarantee(s) during the
performance and guarantee tests shall be assessed and recovered from the
Contractor as specified elsewhere in this specification.

7.00.00 DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITY

CONSIDERATIONS

7.01.00 DESIGN OF FACILITIES

All the design procedures, systems and components proposed shall have already
been adequately developed and shall have demonstrated good reliability under
similar conditions elsewhere.

The Contractor shall be responsible for the selection and design of appropriate
equipments to provide the best co-ordinated performance of the entire system. The
basic requirements are detailed out in various clauses of the Technical
Specifications. The design of various components, assemblies and subassemblies
shall be done so that it facilitates easy field assembly and dismantling. All the
rotating components shall be so selected that the natural frequency of the complete
unit is not critical or close to the operating range of the unit.

7.02.00 MAINTENANCE AND AVILABILITY CONSIDERATIONS

Equipment/works offered shall be designed for high availability, low

maintenance and ease of maintenance. The Bidder shall specifically state the design
features incorporated to achieve high degree of reliability/ availability and
ease of maintenance. The Bidder shall also furnish details of availability records
in the reference plants stated in his experience list.

Bidder shall state in his offer the various maintenance intervals, spare parts and
man-hour requirement during such operation. The intervals for each type
of maintenance namely inspection of the furnace, inspection of the entire hot gas path

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and the minor and major overhauls shall be specified in terms of fired hours , clearly
defining the spare parts and man-hour requirement for each stage.

Lifting devices i.e. hoists and chain pulley jacks ,etc. shall be provided by the
contractor for handling of any equipment or any of its part having weight in excess of
500 Kgs during erection and maintenance activities.

Lifting devices like lifting tackles, slings, etc. to be connected to hook of the hoist /
crane shall be provided by the contractor for lifting the equipment and accessories
covered under the specification.

8.00.00 DOCUMENTS, DATA AND DRAWINGS TO BE FURNISHED BY

CONTRACTOR

8.01.00 Bidders may note that this is a contract inclusive of the scope as indicated
elsewhere in the specification. Each of the plant and equipment shall be fully
integrated, engineered and designed to perform in accordance with the technical
specification. All engineering and technical services required to ensure a completely
engineered plant shall be provided in respect of mechanical, electrical, control &
instrumentation, civil & structural works as per the scope.

Each main and auxiliary equipment/item of the plant including instruments shall be
assigned a unique tag number. The assignment of tag numbers shall be in
accordance with KKS system. In all drawings/documents/data heet etc. KKS tag
number of the equipment/item/instrument etc. shall be indicated.

The Contractor shall furnish engineering data /drawings in accordance with the
schedule of information as specified in Technical Data Sheets and Technical
Specification.

A comprehensive engineering and quality coordination procedure shall be

finalized with the successful bidder covering salient features as described in this
section of specifications.

8.02.00 The number of copies/prints/CD-ROMs/manuals to be furnished for various types of

document is given in Annexure-VI to this Part-C, Section-VI of the Technical
Specification.

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8.03.00 The documentation that shall be provided by the Contractor is indicated in the
various sections of specification. This documentation shall include but not be limited
to the following:

8.03.01 A) BASIC ENGINEERING DOCUMENTATION

Prior to commencement of the detailed engineering work, the Contractor

shall furnish a Plant Definition Manual within 12 weeks from the date of the
Notification of Award. This manual shall contain the following as a minimum:

i) System description of all the mechanical, electrical, control &

instrumentation & civil systems.

ii) Technology scan for each system / sub-system & equipment.

ii) Selection of appropriate technology / schemes for various systems/

subsystems including techno-economic studies between various
options.

iv) Optimisation studies including thermal cycle optimisation.

v) Sizing criteria of all the systems, sub-systems/ equipments/

structures/ equipment foundations along with all calculations justifying and
identifying the sizing and the design margins.

vi) Schemes and Process & Instrumentation diagrams for the various
systems/ sub-systems with functional write-ups.

vii) Operation Philosophy and the control philosophy of the

equipments/system covered under the scope.

ix) General Layout plan of the FGD System incorporating all facilities in
Bidder's as well as those in the Client (EPIL) / NTPC's scope.

x) Basic layouts and cross sections of the main plant building (various
floor elevations), boiler, fuel oil area and other areas included in the scope of
the bidder.

xi) Documentation in respect of Quality Assurance System as listed out

elsewhere in this specification.

The successful bidder shall furnish within three (3) weeks from the date of
Notification of Award, a list of contents of the Plant Definition Manual (PDMs)

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STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

including techno-economic studies, which shall then be mutually discussed &

finalised with the Client (EPIL) / NTPC.

8.03.01 B) DETAILED ENGINEERING DOCUMENTS

i) General layout plan of the FGD System.

ii) Layouts, general arrangements, elevations and cross-sections

drawings for all the equipment and facilities of the plant.

iii) Flow diagram, process and instrumentation diagrams along with write
up and system description.
iv) Performance curves for Absorber
v) Piping isometric, composite layout and fabrication drawings.
vi) Piping engineering diagrams, pipe and fittings schedules, valve
schedules, hanger and support schedules, insulation schedules.
vii) Technical data sheets for all bought out and manufactured items.
Contractor shall use the Client (EPIL) / NTPC‟s specifications as a base
for placement of orders on their sub vendors.
viii) Detailed design calculations for components, system, piping etc.,
wherever applicable including sizing calculations for all auxiliaries like
mills, fans etc. as per criteria specified elsewhere in specification.
ix) Absorber sizing calculations. Absorber performance data.
x) Mass Balance Diagram
xi) Characteristic Curves/ Performance Correction Curves.
xii) Comprehensive list of all terminal points which interface with Client
(EPIL) / NTPC's facilities, giving details of location, terminal pressure,
temperature, fluid handled, end connection details, forces, moments etc.
xiii) Power supply single line diagram, block logics, control schematics,
electrical schematics, etc.
xiv) Protection systems diagrams and relay settings.
xv) Cables schedules and interconnection diagrams.
xvi) Cable routing plan.
xvii) Instrument schedule, measuring point list, I/O list, Interconnection
& wiring diagram, functional write-ups, and installation drawings for
field mounted instruments, logic diagrams, control schematics, wiring

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FGD System

and tubing diagrams of panels and enclosures etc. Drawings for open
loop and close loop controls (both hardware and software). Motor list
and valve schedule including type of actuator etc.
xviii) Alarm and annunciation/ Sequence of Event (SOE) list and alarms & trip
set points.
xix) Sequence and protection interlock schemes.
xx) Type test reports, insulation co-ordination study report
xxi) Control system configuration diagrams and card circuit diagrams and
maintenance details.
xxii) Detailed Control system manuals.
xxiii) Detailed flow chart for digital control system.
xxiv) Mimic diagram layout, Assignment for other application
engineering .drawings and documents.
xxv) Civil and Structural works drawings and documents for all structures,
facilities, architectural works, foundations underground and
over ground works and super-structural works as included in the
scope of the bidder civil calculation sheets including structural
analysis and design along with output results.
xxvi) Underground facilities, leveling, sanitary, land-scaping drawings
xxvii) Geotechnical investigation and site survey reports (if and as
applicable).
xxviii) Model study reports wherever applicable
xxix) Functional & guarantee test procedures and test reports.
xxx) Documentation in respect of Quality Assurance System and
Documentation in respect of Commissioning, as listed out elsewhere in
this specification.
xxxi) Maintenance schedule for Absorber & auxiliaries clearly indicating
interval, duration if shutdown required, man-hours required and tools &
tackles required for maintenance.

The Contractor's while submitting the above documents/ drawings for

approval/ reference as the case may be, shall mark on each copy of submission
the reference letter along with the date vide which the submissions are made.

8.03.02 INSTRUCTION MANUALS

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FGD System

The Contractor shall make first submission of instruction manual for all
the equipments covered under the Contract as per agreed engineering information
schedule. The Instruction manuals shall contain full details required for erection,
commissioning, operation and maintenance of each equipment. The manual shall be
specifically compiled for this project. After finalisation and approval of the Client
(EPIL) / NTPC the Instruction Manuals shall be submitted as indicated in
Annexure-IV. The Contract shall not be considered to be completed for purposes of
taking over until the final Instructions manuals have been supplied to the Client
(EPIL) / NTPC. The Instruction Manuals shall comprise of the following.

A ERECTION MANUALS

The erection manuals shall be submitted atleast three (3) months prior to the
commencement of erection activities of particular equipment/system. The
erection manual should contain the following as a minimum.

a) Erection strategy.

b) Sequence of erection

c) Erection instructions

d) Critical checks and permissible deviation/tolerances

e) List of tool, tackles, heavy equipments like cranes, dozers, etc.

f) Bill of Materials

g) Procedure for erection and general Safety procedures to followed during

erection/installation.

h) Procedure for initial checking after erection.

i) Procedure for testing and acceptance norms.

j) Procedure / Check list for pre-commissioning activities.

k) Procedure / Check list for commissioning of the system.

l) Safety precautions to be followed in electrical supply distribution during

erection.

B) OPERATION & MAINTENANCE MANUALS

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FGD System

a) The manual shall be a two rim PVC bound stiff sided binder able to
withstand constant usage or where a thicker type is required it shall have
locking steel pins, the size of the manual shall not be larger than
international size A3. The cover shall be printed with the Project
Name, Services covered and Volume / Book number Each section of the
manual shall be divided by a stiff divider of the same size as the holder.
The dividers shall clearly state the section number and title. All written
instructions within the manual not provided by the manufacturers
shall be typewritten with a margin on the left hand side.

b) The arrangement and contents of O & M manuals shall be as follows:

1) Chapter 1 - Plant Description:

To contain the following sections specific to the equipment/system

supplied : -

a) Description of operating principle of equipment / system

with schematic drawing / layouts.
b) Functional description of associated accessories / controls.
Control interlock protection write up.
c) Integrated operation of the equipment alongwith the intended
system. (This is to be given by the supplier of the Main equipment
by taking into account the operating instruction given by
the associated suppliers).
d) Exploded view of the main equipment, associated accessories
and auxiliaries with description. Schematic drawing of the
equipment along with its accessories and auxiliaries.
e) Design data against which the plant performance will be
compared.
f) Master list of equipments, Technical specification of the
equipment/system and approved data sheets.
g) Identification system adopted for the various components, (it will
be of a simple process linked tagging system).
Master list of drawings (as built drawing - Drawings to be enclosed in a
separate volume).

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FGD System

2) Chapter 2.0 - Plant Operation:

To contain the following sections specific to the equipment supplied :-

a) Protection logics provided for the equipment along with

brief philosophy behind the logic, Drawings etc.
b) Limiting values of all protection settings.
c) Various settings of annunciation/interlocks provided.
d) Startup and shut down procedure for equipment along
with the associated systems in step mode.
e) Do's and Don'ts related to operation of the equipment.
f) Safety precautions to be take during normal operation.
Emergency instruction on total power failure
condition/lubrication failure/any other conditions
g) Parameters to be monitored with normal value and limiting
values.
h) Equipment isolating procedures.
i) Trouble shooting with causes and remedial measures.
j) Routine testing procedure to ascertain healthiness of the safety
devices along with schedule of testing.
k) Routine Operational Checks, Recommended Logs and Records
l) Change over schedule if more than one auxiliary for the
same purpose is given.
m) Preservation procedure on long shut down.
n) System/plant commissioning procedure.

3) Chapter 3.0 - Plant Maintenance:

To contain the following sections specific to the equipment supplied:-

a) Exploded view of each of the equipments. Drawings along with

bill of materials including name, code no. & population
b) Exploded view of the spare parts and critical
components with dimensional drawings (In case of Electronic
cards, the circuit diagram to be given) and spare parts catalogue
for each equipment.

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FGD System

c) List of Special T/P required for Overhauling /Trouble

shooting including special testing equipment required for
calibration etc.
d) Stepwise dismantling and assembly procedure clearly specifying
the tools to be used, checks to be made, records to be maintained,
Clearance to be maintained etc.
e) Preventive Maintenance schedules linked with running hours/
calendar period along with checks to be carried out.
f) Overhauling schedules linked with running hours/calendar
period along with checks to be done.
g) Long term maintenance schedules
h) Consumables list along with the estimated quantity required
during normal running and during maintenance like Preventive
Maintenance and Overhauling.
i) List of lubricants with their Indian equivalent, Lubrication
Schedule including charts showing lubrication checking,
testing and replacement procedure to be carried daily, weekly,
monthly & at longer intervals to ensure trouble free operation
and quantity required for complete replacement.
j) Tolerance for fitment of various components.
k) Details of sub vendors with their part no. in case of bought out
items.
l) List of spare parts with their Part No, total population, life
expediency & their interchangeability with already supplied
spares to NTPC.
m) List of mandatory and recommended spare list along with
manufacturing drawings, material specification & quality plan for
fast moving consumable spares.
n) Lead time required for ordering of spares from the equipment
supplier, instructions for storage and preservation of spares.
o) General information on the equipment such as modification
carried out in the equipment from its inception, equipment
population in the country / foreign country and list of utilities
where similar equipments have been supplied.

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FGD System

C) After finalization and approval of the Client (EPIL) / NTPC, the O & M Manuals
shall be submitted as indicated in Annexure-VI. The Contract shall not be
considered to be completed for purposes of taking over until the final
Instructions manuals (both erection and O & M manuals have been supplied to
the Client (EPIL) / NTPC.

If after the commissioning and initial operation of the plant, the

instruction manuals (Erection and /or O &M manuals) require
modifications/additions/ changes, the same shall be incorporated and the
updated final instruction manuals shall be submitted by the Contractor to
the Client (EPIL) / NTPC for records and number of copies shall be as
mentioned in Annexure-VI.

8.03.03 PLANT HANDBOOK AND PROJECT COMPLETION REPORT

8.03.03.01 PLANT HANDBOOK

The Contractor shall submit to the Client (EPIL) / NTPC a preliminary plant
hand book preferably in A-4 size sheets which shall contain the design and
performance data of various plants, equipments and systems covering the complete
project including;

i) Design and performance data.

ii) Process & Instrumentation diagrams.

iii) Single line diagrams.

iv) Sequence & Protection Interlock Schemes.

v) Alarm and trip values.

vi) Performance Curves.

vii) General layout plan and layout of main plant building and auxiliary buildings

viii) Important Do's & Don't's

The plant handbook shall be submitted within twelve (12) months from the date of
award of contract. After the incorporation of Client (EPIL) / NTPC's comments,
the final plant handbook complete in all respects shall be submitted three (3) months
before start- up and commissioning activities.

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STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

8.03.03.02 PROJECT COMPLETION REPORT

The Contractor shall submit a Project Completion Report at the time of handing over
the plant.

8.03.04 DRAWINGS

a) i) All the FGD plant layouts shall be made in computerised 3D

modelling system. The Client (EPIL) / NTPC reserves the right to review the
3D model at different stages during the progress of engineering. The
layout drawings submitted for Client (EPIL) / NTPC's review shall be
fully dimensioned and extracted from 3D model after interference check.

ii) All documents submitted by the Contractor for Client (EPIL) / NTPC's
review shall be in electronic form (soft copies) along with the desired number
of hard copies as per Annexure-VI of Part-C. The soft copies shall be
uploaded by the vendors in C-folders, a Web-based system of NTPC ERP, for
which a username and password will be allotted to the new vendor by NTPC.

Similarly, the vendor can download the drawings/documents,

approved/ commented by NTPC, through above site.

The soft copies of identified drawings/documents shall be in pdf format,

whereas the attachments/reply to the submitted document(s) can be in .doc,
.xls, .pdf, .dwg or .std formats.

iii) Final copies of the approved drawings along with requisite number of hard
copies shall be submitted as per Annexure-VI of this Section.

iv) Contractor shall prepare the model of all the facilities located in FLUE GAS
DESULPHURISATION (FGD) SYSTEM PACKAGE (including all facilities),
and any other facility in an integrated & intelligent 3D software solution
using rule-based, data centric 3D Design software with equipment
drawings, data sheets, intelligent P&ID correlated with intelligent 3D
Model, BOQ, schematics and logic diagrams etc. attached to the
respective equipment / systems in the aforesaid 3D model. Contractor
shall make a presentation on 3D model every 3 months from LOA to
enable NTPC to review the progress of engineering. After the

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FGD System

completion of engineering the corresponding complete 3D review model shall

be handed over to the Client (EPIL) / NTPC for its reference.

Contractor shall provide 3D model (which shall include visual

interference check, walk-through animation, video simulation for
major equipment placement and removal, visual effect, photo realism etc),
which is extracted from intelligent 3D model, for Client (EPIL) / NTPC‟s
review as & when desired by Client (EPIL) / NTPC. However, all piping
layouts, equipment layouts, floor plans, ducting layout (Air/flue gas,
A/C, Ventilation etc.), General Arrangement drawings of major
buildings, structural arrangement drawings and RCC layout drawings
shall necessarily be extracted from the aforesaid 3D model and submitted for
Client (EPIL) / NTPC‟s review along with the 3D review model to
enable NTPC to review and approve these drawings.

b) All documents/text information shall be in latest version of MS Office / MS Excel

/PDF FORMAT as applicable.

c) All drawings submitted by the Contractor including those submitted at the

time of bid shall be in sufficient detail indicating the type, size, arrangement,
weight of each component for packing and shipment, the external
connection, fixing arrangement required, the dimensions required for
installation and interconnections with other equipments and materials,
clearance and spaces required between various portions of equipment and
any other information specifically requested in the drawing schedules.

d) Each drawing submitted by the Contractor (including those of sub-vendors)

shall bear a title block at the right hand bottom corner with clear mention of the
name of the Client (EPIL) / NTPC, the system designation, the specifications
title, the specification number, the name of the Project, drawing number and
revisions. If standard catalogue pages are submitted the applicable items
shall be indicated therein. All titles, noting, markings and writings on the
drawing shall be in English. All the dimensions should be in metric units.

e) The drawings submitted by the Contractor (or their sub-vendors) shall bear
Client (EPIL) / NTPC's drawing number in addition to contractor's (their sub-
vendor's) own drawing number. Client (EPIL) / NTPC's drawing numbering

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FGD System

system shall be made available to the successful bidder so as to enable him to

assign Client (EPIL) / NTPC's drawing numbers to the drawings to be submitted
by him during the course of execution of the Contract.

The Contractor shall also furnish a "Master Drawing List" which shall be a
comprehensive list of all drawings/ documents/ calculations envisaged to be
furnished by him during the detailed engineering to the Client (EPIL) / NTPC.
Such list should clearly indicate the purpose of submission of these drawings
i.e. "FOR APPROVAL" or "FOR INFORMATION ONLY".

Similarly, all the drawings/ documents submitted by the Contractor during

detailed engineering stage shall be marked "FOR APPROVAL" or "FOR
INFORMATION" prior to submission. Further, space shall be identified on each
drawing for Approval stamp and electronic signature.

f) The furnishing of detailed engineering data and drawings by the Contractor shall
be in accordance with the time schedule for the project. The review of these
documents/ data/ drawings by the Client (EPIL) / NTPC will cover only
general conformance of the data/ drawings/ documents to the specifications
and contract, interfaces with the equipments provided by others and external
connections & dimensions which might affect plant layout. The review by the
Client (EPIL) / NTPC should not be construed to be a thorough review of all
dimensions, quantities and details of the equipments, materials, any devices
or items indicated or the accuracy of the information submitted. The review
and/ or approval by the Client (EPIL) / NTPC/ Project Manager shall not relieve
the Contractor of any of his responsibilities and liabilities under this contract.

g) After the approval of the drawings, further work by the Contractor shall be in
strict accordance with these approved drawings and no deviation shall be
permitted without the written approval of the Client (EPIL) / NTPC.

h) All manufacturing, fabrication and execution of work in connection with the

equipment / system, prior to the approval of the drawings, shall be at the
Contractor's risk. The Contractor is expected not to make any changes in the
design of the equipment /system, once they are approved by the Client (EPIL) /
NTPC. However, if some changes are necessitated in the design of the
equipment/system at a later date, the Contractor may do so, but such

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FGD System

changes shall promptly be brought to the notice of the Client (EPIL) / NTPC
indicating the reasons for the change and get the revised drawing approved
again in strict conformance to the provisions of the Technical Specification.

i) Drawings shall include all installations and detailed piping layout drawings.
Layout drawings for all piping of 65 mm and larger diameter shall be
submitted for review/ approval of Client (EPIL) / NTPC prior to erection. Small
diameter pipes shall however be routed as per site conditions in consultation with
site authority/ representative of Client (EPIL) / NTPC based on requirements of
such piping indicated in approved/finalized Flow Scheme/ Process &
Instrumentation Diagrams and/or the requirements cropping up for draining
& venting of larger diameter piping or otherwise after their erection as per actual
physical condition for the entire scope of work of this package.

Assessing & anticipating the requirement and supply of all piping and equipment
shall be done by the contractor well in advance so as not to hinder the
progress of piping & equipment erection, subsequent system charging and
its effective draining & venting arrangement as per site suitability.

j) As Built Drawings

After final acceptance of individual equipment / system by the Client (EPIL) /

NTPC, the Contractor will update all original drawings and documents for the
equipment / system to “As built” conditions and submit no. of copies as per
Annexure VI.

k) Drawings must be checked by the Contractor in terms of its completeness, data

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

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FGD System

systems, facilities, equipment & works under Client (EPIL) / NTPC's scope and
submit all necessary drawings/ documents for the same.

l) The Contractor shall submit adequate prints of drawing /data/ document for
Client (EPIL) / NTPC's review and approval. The Client (EPIL) / NTPC shall
review the drawings and return soft copy to the Contractor authorizing
either to proceed with manufacture or fabrication, or marked to show
changes desired. When changes are required, drawings shall be re-
submitted promptly, with revisions clearly marked, for final review. Any delays
arising out of the failure of the Contractor to submit/rectify and resubmit in time
shall not be accepted as a reason for delay in the contract schedule.

m) All engineering data submitted by the Contractor after final process including
review and approval by the Project Manager/ Client (EPIL) / NTPC shall form
part of the contract documents and the entire works covered under these
specification shall be performed in strict conformity with technical
specifications unless otherwise expressly requested by the Project Manager in
writing.

n) The Contractor shall submit drawings in line with the suggestive MDL which will
be finalised at the time of award finalised covered in Part-B, Section-VI of
Technical Specification and which shall be duly integrated with approved
PERT network.

8.04.00 ENGINEERING INFORMATION SUBMISSION SCHEDULE

Prior to the award of Contract, a Detailed Engineering Information Submission

Scheduler/Master Drawing List duly integrated with approved PERT network shall be
tied up with the Client (EPIL) / NTPC. For this, the bidder shall furnish a detailed
list of engineering information along with the proposed submission schedule. This list
would be a comprehensive one including all engineering data / drawings /
information for all bought out items and manufactured items. The information shall be
categorized into the following parts.

i) Information that shall be submitted for the approval to the Client (EPIL) /
NTPC before proceeding further, and

ii) Information that would be submitted for Client (EPIL) / NTPC's information
only.

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FGD System

The Master Drawing List (MDL) shall be updated periodically and submitted to the
Client (EPIL) / NTPC, highlighting the changes made in MDL.

The schedule should allow adequate time for proper review and incorporation
of changes/ modifications, if any, to meet the contract without affecting the equipment
delivery schedule and overall project schedule. The early submission of
drawings and data is as important as the manufacture and delivery of
equipment and hardware and this shall be duly considered while
determining the overall performance and progress.

8.05.00 ENGINEERING PROGRESS AND EXCEPTION REPORT

8.05.01 The Contractor shall submit every month an Engineering progress and Exception
Report giving the status of each engineering information including

a) A list of drawings/engineering information which remains unapproved for

more than four (4) weeks after the date of first submission.

b) Drawings which were not submitted as per agreed schedule.

8.05.02 The draft format for this report shall be furnished to the Client (EPIL) / NTPC
within four (4) weeks of the award of the contract, which shall then be discussed and
finalised with the Client (EPIL) / NTPC.

8.06.00 Engineering Co-ordination Procedure

8.06.01 The following principal coordinators will be identified by respective organizations at

time of award of contract:

NTPC /EPI Engineering Coordinator (EPI/ NTPC EC):

Name :

Designation :

Address :

a) Postal :

b) Telegraphic / e-Mail :

c) FAX : TELEPHONE :

Contractor‟s/ Vendor‟s Engineering Coordinator (VENDOR EC):

Name :

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FGD System

Designation :

Address :

a) Postal :

b) Telegraphic / e-Mail :

c) FAX : TELEPHONE :

8.06.02 All engineering correspondence shall be in the name of above coordinators on

behalf of the respective organizations.

8.06.03 Contractor‟s/Vendor‟s Drawing Submission and Approval Procedure:

a) All data/information furnished by Vendor in the form of drawings/

documents/catalogues or in any other form for NTPC‟s information/ interface
and or review and approval are referred by the general term “drawings”.

b) The „Master drawings list‟ indicating titles, Drawing Number, Date of

submission and approval etc. shall be finalised mutually between Contractor
and Client (EPIL) / NTPC before the award of contract. This list shall be
updated if required at suitable interval during detailed engineering.

c) All drawings (including those of subvendor‟s) shall bear at the right hand
bottom corner the „title plate‟ with all relevant information duly filled in.
The Contractor shall furnish this format to his subvendor along with his
purchase order for subvendor‟s compliance.

d) Client (EPIL) / NTPC and contractor shall follow their own numbering
systems for the drawings. However, Client (EPIL) / NTPC shall intimate the
contractor, NTPC drawing number on receipt of the first submission of
each drawing. Vendor, thereafter, shall indicate NTPC‟s drawing number in
subsequent Submission, in the space provided for this purpose in title plate,
in addition to his own drawing number.

e) The contractor shall make a visit to site to see the existing facilities and
understand the layout completely and collect all necessary data / drawings at
site which are needed as an input to the engineering. The contractor shall do the
complete engineering including interfacing and integration of all his

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FGD System

equipment, systems & facilities within his scope of work as well as interface
engineering & integration of systems, facilities, equipment & works under
Client (EPIL) / NTPC‟s scope and submit all necessary drawings/
documents for the same.

f) Drawings must be checked by the Contractor in terms of its completeness, data

adequacy and relevance with respect to engineering schedule prior to
submission to the Client (EPIL) / NTPC. In case drawings are found to be
submitted without proper endorsement for checking by the Contractor, the same
shall not be reviewed and returned to the Contractor for re-submission.

g) The Contractor shall submit adequate prints of drawing / data / document for
Client (EPIL) / NTPC‟s review and approval. The drawings submitted
by the Contractor/vendor shall be reviewed by NTPC and their comments
shall be forwarded within four (4) weeks of receipt of drawings. Upon review of
each drawing, depending on the correctness and completeness of the drawing,
the same will be categorized and approval accorded in one of the
following categories :

CATEGORY- I: Approved

CATEGORY- II: Approved, subject to incorporation of comments/

modification as noted. Resubmit revised drawing
incorporating the comments.

CATEGORY–III: Not approved. Resubmit revised drawings for approval

after incorporating comments/ modification as noted.

CATEGORY –IV: For information and records.

h) Contractor shall resubmit the drawings approved under Category II, III & IVR
within three (3) weeks of receipt of comments on the drawings, incorporating all
comments. Every revision of the drawing shall bear a revision index
wherein such revisions shall be highlighted in the form of description or
marked up in the drawing identifying the same with relevant revision Number
enclosed in a triangle (eg. 1, 2, 3 etc). Contractor shall not make any
changes in the portions of the drawing other than those commented. If
changes are required to be made in the portions already approved, the
Contractor shall resubmit the drawing identifying the changes for Client (EPIL)

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/ NTPC‟s review and approval. Drawings resubmitted shall show clearly

the portions where the same are revised marking the relevant revision
numbers and Client (EPIL) / NTPC shall review only such revised portion
of documents.

i) In case, the Contractor/ Vendor does not agree with any specific comment, he
shall furnish the explanation for the same to NTPC for consideration. In all such
cases the Contractor shall necessarily enclose explanations along with the
revised drawing (taking care of balance comments) to avoid any delay
and/or duplication in review work.

j) It is responsibility of the Contractor/ Vendor to get all the drawings approved in

the Category I & IV (as the case may be) and complete engineering
activities within the agreed schedule. Any delay arising out of submission and
modification of drawings shall not alter the contract completion schedule.

k) If Contractor/ Vendor fails to resubmit the drawings as per the schedule,

construction work at site will not be held up and work will be carried out on the
basis of comments furnished on previous issues of the drawing.

l) These comments will be taken care by the contractor while submitting the
revised drawing.

The contractor shall use a single transmittal for drawing submission. This shall
include transmittal numbers and date, number of copies being sent, names
of the agencies to whom copies being sent, drawing number and titles,
remarks or special notes if any etc.

9.00.00 TECHNICAL CO-ORDINATION MEETING

9.01.00 The Contractor shall be called upon to organise and attend monthly Design/
Technical Co-ordination Meetings (TCMs) with the Client (EPIL) /
NTPC/Client (EPIL) / NTPC's representatives and other Contractors of the Client
(EPIL) / NTPC during the period of contract. The Contractor shall attend such
meetings at his own cost at NEW DELHI / NOIDA or at mutually agreed venue as
and when required and fully co-operate with such persons and agencies involved
during the discussions.

9.02.00 The Contractor should note that Time is the essence of the contract. In order to
expedite the early completion of engineering activities, the Contractor shall submit all

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drawings as per the agreed Engineering Information Submission Schedule. The

drawings submitted by the Contractor will be reviewed by the Client (EPIL) /
NTPC as far as practicable within three (3) weeks from the date of receipt of
the drawing. The comments of the Client (EPIL) / NTPC shall then be discussed
across the table during the above Technical Co-ordination Meeting (s) wherein
best efforts shall be made by both sides to ensure the approval of the drawing.

9.02.01 The Contractor shall ensure availability of the concerned experts / consultants/
personnel who are empowered to take necessary decisions during these meetings. The
Contractor shall be equipped with necessary tools and facilities so that the
drawings/documents can be resubmitted after incorporating necessary changes and
approved during the meeting itself.

9.02.02 Should any drawing remain unapproved for more than six (6) weeks after it's
first submission ,this shall be brought out in the monthly Engineering Progress
and Exception Report with reasons thereof.

9.02.03 Any delays arising out of failure by the Contractor to incorporate Client (EPIL) /
NTPC's comments and resubmit the same during the TCM shall be considered as a
default and in no case shall entitle the Contractor to alter the Contract completion date.

10.00.00 DESIGN IMPROVEMENTS

The Client (EPIL) / NTPC or the Contractor may propose changes in the
specification of the equipment or quality thereof and if the parties agree upon
any such changes the specification shall be modified accordingly.

If any such agreed upon change is such that it affects the price and schedule of
completion, the parties shall agree in writing as to the extent of any changing
the price and/or schedule of completion before the Contractor proceeds with the
change. Following such agreement, the provision thereof, shall be deemed to
have been amended accordingly.

11.00.00 EQUIPMENT BASES

A cast iron or welded steel base plate shall be provided for all rotating
equipment which is to be installed on a concrete base, unless otherwise specifically
agreed to by the Client (EPIL) / NTPC. Each base plate shall support the unit and its
drive assembly, shall be of a neat design with pads for anchoring the units, shall have
a raised lip all around, and shall have threaded drain connections.

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12.00.00 PROTECTIVE GUARDS

Suitable guards shall be provided for protection of personnel on all exposed rotating
and/or moving machine parts. All such guards shall be designed for easy installation
and removal for maintenance purpose.

13.00.00 LUBRICANTS, SERVO FLUIDS AND CHEMICALS

13.01.00 All the first fills of consumables and one year topping requirement of
consumables such as greases, oil, lubricants, servo fluids / control fluids, gases
and essential chemicals etc. which will be required to put the equipment
covered under the scope of specifications, into successful commissioning /
initial operation and to establish completion of facilities shall be supplied by the
Contractor. Suitable standard lubricants as available in India are desired. Efforts
should be made to limit the variety of lubricants to minimum.

Bidder shall supply a quantity not less than 10 % of the full charge or one (1) year
topping requirement mentioned above (whichever is higher) of each variety of
lubricants, servo fluids, gases, chemicals etc (as detailed above) which is expected to
be utilized during the first year of operation. The additional quantity shall be
supplied in separate container.

13.02.00 As far as possible lubricants marketed by the Indian Oil Corporation shall be used.
The variety of lubricants shall be kept to a minimum possible.

Detailed specifications for the lubricating oil, grease, gases, servo fluids, control
fluids, chemicals etc required for the complete plant covered herein shall be
furnished. On completion of erection, a complete list of bearings/ equipment giving
their location and identification marks shall be furnished to the Client (EPIL) / NTPC
along with lubrication requirements.

14.00.00 LUBRICATION
14.01.00 Equipment shall be lubricated by systems designed for continuous operation.
Lubricant level indicators shall be furnished and marked to indicate proper
levels under both standstill and operating conditions.

15.00.00 TERIAL OF CONSTRUCTION

15.01.00 All materials used for the construction of the equipment shall be new and shall be in
accordance with the requirements of this specification. Materials utilised for various
components shall be those which have established themselves for use in such
applications.

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16.00.00 RATING PLATES, NAME PLATES & LABELS

16.01.00 Each main and auxiliary item of plant including instruments shall have permanently
attached to it in a conspicuous position, a rating plate of non-corrosive material upon
which shall be engraved manufacturer‟s name, equipment, type or serial number
together with details of the ratings, service conditions under which the item of plant in
question has been designed to operate, and such diagram plates as may be
required by the Client (EPIL) / NTPC.

16.02.00 Each item of plant shall be provided with nameplate or label designating the service of
the particular equipment. The inscriptions shall be approved by the Client (EPIL) /
NTPC or as detailed in appropriate section of the technical specifications.

16.03.00 Such nameplates or labels shall be of white non-hygroscopic material with engraved
black lettering or alternately, in the case of indoor circuit breakers, starters, etc. of
transparent plastic material with suitably coloured lettering engraved on the back.
The name plates shall be suitably fixed on both front and rear side.

16.04.00 Items of plant such as valves, which are subject to handling, shall be provided with an
engraved chromium plated nameplate or label with engraving filled with enamel. The
name plates for valves shall be marked in accordance with MSS standard SP-25 and
ANSI B 16.34 as a minimum.

16.05.00 Hanger/ support numbers shall be marked on all pipe supports, anchors, hangers,
snubbers and restraint assemblies. Each constant and variable spring support shall
also have stamped upon it the designed hot and cold load which it is intended
to support. Suitable scale shall also be provided to indicate load on support or hanger.

16.06.00 Valves, steam traps and strainers shall be identified by Client (EPIL) / NTPC's tag
number of a metal tap permanently attached to non pressure parts such as the
yoke by a stainless steel wire. The direction of flow shall also be marked on the body.

16.07.00 Safety and relief valves shall be provided with the following:

a) Manufacturer's identification.

b) Nominal inlet and outlet sizes in mm.

c) Set pressure in Kg/cm2 (abs).

d) Blow down and accumulation as percentage of set pressure.

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e) Certified capacity in Kg of saturated steam per hour or in case of liquid

certified capacity in litres of water per minute.

16.08.00 All such plates, instruction plates, etc. shall be bilingual with Hindi inscription
first, followed by English. Alternatively, two separate plates one with Hindi and the
other with English inscriptions may be provided.

16.09.00 All segregated phases of conductors or bus ducts, indoor or outdoor, shall be
provided with coloured phase plates to clearly identify the phase of the system.

17.00.00 TOOLS AND TACKLES

The Contractor shall supply with the equipment one complete set of all special tools
and tackles and other instruments required and other instruments for the
erection, assembly, disassembly and proper maintenance of the plant and
equipment and systems (including software). These special tools will also include
special material handling equipment, jigs and fixtures for maintenance and calibration
/ re-adjustment, checking and measurement aids etc. A list of such tools and tackles
shall be submitted by the Bidder along with the offer.

The price of each tool / tackle shall be deemed to have been included in the total bid
price. These tools and tackles shall be separately packed and sent to site. The
Contractor shall also ensure that these tools and tackles are not used by him during
erection, commissioning and initial operation. For this period the Contractor should
bring his own tools and tackles. In case these tools and tackles are used by the
Contractor during erection, commissioning or initial operation the same shall be
refurbished repaired/replaced as required to the satisfaction of the Client (EPIL) /
NTPC before handing over to the Client (EPIL) / NTPC. All the tools and tackles
shall be of reputed make acceptable to the Client (EPIL) / NTPC.

18.00.00 WELDING
18.01.00 If the manufacturer has special requirements relating to the welding procedures for
welds at the terminals of the equipments to be per formed by others the
requirements shall be submitted to the Client (EPIL) / NTPC in advance of
commencement of erection work.

19.00.00 COLOUR CODE FOR ALL EQUIPMENTS/ PIPINGS/ PIPE SERVICES

19.01.00 All equipment/ piping/ pipe services are to be painted by the Contractor
in accordance with Client (EPIL) / NTPC's standard colour coding scheme, which will
be furnished to the Contractor during detailed engineering stage.

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20.00.00 PROTECTION AND PRESERVATIVE SHOP COATING

20.01.00 PROTECTION

All coated surfaces shall be protected against abrasion, impact, discoloration and
any other damages. All exposed threaded portions shall be suitably protected with
either metallic or a non-metallic protection device. All ends of all valves and piping
and conduit equipment connections shall be properly sealed with suitable devices to
protect them from damage. The parts which are likely to get rusted, due to exposure to
weather, should also be properly treated and protected in a suitable manner. All
primers/paints/coatings shall take into account the hot humid, corrosive & alkaline,
subsoil or over ground environment as the case may be. The requirements for
painting specification shall be complied with as detailed out in Part-A & B of
the Technical Specification.

20.02.00 PRESERVATIVE SHOP COATING

All exposed metallic surfaces subject to corrosion shall be protected by shop

application of suitable coatings. All surfaces which will not be easily accessible after
the shop assembly, shall be treated beforehand and protected for the life of the
equipment. All surfaces shall be thoroughly cleaned of all mill scales, oxides
and other coatings and prepared in the shop. The surfaces that are to be finish-painted
after installation or require corrosion protection until installation, shall be shop
painted as per the requirements covered in the relevant part of the Technical
Specification.

Transformers and other electrical equipments, if included shall be shop finished with
one or more coats of primer and two coats of high grade resistance enamel.
The finished colors shall be as per manufacturer's standards, to be selected and
specified by the Client (EPIL) / NTPC at a later date.

20.03.00 Shop primer for all steel surfaces which will be exposed to operating
temperature below 95 degrees Celsius shall be selected by the Contractor after
obtaining specific approval of the Client (EPIL) / NTPC regarding the quality of
primer proposed to be applied. Special high temperature primer shall be used on
surfaces exposed to temperature higher than 95 degrees Celsius and such primer shall
also be subject to the approval of the Client (EPIL) / NTPC.

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20.04.00 All other steel surfaces which are not to be painted shall be coated with suitable dust
preventive compound subject to the approval of the Client (EPIL) / NTPC.

20.05.00 All piping shall be cleaned after shop assembly by shot blasting or other means
approved by the Client (EPIL) / NTPC. Lube oil piping or carbon steel shall be
pickled.

20.06.00 Painting for Civil structures and equipment/system covered under this package shall
be done as specified under technical requirements on civil works in relevant part of
this specifications.

21.00.00 QUALITY ASSURANCE PROGRAMME

21.01.00 To ensure that the equipment and services under the scope of contract whether
manufactured or performed within the Contractor‟s works or at his sub-contractor‟s
premises or at the Client (EPIL) / NTPC‟s site or at any other place of work are in
accordance with the specifications, the Contractor shall adopt suitable quality
assurance programme to control such activities at all points, as necessary. Such
programmes shall be outlined by the Contractor and shall be finally
accepted by the Client (EPIL) / NTPC/authorised representative after
discussions before the award of the contract. The QA programme shall be
generally in line with ISO-9001/IS-14001. A quality assurance programme of the
contractor shall generally cover the following:

a) His organisation structure for the management and implementation of the

proposed quality assurance programme

b) Quality System Manual

c) Design Control System

d) Documentation Control System

e) Qualification data for Bidder‟s key Personnel.

f) The procedure for purchase of materials, parts, components and selection of

sub-contractor‟s services including vendor analysis, source inspection,
incoming raw-material inspection, verification of materials purchased etc.

g) System for shop manufacturing and site erection control including process
controls and fabrication and assembly controls.

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h) Control of non-conforming items and system for corrective actions.

i) Inspection and test procedure both for manufacture and field activities.

j) Control of calibration and testing of measuring testing equipments.

k) System for Quality Audits.

l) System for indication and appraisal of inspection status.

m) System for authorising release of manufactured product to the Client (EPIL) /

NTPC.

n) System for handling storage and delivery.

o) System for maintenance of records, and

p) Furnishing of quality plans for manufacturing and field activities detailing

out the specific quality control procedure adopted for controlling the
quality characteristics relevant to each item of equipment/component as per
formats enclosed as Annexure-I and Annexure-II respectively.

22.00.00 GENERAL REQUIREMENTS - QUALITY ASSURANCE

22.01.00 All materials, components and equipment covered under this specification shall be
procured, manufactured, erected, commissioned and tested at all the stages, as per a
comprehensive Quality Assurance Programme. An indicative programme of
inspection/tests to be carried out by the contractor for some of the major items
is given in the respective technical specification. This is, however, not intended to
form a comprehensive programme as it is the contractor‟s responsibility to draw up
and implement such programme duly approved by the Client (EPIL) / NTPC. The
detailed Quality Plans for manufacturing and field activities shall be drawn up by the
Bidder and will be submitted to Client (EPIL) / NTPC for approval. Schedule of
finalisation of such quality plans will be finalised before award on enclosed
format No. QS-01-QAI-P-1/F3-R0. Monthly progress reports shall be furnished.

22.02.00 Manufacturing Quality Plan will detail out for all the components and
equipment, various tests/inspection, to be carried out as per the
requirements of this specification and standards mentioned therein and quality
practices and procedures followed by Contractor‟s/ Sub-contractor‟s/ sub-
supplier's Quality Control Organisation, the relevant reference documents and
standards, acceptance norms, inspection documents raised etc., during all stages of

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materials procurement, manufacture, assembly and final testing/performance testing.

The Quality Plan shall be submitted on electronic media through C-folders, a web
based system of NTPC ERP in addition to hard copy, for review and approval. After
approval the same shall be submitted in compiled form on CD-ROM (As per format at
Annexure-I).

22.03.00 Field Quality Plans will detail out for all the equipment, the quality practices
and procedures etc. to be followed by the Contractor‟s "Site Quality Control
Organisation", during various stages of site activities starting from receipt
of materials/equipment at site (As per format at Annexure – II).

22.04.00 The Bidder shall also furnish copies of the reference documents/plant
standards/acceptance norms/tests and inspection procedure etc., as referred in
Quality Plans along with Quality Plans. These Quality Plans and reference
documents/standards etc. will be subject to Client (EPIL) / NTPC‟s approval
without which manufacturer shall not proceed. These approved documents shall
form a part of the contract. In these approved Quality Plans, Client (EPIL) / NTPC
shall identify customer hold points (CHP), i.e. test/checks which shall be
carried out in presence of the Client (EPIL) / NTPC‟s Project Manager or his
authorised representative and beyond which the work will not proceed without
consent of Client (EPIL) / NTPC in writing. All deviations to this specification,
approved quality plans and applicable standards must be documented and referred
to Client (EPIL) / NTPC along with technical justification for approval and
dispositioning.

22.05.00 The contractor shall submit to the Client (EPIL) / NTPC Field Welding Schedule for
field welding activities in the format enclosed at Annexure-V. The field welding
schedule shall be submitted to the Client (EPIL) / NTPC along with all
supporting documents, like welding procedures, heat treatment procedures,
NDT procedures etc. at least ninety days before schedule start of erection work at
site.

22.06.00 The contractor shall have suitable Field Quality Organization with adequate
manpower at Client (EPIL) / NTPC's site, to effectively implement the Field Quality
Plan (FQP) and Field Quality Management System for site activities. The contractor
shall submit the details of proposed FQA setup (organizational structure and

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manpower) for Client (EPIL) / NTPC's approval. The FQA setup shall be in place at
least one month before the start of site activities.

22.07.00 No material shall be despatched from the manufacturer‟s works before the same is
accepted, by Client (EPIL) / NTPC's Project Manager/Authorised representative
and duly authorised for despatch by issuance of Material Despatch Clearance
Certificate (MDCC / CHP Clearance.

22.08.00 All material used for equipment manufacture including casting and forging etc. shall
be of tested quality as per relevant codes/standards. Details of results of the tests
conducted to determine the mechanical properties; chemical analysis and details of
heat treatment procedure recommended and actually followed shall be recorded on
certificates and time temperature chart. Tests shall be carried out as per applicable
material standards and/or agreed details.

22.09.00 All welding and brazing shall be carried out as per procedure drawn and qualified in
accordance with requirements of ASME Section IX/BS-4870 or other International
equivalent standard acceptable to the Client (EPIL) / NTPC.

All welding/brazing procedures shall be submitted to the Client (EPIL) / NTPC or its
authorised representative for approval prior to carrying out the welding/brazing.

22.10.00 All brazers, welders and welding operators employed on any part of the
contract either in Contractor‟s/his sub-contractor‟s works or at site or elsewhere
shall be qualified as per ASME Section-IX or BS-4871 or other equivalent
International Standards acceptable to the Client (EPIL) / NTPC.

22.11.00 Welder qualification test results shall be furnished to the Client (EPIL) / NTPC
for approval. However, where required by the Client (EPIL) / NTPC, tests shall be
conducted in presence of Client (EPIL) / NTPC/authorized representative.

22.12.00 For all IBR pressure parts and high pressure piping welding, the latest
applicable requirements of the IBR (Indian Boiler Regulations) shall also be
essentially complied with. However, other piping system ASME B31.1 or other
relevant code as applicable shall be followed. Similarly, any other statutory
requirements for the equipment/systems shall also be complied with. On all back-
gauged welds MPI/LPI shall be carried before seal welding.

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22.13.00 All the heat treatment results shall be recorded on time temperature charts and
verified with recommended regimes.

22.14.00 No welding shall be carried out on cast iron components for repair.

22.15.00 Unless otherwise proven and specifically agreed with the Client (EPIL) / NTPC,
welding of dissimilar materials and high alloy materials shall be carried out at shop
only.

22.16.00 All non-destructive examination shall be performed in accordance with written

procedures as per International Standards. The NDT operator shall be qualified as per
SNT-TC-IA (of the American Society of non-destructive examination) or
equivalent. NDT shall be recorded in a report, which includes details of
methods and equipment used, result/evaluation, job data and identification of
personnel employed and details of co-relation of the test report with the job.

In general all plates of thickness greater than 40mm & for pressure parts plates of
thickness equal to or greater than 25mm shall be ultrasonically tested otherwise as
specified in respective equipment specification. All bar stock/Forging of diameter
equal to or greater than 40 mm shall be ultrasonically tested.

22.17.00 The Contractor shall list out all major items/ equipment/ components to
be manufactured in house as well as procured from sub-contractors (BOI). All the sub-
contractor proposed by the Contractor for procurement of major bought out
items including castings, forging, semi-finished and finished
components/equipment etc., list of which shall be drawn up by the Contractor
and finalised with the Client (EPIL) / NTPC, shall be subject to Client (EPIL) /
NTPC's approval on enclosed format No. QS-01-QAI-P-01/F3. The contractor‟s
proposal shall include vendor‟s facilities established at the respective works,
the process capability, process stabilization, QC systems followed, experience list, etc.
along with his own technical evaluation for identified sub- contractors enclosed
and shall be submitted to the Client (EPIL) / NTPC for approval within the period
agreed at the time of pre-awards discussion and identified in "DR" category prior to
any procurement. Monthly progress reports on sub-contractor detail
submission / approval shall be furnished preferably on enclosed format at
Annexure-IV. Such vendor approval shall not relieve the contractor from any
obligation, duty or responsibility under the contract.

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22.17.00a An indicative list of sub-vendors accepted by NTPC in the past for Corporate
Awarded similar packages is enclosed for reference purpose as Indicative Sub-
vendors List. The bidders‟ specific attention is drawn to the „Disclaimer for the
Indicative Vendor List‟ placed at the start of the Indicative Sub-vendor List. This is
attached separately with the QA specification.

22.18.00 For components/equipment procured by the contractors for the purpose of the
contract, after obtaining the written approval of the Client (EPIL) / NTPC, the
contractor‟s purchase specifications and inquiries shall call for quality plans to be
submitted by the suppliers. The quality plans called for from the sub-contractor
shall set out, during the various stages of manufacture and installation, the quality
practices and procedures followed by the vendor‟s quality control organisation,
the relevant reference documents/standards used, acceptance level,
inspection of documentation raised, etc.

Such quality plans of the successful vendors shall be finalised with the Client
(EPIL) / NTPC and such approved Quality Plans shall form a part of the
purchase order/contract between the Contractor and sub-contractor. Within three
weeks of the release of the purchase orders /contracts for such bought out items
/components, a copy of the same without price details but together with the
detailed purchase specifications, quality plans and delivery conditions shall be
furnished to the Client (EPIL) / NTPC on the monthly basis by the Contractor along
with a report of the Purchase Order placed so far for the contract.

22.19.00 Client (EPIL) / NTPC reserves the right to carry out quality audit and quality
surveillance of the systems and procedures of the Contractor‟s or their sub-
contractor‟s quality management and control activities. The contractor shall provide
all necessary assistance to enable the Client (EPIL) / NTPC carry out such audit and
surveillance.

22.20.00 The contractor shall carry out an inspection and testing programme during
manufacture in his work and that of his sub-contractor‟s and at site to ensure
the mechanical accuracy of components, compliance with drawings, conformance
to functional and performance requirements, identity and acceptability of all materials
parts and equipment. Contractor shall carry out all tests/inspection required to
establish that the items/equipment conform to requirements of the specification and

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the relevant codes/standards specified in the specification, in addition to carrying out

tests as per the approved quality plan.

22.21.00 Quality audit/surveillance/approval of the results of the tests and inspection will not,
however, prejudice the right of the Client (EPIL) / NTPC to reject the equipment
if it does not comply with the specification when erected or does not give complete
satisfaction in service and the above shall in no way limit the liabilities and
responsibilities of the Contractor in ensuring complete conformance of the
materials/equipment supplied to relevant specification, standard, data sheets,
drawings, etc.

22.22.00 For all spares and replacement items, the quality requirements as agreed for the
main equipment supply shall be applicable.

22.23.00 Repair/rectification procedures to be adopted to make the job acceptable shall

be subject to the approval of the Client (EPIL) / NTPC/authorised representative.

22.24.00 Environmental Stress Screening:

Environmental stress screening test process / procedure for eliminating infant mortile
components for DDCMIS / PLC based system & for other systems having
substantial electronics components (as determined by Client (EPIL) / NTPC) like
Electronic transmitter, CCTV components, PA systems etc. shall be furnished for
Client (EPIL) / NTPC acceptance.

22.25.00 The Contractor/ Sub-contractor shall carry out routine test on 100% item at
contractor/ sub-contractor's works. The quantum of check /test for routine &
acceptance test by Client (EPIL) / NTPC shall be generally as per criteria /
sampling plan defined in referred standards. Wherever standards have not
been mentioned quantum of check / test for routine / acceptance test shall be as
agreed during detailed engineering stage.

22.26.00 Software Reliability / Quality Certification

Certification from OEM‟s authorized signatory that software offered with

DDCMIS, PLC, CCTV, PA, Pyrometer, CEMS, AAQMS, EQMS, BHMS etc. declaring
that the all the offered software(s) had gone through the established software quality
test and offered software is not of β-version and offered software is also free from all

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FGD System

known bugs as on date of approval of systems documents by NTPC as a part

of quality documentation review and approval process during detail engineering.

23.00.00 QUALITY ASSURANCE DOCUMENTS

23.01.00 The Contractor shall be required to submit the QA Documentation in two hard copies
and two CD ROMs, as identified in respective quality plan with tick ( ) mark.

23.01.01 Each QA Documentation shall have a project specific Cover Sheet bearing name &
identification number of equipment and including an index of its contents with page
control on each document.

The QA Documentation file shall be progressively completed by the Supplier‟s sub-

supplier to allow regular reviews by all parties during the manufacturing.

The final quality document will be compiled and issued at the final assembly place of
equipment before despatch. However CD-Rom may be issued not later than three
weeks.

23.02.00 Typical contents of QA Documentation is as below:-

(a.) Quality Plan

(b.) Material mill test reports on components as specified by the specification and
approved Quality Plans.

(c.) Manufacturer /works test reports/results for testing required as per

applicable codes and standard referred in the specification and approved
Quality Plans.

(d.) Non-destructive examination results /reports including radiography

interpretation reports. Sketches/drawings used for indicating the method of
traceability of the radiographs to the location on the equipment.

(e.) Heat Treatment Certificate/Record (Time- temperature Chart)

(f.) All the accepted Non-conformance Reports (Major/Minor)/deviation, including

complete technical details / repair procedure).

(g.) CHP / Inspection reports duly signed by the Inspector of the Client (EPIL) /
NTPC and Contractor for the agreed Customer Hold Points.

(h.) Certificate of Conformance (COC) wherever applicable.

(i.) MDCC

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FGD System

23.03.00 Similarly, the contractor shall be required to submit two sets (two hard copies and two
CD ROMs), containing QA Documentation pertaining to field activities as per
Approved Field Quality Plans and other agreed manuals/ procedures, prior to
commissioning of individual system.

23.04.00 Before despatch / commissioning of any equipment, the Supplier shall make
sure that the corresponding quality document or in the case of protracted
phased deliveries, the applicable section of the quality document file is
completed. The supplier will then notify the Inspector regarding the
readiness of the quality document (or applicable section) for review.

(a.) If the result of the review carried out by the Inspector is satisfactory, the
Inspector shall stamp the quality document (or applicable section) for
release.

(b.) If the quality document is unsatisfactory, the Supplier shall endeavor to

correct the incompleteness, thus allowing to finalize the quality document (or
applicable section) by time compatible with the requirements as per contract
documents. When it is done, the quality document (or applicable section) is
stamped by the Inspector.

(c.) If a decision is made for despatch, whereas all outstanding actions cannot be
readily cleared for the release of the quality document by that time, the
supplier shall immediately, upon shipment of the equipment, send a copy of the
quality document Review Status signed by the Supplier Representative to the
Inspector and notify of the committed date for the completion of all
outstanding actions & submission. The Inspector shall stamp the quality
document for applicable section when it is effectively completed. The
submission of QA documentation package shall not be later than 3 weeks
after the despatch of equipment.

23.05.00 TRANSMISSION OF QA DOCUMENTATION

On release of QA Documentation by Inspector, one set of quality document shall be

forwarded to Corporate Quality Assurance Department and other set to respective
Project Site of Client (EPIL) / NTPC.

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FGD System

For the particular case of phased deliveries, the complete quality document to the
Client (EPIL) / NTPC shall be issued not later than 3 weeks after the date of the last
delivery of equipment.

24.00.00 PROJECT MANAGER’S SUPERVISION

24.01.00 To eliminate delays and avoid disputes and litigation, it is agreed between the
parties to the Contract that all matters and questions shall be referred to the Project
Manager and without prejudice to the provisions of „Arbitration‟ clause in
Section GCC, the Contractor shall proceed to comply with the Project Manager's
decision.

24.02.00 The work shall be performed under the supervision of the Project Manager. The scope
of the duties of the Project Manager pursuant to the Contract, will include but not be
limited to the following:

(a.) Interpretation of all the terms and conditions of these documents and
specifications.

(b.) Review and interpretation of all the Contractor‟s drawing, engineering data, etc

(c.) Witness or his authorised representative to witness tests and trials either at the
manufacturer‟s works or at site, or at any place where work is performed under
the contract.

(d.) Inspect, accept or reject any equipment, material and work under the
contract.

(e.) Issue certificate of acceptance and/or progressive payment and final

payment certificates.

(f.) Review and suggest modifications and improvement in completion schedules

from time to time, and

(g.) Supervise Quality Assurance Programme implementation at all stages of the

works.

25.00.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES

25.01.00 The word „Inspector‟ shall mean the Project Manager and/or his authorised
representative and/or an outside inspection agency acting on behalf of the Client
(EPIL) / NTPC to inspect and examine the materials and workmanship of the
works during its manufacture or erection.

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FGD System

25.02.00 The Project Manager or his duly authorised representative and/or an outside
inspection agency acting on behalf of the Client (EPIL) / NTPC shall have access
at all reasonable times to inspect and examine the materials and workmanship
of the works during its manufacture or erection and if part of the works
is being manufactured or assembled on other premises or works, the Contractor shall
obtain for the Project Manager and for his duly authorised representative
permission to inspect as if the works were manufactured or assembled on the
Contractor‟s own premises or works.

25.03.00 The Contractor shall give the Project Manager/Inspector fifteen (15) days written
notice of any material being ready for testing. Such tests shall be to the Contractor‟s
account except for the expenses of the Inspector‟s. The Project Manager/Inspector,
unless the witnessing of the tests is virtually waived and confirmed in writing,
will attend such tests within fifteen (15) days of the date on which the
equipment is noticed as being ready for test/inspection failing which the contractor
may proceed with test which shall be deemed to have been made in the inspector‟s
presence and he shall forthwith forward to the inspector duly certified copies of test
reports in two (2) copies.

25.04.00 The Project Manager or Inspector shall within fifteen (15) days from the date of
inspection as defined herein give notice in writing to the Contractor, or any objection
to any drawings and all or any equipment and workmanship which is in his opinion
not in accordance with the contract. The Contractor shall give due consideration to
such objections and shall either make modifications that may be necessary to meet the
said objections or shall inform in writing to the Project Manager/Inspector giving
reasons therein, that no modifications are necessary to comply with the contract.

25.05.00 When the factory tests have been completed at the Contractor‟s or sub-contractor‟s
works, the Project Manager /Inspector shall issue a certificate to this effect Ten (10)
days after completion of tests but if the tests are not witnessed by the Project
Manager /Inspectors, the certificate shall be issued within Ten (10) days of the
receipt of the Contractor‟s test certificate by the Project Manager /Inspector. Failure on
the part of Project Manager /Inspector to issue such a certificate shall not prevent the
Contractor from proceeding with the works. The completion of these tests or the issue
of the certificates shall not bind the Client (EPIL) / NTPC to accept the equipment
should it, on further tests after erection be found not to comply with the contract.

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FGD System

25.06.00 In all cases where the contract provides for tests whether at the premises or works of
the Contractor or any sub-contractor, the Contractor, except where otherwise
specified shall provide free of charge such items as labour, material, electricity, fuel,
water, stores, apparatus and instruments as may be reasonably demanded by the
Project Manager /Inspector or his authorised representatives to carry out effectively
such tests on the equipment in accordance with the Contractor and shall give
facilities to the Project Manager/Inspector or to his authorised representative to
accomplish testing.

25.07.00 The inspection by Project Manager / Inspector and issue of Inspection

Certificate thereon shall in no way limit the liabilities and responsibilities of the
Contractor in respect of the agreed Quality Assurance Programme forming a part of
the contract.

25.08.00 To facilitate advance planning of inspection in addition to giving inspection notice as

specified at clause no 25.03.00 of this chapter, the Contractor shall furnish quarterly
inspection programme indicating schedule dates of inspection at Customer Hold
Point and final inspection stages. Updated quarterly inspection plans will be made
for each three consecutive months and shall be furnished before beginning of each
calendar month.

25.09.00 All inspection, measuring and test equipment used by contractor shall be calibrated
periodically depending on its use and criticality of the test/measurement to be done.
The Contractor shall maintain all the relevant records of periodic calibration and
instrument identification, and shall produce the same for inspection by NTPC.
Wherever asked specifically, the contractor shall re-calibrate the measuring/test
equipment in the presence of Project Manager / Inspector.

25.10.00 Associated document for Quality Assurance programme

25.10.01 Manufacturing Quality Plan Format No. : QS-01-QAI-P-09/F1-R1 enclosed at

Annexure-I.

25.10.02 Field Quality Plan Format No.: QS-01-QAI-P-09/F2-R1 enclosed at Annexure-II.

25.10.03 List of items requiring quality plan and sub supplier approval. Format No.: QS-01-
QAI-P-01/F3-R0 (Annexure-III).

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FGD System

25.10.04 Status of items requiring Quality Plan and sub supplier approval. Format enclosed at
Annexure-IV.

25.10.05 Field Welding Schedule Format enclosed at Annexure-V.

25.11.00 Not Used.

25.12.00 DEMONSTRATION OF APPLICATION ENGINEERING

25.12.01 Based on NTPC inputs, the Contractor shall prepare and submit typical implemented
scheme in their system (Control system & HMI) on sample basis. The typical cases to
be covered shall include but not be limited to the following.

(i) Logics/Loops:

a) Drive logics implementation for each type of binary drive along with its
display in HMI.

b) Sequence implementation along with its display in HMI.

c) Single non-cascade controller implementation.

d) Cascade loop implementation.

e) Master slave implementation with different slave combination.

f) Temperature & pressure compensation for flow signals & Pressure

compensation for level signals as applicable.

(ii) HMI Functions:

a) LVS Annunciation.

b) Graphics.

c) HSR

d) Logs/Reports.

e) Calculations (Basic & Performance Calculations).

25.12.02 The above typical cases shall be finalized with the Client (EPIL) / NTPC through
Technical Co- ordination meetings.

After review and finalization of the typical cases, the implementation of each logic &
control loop shall be carried out by the Contractor based on NTPC inputs.
After implementation of these logics & loops, the Contractor shall test each logic /loop

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FGD System

and record the observations in a format to be provided by the Client (EPIL) / NTPC
and demonstrate to Client (EPIL) / NTPC at Client (EPIL) / NTPC premises during
engineering finalization. Any modifications as a result of the demonstration shall be
done and documented as part of the test report along with the final scheme.
Similarly, HMI functions shall also be demonstrated by the Contractor at
Client (EPIL) / NTPC premises & the results shall be documented as part of test
report.

25.12.03 During the integrated testing at the Contractor‟s works, only sample checks shall be
done by the Client (EPIL) / NTPC for the items covered in above application
engineering demonstration.

26.00.00 PRE-COMMISSIONING AND COMMISSIONING FACILITIES

26.01.00 (a) As soon as the facilities or part thereof has been completed operationally and
structurally and before start-up, each item of the equipment and systems
forming part of facilities shall be thoroughly cleaned and then inspected
jointly by the Client (EPIL) / NTPC and the Contractor for correctness
of and completeness of facility or part thereof and acceptability for initial
pre- commissioning tests, commissioning and start-up at Site. The list of
pre- commissioning tests to be performed shall be as mutually agreed and
included in the Contractor‟s quality assurance programme as well as those
included in Part-D, Section-VI and elsewhere in the Technical Specifications.

(b) The Contractor‟s pre-commissioning/commissioning/start-up engineers,

specially identified as far as possible, shall be responsible for carrying out all the
pre-commissioning tests at Site. On completion of inspection, checking and
after the pre-commissioning tests are satisfactorily over, the commissioning of
the complete facilities shall be commenced during which period the
complete facilities, equipments shall be operated integral with sub- systems and
supporting equipment as a complete plant.

(c) All piping system shall be flushed, steam blown, air blown as required and
cleanliness demonstrated using acceptable industry standards. Procedures to
accomplish this work shall be submitted for approval to the Client (EPIL) /
NTPC six months prior to the respective implementations. The Client (EPIL) /
NTPC will approve final verification of cleanliness.

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FGD System

(d) The time consumed in the inspection and checking of the units shall be
considered as a part of the erection and installation period.

(e) The check outs during the pre -commissioning period should be programmed
to follow the construction completion schedule. Each equipment/system, as
it is completed in construction and turned over to Client (EPIL) / NTPC's
commissioning (start-up) Engineer(s), should be checked out and cleaned. The
checking and inspection of individual systems should then follow a prescribed
commissioning documentation [SLs (standard check list)/TS(testing schedule)/
CS(commissioning schedule)] approved by the Client (EPIL) / NTPC.

(f) The Contractor during initial operation and performance testing shall conduct
vibration testing to determine the „base line‟ of performance of all plant
rotating equipment. These tests shall be conducted when the equipment is
running at the base load, peak load as well as lowest sustained operating
condition as far as practicable.

26.01.01 Contractor shall furnish the commissioning organization chart for review &
acceptance of Client (EPIL) / NTPC at least twelve months prior to the schedule
date of commissioning of 1st unit. The chart should contain:

(1.) Biodata including experience of the Commissioning Engineers.

(2.) Role and responsibilities of the Commissioning Organisation members.

(3.) Expected duration of posting of the above Commissioning Engineers at site.

26.02.00 Initial Operation

(a) On completion of all pre-commissioning activities/ tests and as a part of

commissioning the complete facilities shall be put on 'Initial Operation' during
which period all necessary adjustments shall be made while operating over the
full load range enabling the facilities to be made ready for the Guarantee Tests.

(b) The 'Initial Operation' of the complete facility as an integral unit shall be
conducted for 720 continuous hours. During the period of initial operation of 720
hours, the equipment shall operate continuously at full load for a period
not less than 72 hours.

The Initial Operation shall be considered successful, provided that each item/
part of the facility can operate continuously at the specified operating

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FGD System

characteristics, for the period of Initial Operation with all operating

parameters within the specified limits and at or near the predicted
performance of the equipment/ facility.

The Contractor shall intimate the Client (EPIL) / NTPC about the
commencement of initial operation and shall furnish adequate notice to the
Client (EPIL) / NTPC in this respect.

(c) Any operational interruption in the equipment due to constraints

attributable to the Client (EPIL) / NTPC shall be construed as Deemed
to be in operation.

(d) An Initial Operation report comprising of observations and recordings of

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

26.03.00 Guarantee Tests

a) The final test as to prove the Functional Guarantees shall be conducted Site
by the Contractor in presence of the Client (EPIL) / NTPC. The
contractor's Commissioning, start-up Engineer shall make the unit ready to
conduct such test before start of initial operation. Such test shall be conducted
along with the Initial Operations.

b) These tests shall be binding on both the parties of the Contract to determine
compliance of the equipment with the functional guarantee.

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FGD System

c) For performance/ demonstration tests instrumentations, of accuracy class

shall be as per specified test codes. The numbers and location of the
instruments shall be as per the specified test codes. In addition the values of
parameters shall be logged from the information system provided under
Client (EPIL) / NTPC's Distributed Digital Control Monitoring and
Information system. Test will be conducted at specified load points.

d) Any special equipment, tools and tackles required for the successful
completion of the Guarantee Tests shall be provided by the Contractor, free of
cost.

e) The Guarantee tests and specific tests to be conducted on equipments have been
brought out in detail elsewhere in the specifications.

27.00.00 TAKING OVER

Upon successful completion of Initial Operations and all the tests conducted to the
Client (EPIL) / NTPC's satisfaction, the Client (EPIL) / NTPC shall issue to the
Contractor a Taking over Certificate as a proof of the final acceptance of the
equipment. Such certificate shall not unreasonably be with held nor will the Client
(EPIL) / NTPC delay the issuance thereof, on account of minor omissions or defects
which do not affect the commercial operation and/or cause any serious risk to the
equipment. Such certificate shall not relieve the Contractor of any of his obligations
which otherwise survive, by the terms and conditions of the Contract after issuance
of such certificate.

28.00.00 TRAINING OF NTPC'S PERSONNEL

28.01.00 Training for NTPCs O&M Personnel

The scope of service under training of NTPC's engineers shall include a training
module covering upto four (4) weeks in the areas of Operation & Maintenance.

Such training should enable the personnel to individually take the responsibility
of operating and maintaining the FGD system in a manner acceptable to NTPC.

28.02.00 Training for NTPCs Engineering Personnel

The scope of services under training for NTPC's engineering personnel shall also
necessarily include two (2) weeks.

28.03.00 Bidder shall furnish in his offer, details of training module(s) covering above
requirements which shall be subject to Client (EPIL) / NTPC's approval.

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FGD System

Consolidated training period included above is indicative only. Client (EPIL) / NTPC
reserves the right to re appropriate the training period between O&M and engineering
depending upon the details of training module proposed by the Bidder.

28.04.00 Exact details, extent of training and the training schedule shall be finalised based on
the Bidder's proposal within four (4) months from placement of award.

28.05.00 In all the above cases, wherever the training of NTPC's personnel is arranged at the
works of the manufacturer's it shall be noted that the lodging and boarding of the
NTPC's personnel shall be at the cost of Contractor. The Contractor shall make all
necessary arrangements towards the same.

28.06.00 Take off prices (product wise) should be indicated by the Bidder in the Bid Proposal
Sheets. Client (EPIL) / NTPC reserves the right to include or exclude these
item(s) during placement of Award.

29.00.00 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION

In addition to the requirements given in Erection Conditions of Contract (ECC) the
following shall also cover:

i) Working platforms should be fenced and shall have means of access.

ii) Ladders in accordance with Client (EPIL) / NTPC‟s safety rules for
construction and erection shall be used. Rungs shall not be welded on
columns. All the stairs shall be provided with handrails immediately after
its erection.

30.00.00 NOISE LEVEL

The equivalent "A" weighted sound pressure level measured at a height of 1.5 m above
floor level in elevation and at a distance of one (1) meter horizontally from the nearest
surface of any equipment/machine, furnished and installed under these specifications,
expressed in decibels to a reference of 0.0002 microbar, shall not exceed 85 dBA.
However for Ball Mills the noise levels as per following shall also be acceptable:

a) Ball Mill: 90 dBA

31.00.00 PACKAGING AND TRANSPORTATION

All the equipments shall be suitably protected, coated, covered or boxed and crated to
prevent damage or deterioration during transit, handling and storage at Site till the
time of erection. While packing all the materials, the limitation from the point of view
of the sizes of railway wagons available in India should be taken account of.

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FGD System

The Contractor shall be responsible for any loss or damage during

transportation, handling and storage due to improper packing. The Contractor
shall ascertain the availability of Railway wagon sizes from the Indian Railways
or any other agency concerned in India well before effecting despatch of equipment.
Before despatch it shall be ensured that complete processing and manufacturing of the
components is carried out at shop, only restricted by transport limitation, in order to
ensure that site works like grinding, welding, cutting & preassembly to bare
minimum. The Client (EPIL) / NTPC's Inspector shall have right to insist for
completion of works in shops before despatch of materials for transportation.

32.00.00 ELECTRICAL EQUIPMENTS/ENCLOSURES

32.01.00 All electrical equipments and devices, including insulation, heating and
ventilation devices shall be designed for ambient temperature and a maximum relative
humidity as specified elsewhere in the specifications.

33.00.00 INSTRUMENTATION AND CONTROL

All instrumentation and control systems/ equipment/ devices/ components,
furnished under this contract shall be in accordance with the requirements stated
herein, unless otherwise specified in the detailed specifications.

33.01.00 All instrument scales and charts shall be calibrated and printed in metric units and
shall have linear graduation. The ranges shall be selected to have the normal
reading at 75% of full scale.

All scales and charts shall be calibrated and printed in Metric Units as follows:

1 Temperature - Degree centigrade (deg C)

2. Pressure - Kilograms per square centimetre (Kg/cm2).

Pressure instrument shall have the unit suffixed
with 'a' to indicate absolute pressure. If nothing is
there, that will mean that the indicated pressure is
gauge pressure.

3. Draught - Millimetres of water column (mm wc).

4. Vacuum - Millimeters of mercury gauge (mm Hg) or water

column (mm Wcl).

5. Flow (Gas) - Tonnes/ hour

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FGD System

6. Flow (Steam) - Tonnes/ hour

7. Flow (Liquid) - Tonnes / hour

8. Flow base - 760 mm Hg. 0 deg.C

9. Density - Grams per cubic centimetre.

33.02.00 All instruments and control devices provided on panels shall be of miniaturized
design, suitable for modular flush mounting on panels with front draw out facility and
flexible plan-in connection at rear.

33.03.00 All electronic modules shall have gold plated connector fingers and further all input
and output modules shall be short circuit proof. These shall also be tropicalised &
components shall be of industrial grade or better.

34.00.00 ELECTRICAL NOISE CONTROL

The equipment furnished by the Contractor shall incorporate necessary techniques to
eliminate measurement and control problems caused by electrical noise. Areas in
Contractor's equipment which are vulnerable to electrical noise shall be hardened to
eliminate possible problems. Any additional equipment, services required for
effectively eliminating the noise problems shall be included in the proposal. The
equipment shall be protected against ESD as per IEC-61000-2. Radio Frequency
interference (RFI) and Electro Magnetic Interference (EMI) protection against
hardware damage and control system mal-operations/errors shall be provided for all
systems as per EN-50082-2 (1995).

35.00.00 SURGE PROTECTION FOR SOLID STATE EQUIPMENT

All solid state systems /equipment shall be able to withstand the electrical noise and
surge as encountered in actual service conditions and inherent in a power plant and
shall meet the requirements of surge protection as defined in ANSI C37.90.1-1989 on
its suitable equivalent class of IEC 254-4. Details of the features incorporated and
relevant tests carried out. The test certificates. etc. shall be submitted by the Bidder.

36.00.00 INSTRUMENT AIR SYSTEM

The instrument air supply system as supplied by the Bidder for various pneumatic
control & instrumentation devices like pneumatic actuators, power cylinders,
E/P converters, piping / tubing etc.

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RSTPP ANALYSERS PACKAGE FOR FGD (Supply, GENERAL TECHNICAL
STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

Each pneumatic instrument shall have an individual air shut - off valve. The pressure
regulating valve shall be equipped with an internal filter, a 50 mm pressure gauge
and a built-in filter housing blow down valve.

37.00.00 TAPPING POINTS FOR MEASUREMENTS

Tapping points shall include probes, wherever applicable, for analytical
measurements and sampling.

For direct temperature measurement of all working media, one stub with
internal threading of approved pattern shall be provided along with suitable plug and
washer. The Contractor will be intimated about thread standard to be adopted.

The following shall be provided on equipment by the Bidder. The standard which is to
be adopted will be intimated to the Contractor.

i) Temperature test pockets with stub and thermowell

ii) Pressure test pockets

38.00.00 SYSTEM DOCUMENTATION

The Bidder shall provide drawings, system overview & description, hardware/
software details, technical literature, functional & hardware schemes, bill of material,
parts list, interconnection diagrams, data sheets, erection/ installation/
commissioning procedures, instruction/ operating manuals, etc. for each of the C& I
system/ sub-systems/ equipment supplied under this package. The documentation
shall include complete details of the C&I systems/ sub-systems/ equipment to enable
review by Client (EPIL) / NTPC during detailed engineering stage and to provide
information to plant personnel for operation & Maintenance (including quick
diagnostics & trouble shooting) of these C&I systems/ sub-systems/ equipment at
site. The minimum documentation requirements for C&I systems shall be as
stipulated under C&I "Technical Data Sheets" Part of specifications. In
addition to this, system documentation for control system shall include as a
minimum to that specified elsewhere in the Technical Specification.

The exact format, submission schedule and contents of various documents shall be as
finalised during detailed engineering stage.

38.01.00 Bill of material (instrument list) for all C&I equipment/ devices shall be furnished by
the bidder in standard formats as approved by the Client (EPIL) / NTPC.

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FGD System

39.00.00 MAINTENANCE MANUALS OF ELECTRONIC MODULES

The Contractor shall have to furnish two (2) sets of all maintenance manual of each
and every electronic card/module as employed on the various systems and
equipment including peripherals etc., offered by him. The Contractor will also have to
furnish the data regarding the expected failure rate of various modules and
other system components. Further , the contractor shall furnish a set of operating
manuals which should include block diagrams ,make, model/type ,details wiring and
external connection drawings etc as required to do the testing and maintenance
of the electronic modules.

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STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

LIST OF CODES AND STANDARDS

Indian Title International and Internationally

Standards recognized standards
IS:277 Galvanised steel sheets (plain or
corrugated)

IS:655 Specification for metal air duct

IS:800 Code of practice for use of structural BS 449:1969

steel in general building
BS 5950
construction
ASA A57, 1-1952

IS:807 Code of practice for design, Draft Revision of A.S. NO. CS.2
manufacture, erection and testing SAA Crane and Hoist code Doc:No.
(Structural portion) of cranes and BU/4 Rev
hoists 6588 (Issued by Standards
Association of Australia).

DIN 120:1936 (Sheet 1)

DIN 120:1936 (Sheet 2)

327 part-I, 1951

BS 466 part-II, 1960 BS 644:1960

BS 1757:1951 BS 2573:part-I:1960
IS:875 Code of practice for design loads National Building code of Canada
(other than earthquake) for (1953)-Part-IV Design section 4.1
buildings and structures Leading
standards (issued by Canadian
Standard) DIN-1055-1955 (Issued by
ASA)
IS:1239 Part-I Mild steel tubes (ISO/R 65-1957)

(ISO/R-64-1958)

(ISO/R-65-1958)

(BS 1387 : 1957)

IS:1239 Part-II Mild steel tubulars and other BS 1387 : 1967; BS 1387 :1967
wrought steel pipe fittings
BS 1740 :1965

IS:2825 Code for unfired vessels

IS:1520 Horizontal centrifugal pumps for

clear cold and fresh water

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STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

Indian Title International and Internationally

Standards recognized standards
IS:1600 Code for practice for performance of
constant speed IC Engines for
general purpose.

IS:1601 Specification for performance of

constant speed IC Engines for
general Purpose

IS:1893 Criteria for earthquake resistant

design of structures

IS1978-1971 Line Pipe April 1969. API Standards 5L

IS:2254-1970 Dimensions of vertical shaft motor IEC Pub 72-1 part I

for pumps
NEMA Pub MG 1 1954

IS:2266 Steel wire ropes for general BS :302 : 1968

engineering purposes

IS:2312 Propellant type Ventilation fans

IS:2365 Steel wire suspension ropes for lifts BS : 1957

and hoists
IS:3346 Method for the determination DIN 52612 (Deutscher
Thermal conductivity of thermal Normenausschuss)
insulation materials (two slab
ASTM C 163-1964 (American
guarded hot plate method)
Society of Testing and materials)
ASTM C 167-1974
ASTM C 177-1963

IS:3354 Outline dimensions for electric lifts

IS:3401 Silica gel

IS:3588 Specification for electrical axial flow

fans

IS:3589 Electrically welded steel pipes for

water, gas and sewage (200mm to
2000 mm Nominal Diameter)

IS:3677 Un-bonded rock and slag wool for

thermal insulation

IS:3815 Point hook with shank for general BS 482 – 1968 ; Doc.:67/3 1284
engineering purposes (Revision of BS 2903) (Issued BS)

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STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

Indian Title International and Internationally

Standards recognized standards
IS:3895 Specification for monocrystallines
Semiconductor rectifier cells and
stacks

IS:3963 Roof extractor unit

IS:3975 Mild steel wires, strips and tapes for

armouring cables

IS:4503 Shell and tube type heat Exchanger

IS:4540 Specification for monorystallines

rectifier assembly equipment

IS:4671 Expanded polystyrene for

thermal insulation purpose

IS:4736 Hot dip zinc coating on steel tubes

IS:4894 Centrifugal fans

IS:5456 Code of practice for testing of
positive displacement type air
compressors and exhauster (For
Test Tolerance Only)

IS:5749 Forged ramshorn hooks Entwurf DIN 15402

Blett 1
Entwurf DIN 15402

BS 3017-1958

IS:6392 Steel pipe flanges BS 4504 : 1969

IS:6524 Code of practice for Part-I design of BS 2799 : 1956

tower cranes Static and rail mounted

IS:7098 Cross linked Polyethylene Standard No. 1 to insulated PVC

sheathed IPCEA (USA) Pub. cables
No. 5-66-524

IS:7373 Specification for wrought

aluminium and aluminium sheet
and strips

IS:7938 Air receivers for compressed air

installation

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RSTPP ANALYSERS PACKAGE FOR FGD (Supply, GENERAL TECHNICAL
STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

Indian Title International and Internationally

Standards recognized standards
ISO:1217 Displacement compressor-Acceptance test

ASHRAE-33. Methods of testing for rating of forced circulation air cooling and air
heating coils.

ASHRAE-52-76 Air cleaning device used in general ventilation for removing particle
matter

ASHRAE-22-72 Method of testing for rating of water cooled refrigerant condensers.

ASHRAE 23-67 Methods of testing for rating of positive displacement refrigerant

compressors.

ARI-450-6 Standard for water cooled refrigerant condensers. ARI-550 Standard for
centrifugal water chilling packages.

ARI-410 Standard for forced circulation air cooling and air heating coils

ARI-430/435 Central station AHU/Application of Central Station AHU Fans

BS:848(Part-1,2)
BS:400 Low carbon steel cylinders for the storage & transport of permanent gases.

BS:401 Low carbon steel cylinders for the storage & transport of liquefied gases.

CTI Code . Acceptance test code for Water Cooling Tower.

ACT-105

ANSI-31.5 Refrigerant piping

ASME-PTC- 23- Atmospheric Water Cooling Equipment

1958

AMCA A-21C Test Code for air moving devices

API:618 Reciprocating Compressor for general refinary services.

HYDRAULIC INSTITUTE STANDARDS.

HYDRANT SYSTEM MANUALS OF TAC.

TAC MANUALS OF SPRAY SYSTEM

NFPA USA/ NSC UK/ UL USA/ FM USA STANDARDS.

INDIAN EXPLOSIVES ACT.

INDIAN FACTORIES ACT.

STANDARD OF TUBULAR EXCHANGER MANUFACTURER'S ASSOCIATION.

CODE AND STANDARD FOR CIVIL WORKS

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STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

Indian Title International and Internationally

Standards recognized standards
Some of the applicable Standards, Codes and references are as follows:

Excavation &
Filling
IS: 2720 (Part-II, IV TO VIII, XIV, XXI, XXIII, XXIV, XXVII TO XXIX, XL) Methods of test for
soils-determination for water content etc.

IS: 4701 Code of practice for earth work on canals.

IS: 9758 Guide lines for Dewatering during construction.

IS: 10379 Code of practice for field control of moisture and compaction of soils
for embankment and sub-grade.

Properties, Storage and Handling of Common Building Materials

IS: 269 Specification for ordinary Portland cement, 33 grade.

IS: 383 Specification for coarse and fine aggregates from natural sources for
concrete.

IS: 432 Specification for mild steel and (Parts 1&2) medium tensile steel bars and
hard-drawn steel wires for concrete reinforcement.

IS: 455 Specification for Portland slag cement.

IS: 702 Specification for Industrial bitumen.

IS: 712 Specification for building limes

IS: 808 Rolled steel Beam channel and angle sections

IS: 1077 Specification for common burnt clay building bricks.

IS: 1161 Specification of steel tubes for structural purposes

IS: 1363 Hexagon head Bolts, Screws and nuts of production grade C.

IS: 1364 Hexagon head Bolts, Screws and Nuts of Production grade A & B.

IS: 1367 Technical supply conditions for Threaded fasteners.

IS: 1489 Specification for Portland-pozzolana cement.

(Part-I) Fly ash based.

(Part-II) Calcined clay based.

IS: 1542 Specification for sand for plaster.

IS: 1566 Specification for hard-drawn steel wire fabric for concrete reinforcement.

IS: 1786 Specification for high strength deformed bars for concrete reinforcement.

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STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

Indian Title International and Internationally

Standards recognized standards
IS: 2062 Specification for steel for general structural purposes.

IS: 2116 Specification for sand for masonry mortars

IS: 2386 Testing of aggregates for concrete.

(Parts-I to VIII)

IS: 3150 Hexagonal wire netting for general purpose.

IS: 3495 Methods of tests of burnt clay building bricks.

(Parts-I to IV)

IS: 3812 Specification for fly ash, for use as pozzolana and admixture.

IS: 4031 Methods of physical tests for hydraulic cement.

IS: 4032 Methods of chemical analysis of hydraulic cement.

IS: 4082 Recommendations on stacking and storage of construction Materials at site.

IS: 8112 Specification for 43 grade ordinary portland cement.

IS: 8500 Medium and high strength structural steel.

IS: 12269 53 grade ordinary portland cement.

IS: 12894 Specification for Fly ash lime bricks. Cast-In-Situ Concrete and Allied
Works

IS: 280 Specification for mild steel wire for general engineering purposes.

IS: 456 Code of practice for plain and reinforced concrete.

IS: 457 Code of practice for general construction of plain & reinforced
concrete for dams & other massive structures.

IS: 516 Method of test for strength of concrete.

IS: 650 Specification for standard sand for testing of cement.

IS: 1199 Methods of sampling and analysis of concrete.

IS: 1791 General requirements for batch type concrete mixers.

IS: 1838 (Part-I) Specification for preformed fillers for expansion joints in
Concrete pavements and structures (non-extruding and resilient
type).

IS: 2204 Code of practice for construction of reinforced concrete shell roof.

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STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

IS: 2210 Criteria for the design of reinforced concrete shell structures and
folded plates.

IS: 2438 Specification for roller pan mixer.

IS: 2502 Code of practice for bending and fixing of bars for concrete
reinforcement.

IS: 2505 General requirements for concrete vibrators, immersion type.

IS: 2506 General requirements for concrete vibrators, screed board type.

IS: 2514 Specification for concrete vibrating tables.

IS: 2645 Specification for Integral cement water proofing compounds.

IS: 2722 Specification for portable swing weigh batches for concrete. (single
and double bucket type)

IS: 2750 Specification for Steel scaffolding.

IS: 2751 Code of practice for welding of mild steel plain and deformed bars
for reinforced concrete construction.

IS: 3025 Methods of sampling and test waste water.

IS: 3366 Specification for Pan vibrators.

IS: 3370(Part I to IV) Code of practice for concrete structures for the storage of liquids.

IS: 3414 Code of practice for design and installation of joints in buildings.

IS: 3550 Methods of test for routine control for water used in industry.

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

IS: 4014(Parts I & II) Code of practice for steel tubular scaffolding.

IS: 4326 Code of practice for earthquake resistant design and construction of
buildings.

IS: 4461 Code of practice for joints in surface hydro-electric power stations.

IS: 4656 Specification for form vibrators for concrete.

IS: 4925 Specification for batching and mixing plant.

IS: 4990 Specification for plywood for concrete shuttering work.

IS: 4995(Parts I & II) Criteria for design of reinforced concrete bins for the storage of
granular and powdery materials.

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STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

IS: 5256 Code or practice for sealing joints in concrete lining on canals.

IS: 5525 Recommendations for detailing of reinforcement in reinforced

concrete work.

IS: 5624 Specification for foundation bolts.

IS: 6461 Glossary of terms relating to cement concrete.

IS: 6494 Code of practice for water proofing of underground water reservoirs
and swimming pools.

IS: 6509 Code of practice for installation of joints in concrete pavements.

IS: 7861(Parts I & II) Code of practice for extreme weather concreting.

IS: 9012 Recommended practice for shot concreting.

IS: 9103 Specification for admixtures for concrete.

IS: 9417 Recommendations for welding cold worked steel bars for reinforced
concrete construction.

IS: 10262 Recommended guidelines for concrete mix design.

IS: 11384 Code of practice for composite construction in structural steel and
concrete.

IS: 11504 Criteria for structural design of reinforced concrete natural draught
cooling towers.

IS: 12118 Specification for two-parts poly sulphide.

IS: 12200 Code of practice for provision of water stops at transverse

contraction joints in masonry and concrete dams.

IS: 13311 Method of non-destructive testing of concrete.

Part-1 Ultrasonic pulse velocity.

Part-2 Rebound hammer.

SP:23 Handbook of concrete mixes

SP: 24 Explanatory Handbook on IS: 456-1978

SP: 34 Handbook on concrete reinforcement and detailing.

Precast Concrete Works

SP: 7(PartVI/ National Building Code- Structural design of prefabrication and

Sec.7) systems building.

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STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

IS: 10297 Code of practice for design and construction of floors and roofs
using precast reinforced/prestressed concrete ribbed or cored slab
units.

IS: 10505 Code of practice for construction of floors and roofs using pre-cast
reinforced concrete units.

Masonary and Allied Works

IS: 1905 Code of Practice for Structural Safety of Buildings-Masonry walls.

IS: 2212 Code of Practice for Brickwork.

IS: 2250 Code of Practice for Preparation and use of Masonry Mortar.

SP: 20 Explanatory hand book on masonry code.

Sheeting Works

IS:277 Galvanised steel sheets (plain or corrugated).

IS: 459 Unreinforced corrugated and semi-corrugated asbestos cement

sheets.

IS: 513 Cold-rolled carbon steel sheets.

IS: 730 Specification for fixing accessories for corrugated sheet

roofing.

IS: 1626 Specification for Asbestos cement building pipes and pipe
fittings, gutters and gutter fittings and roofing fittings.

IS: 2527 Code of practice for fixing rain water gutters and down pipe
for roof drainage.

IS: 3007 Code of practice for laying of asbestos cement sheets.

IS: 5913 Methods of test for asbestos cement products.

IS: 7178 Technical supply conditions for tapping screw.

IS: 8183 Bonded mineral wool.

IS: 8869 Washers for corrugated sheet roofing.

IS: 12093 Code of practice for laying and fixing of sloped roof covering using
plain and corrugated galvanised steel sheets.

IS: 12866 Plastic translucent sheets made from thermosetting polyster resin
(glass fibre reinforced).

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STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

IS: 14246 Specification for continuously pre-painted galvanised steel sheets

and coils.

Fabrication and Erection of Structural Steel Work

IS: 2016 Specification for plain washers.

IS: 814 Specification for covered Electrodes for Metal Arc Welding for
weld steel.

IS: 1852 Specification for Rolling and Cutting Tolerances for Hot rolled
steel products.

IS: 3502 Specifications for chequered plate.

IS: 6911 Specification for stainless steel plate, sheet and strip.

IS: 3757 Specification for high strength structural bolts.

IS: 6623 Specification for high strength structural nuts.

IS: 6649 High Tensile friction grip washers.

IS: 800 Code of practice for use of structural steel in general building
construction.

IS: 816 Code of practice for use of Metal Arc Welding for General
Construction.

IS: 4000 Code of practice for assembly of structural joints using high
tensile friction grip fasteners.

IS: 9595 Code of procedure of Manual Metal Arc Welding of Mild Steel.

IS: 817 Code of practice for Training and Testing of Metal Arc Welders.

IS: 1811 Qualifying tests for Metal Arc Welders (engaged in welding
structures other than pipes).

IS: 9178 Criteria for Design of steel bins for storage of Bulk Materials.

IS: 9006 Recommended Practice for Welding of Clad Steel.

IS: 7215 Tolerances for fabrication steel structures.

IS: 12843 Tolerance for erection of structural steel.

IS: 4353 Recommendations for submerged arc welding of mild steel and
low alloy steels.

SP: 6 ISI Hand book for structural Engineers. (Part 1 to 7)

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STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

IS: 1608 Method of Tensile Testing of Steel products other than sheets,
strip, wire and tube.

IS: 1599 Method of Bend Tests for Steel products other than sheet, strip, wire
and tube.

IS : 228 Methods of chemical Analysis of pig iron, cast iron and plain
carbon and low alloy steel.

IS : 2595 Code of Practice for Radio graphic testing.

IS : 1182 Recommended practice for Radiographic Examination of fusion

welded butt joints in steel plates.

IS : 3664 Code of practice for Ultra sonic Testing by pulse echo method.

IS : 3613 Acceptance tests for wire flux combination for submerged Arc
Welding.

IS : 3658 Code of practice for Liquid penetrant Flaw Detection.

IS : 5334 Code of practice for Magnetic Particle Flaw Detection of Welds.

Plastering and Allied Works

IS : 1635 Code of practice for field slaking of Building lime and preparation of
putty.

IS : 1661 Application of cement and cement lime plaster finishes.

IS : 2333 Plaster-of-paris.

IS : 2402 Code of practice for external rendered finishes.

IS : 2547 Gypsum building plaster.

IS : 3150 Hexagonal wire netting for general purpose.

Acid and Alkali Resistant Lining

IS : 158 Ready mixed paint, brushing, bituminous, black, lead free, acid,
alkali & heat resisting.

IS : 412 Specification for expanded metal steel sheets for general

purpose.

IS : 4441 Code of practice for use of silicate type chemical resistant

mortars.

IS : 4443 Code of practice for use of resin type chemical resistant

mortars.

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STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

IS : 4456(Part I & II) Method of test for chemical resistant tiles.

IS : 4457 Specification for ceramic unglazed vitreous acid resistant tiles.

IS : 4832 Specification for chemical resistant mortars.

Part I Silicate type

Part II Resin type

Part III Sulphur type

IS : 4860 Specification for acid resistant bricks.

IS : 9510 Specification for bitumasitc, Acid resisting grade.

Water Supply, Drainage and Sanitation

IS : 458 Specification for concrete pipes.

IS : 554 Dimensions for pipe threads, where pressure tight joints are made on
thread.

IS : 651 Specification for salt glazed stoneware pipes.

IS : 774 Flushing cisterns for water closets and urinals.

IS : 775 Cast iron brackets and supports for wash basins and sinks.

IS : 778 Copper alloy gate, globe and check valves for water works
purposes.

IS : 781 Cast copper alloy screw down bib taps and stop valves for water
services.

IS : 782 Caulking lead.

IS : 783 Code of practice for laying of concrete pipes.

IS : 1172 Basic requirements for water supply, drainage and sanitation.

IS : 1230 Cast iron rain water pipes and fittings.

IS : 1239 Mild steel tubes, tubulars and other wrought steel fittings.

IS : 1536 Centrifugally cast (Spun) iron pressure pipes for water, gas and
sewage.

IS : 1537 Vertically cast iron pressure pipes for water, gas and sewage.

IS : 1538 Cast iron fittings for pressure pipe for water, gas and sewage.

IS : 1703 Ball valves (horizontal plunger type) including float for water
supply purposes.

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STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

IS : 1726 Cast iron manhole covers and frames.

IS : 1729 Sand cast iron spigot and socket, soil, water and ventilating pipes,
fittings and accessories.

IS : 1742 Code of practice for building drainage.

IS : 1795 Pillar taps for water supply purposes.

IS : 1879 Malleable cast iron pipe fittings.

IS : 2064 Code of practice for selection, installation and maintenance of

sanitary appliances.

IS : 2065 Code of practice for water supply in building.

IS : 2326 Automatic flushing cisterns for urinals.

IS : 2470 Code of practice for installation of septic tanks. (Part-I & II)

IS : 2501 Copper tubes for general engineering purposes.

IS : 2548 Plastic seat and cover for water-closets.

IS : 2556 Vitreous sanitary appliances (vitreous china). (Part 1 to 15)

IS : 2963 Non-ferrous waste fittings for wash basins and sinks.

IS : 3114 Code of practice for laying of cast iron pipes.

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

IS : 3438 Silvered glass mirrors for general purposes.

IS : 3486 Cast iron spigot and socket drain pipes.

IS : 3589 Electrically welded steel pipes for water, gas and

sewage(200mm to 2000mm nominal diameter).

IS : 3989 Centrifugally cast (Spun) iron spigot and socket soil, waste and
ventilating pipes, fittings and accessories.

IS : 4111. (Part I to IV) Code of practice for ancillary structure in sewerage system

IS : 4127 Code of practice for laying of glazed stone-ware pipes.

IS : 4764 Tolerance limits for sewage effluents discharged into inland-

surface waters.

IS : 4827 Electro plated coating of nickel and chromium on copper and

copper alloys.

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STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

IS : 5329 Code of practice for sanitary pipe work above ground for
buildings.

IS : 5382 Rubber sealing rings for gas mains, water mains and sewers.

IS : 5822 Code of practice for laying of welded steel pipes for water
supply.

IS : 5961 Cast iron grating for drainage purpose.

IS : 7740 Code of practice for road gullies.

IS : 8931 Cast copper alloy fancy bib taps and stop valves for water
services.

IS : 8934 Cast copper alloy fancy pillar taps for water services.

IS : 9762 Polyethylene floats for ball valves.

IS : 10446 Glossary of terms for water supply and sanitation.

IS : 10592 Industrial emergency showers, eye and face fountains and

combination units.

IS : 12592 Specification for precast concrete manhole covers and frames.

IS : 12701 Rotational moulded polyethylene water storage tanks.

SP: 35 Hand book on water supply and drainage.

---- Manual on Sewerage and sewage treatment (Published by CPH &

EEO) As updated.

Doors, Windows and Allied Works

IS : 204 Tower Bolts

Part-I Ferrous metals.

Part-II Nonferrous metals.

IS : 208 Door Handles.

IS : 281 Mild steel sliding door bolts for use with padlocks.

IS : 362 Parliament Hinges.

IS : 420 Specification for putty, for use on metal frames.

IS : 1003 (Part-I) Specification for timber panelled and glazed shutters-door

shutters.

IS : 1038 Steel doors, windows and ventilators.

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 CEMS FOR CHIMNEY & INLET GAS
RSTPP ANALYSERS PACKAGE FOR FGD (Supply, GENERAL TECHNICAL
STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

IS : 1081 Code of practice for fixing and glazing of metal (steel and
aluminium) doors, windows and ventilators.

IS : 1341 Steel butt hinges.

IS : 1361 Steel windows for industrial buildings.

IS : 1823 Floor door stoppers.

IS : 1868 Anodic coatings on Aluminium and its alloys.

IS : 2202(Part-II) Specification for wooden flush door shutters (solid core type);
particle board face panels and hard board face panels

IS:2209 Mortice locks (vertical type).

IS:2553 Safety glass

IS:2835 Flat transparent sheet glass.

IS:3548 Code of practice for glazing in buildings.

IS:3564 Door closers (Hydraulically regulated).

IS : 3614 Fire check doors; plate, metal covered and rolling type. IS:4351
Steel door frames.

IS:5187 Flush bolts.

IS:5437 Wired and figured glass

IS:6248 Metal rolling shutters and rolling grills.

IS:6315 Floor springs (hydraulically regulated) for heavy doors.

IS:7196 Hold fasts.

IS:7452 Hot rolled steel sections for doors, windows and ventilators.

IS:10019 Mild steel stays and fasteners.

IS:10451 Steel sliding shutters (top hung type).

IS:10521 Collapsible gates.

Roof Water Proofing and Allied Works

IS:1203 Methods of testing tar and bitumen.

IS:1322 Specification for bitumen felts for water proofing and damp
proofing.

IS:1346 Code of practice for water proofing of roofs with bitumen felts.

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 CEMS FOR CHIMNEY & INLET GAS
RSTPP ANALYSERS PACKAGE FOR FGD (Supply, GENERAL TECHNICAL
STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

IS:1580 Specification for bituminous compound for water proofing and

caulking purposes.

IS:3067 Code of practice for general design details and preparatory work for
damp proofing and water proofing of buildings.

IS:3384 Specification for bitumen primer for use in water proofing and
damp proofing.

Floor Finishes and Allied Works

IS:1237 Specification for cement concrete flooring tiles.

IS:1443 Code of practice for laying and finishing of cement concrete

flooring tiles.

IS:2114 Code of practice for laying in-situ terrazzo floor finish.

IS:2571 Code of practice for laying in-situ cement concrete flooring.

IS:3462 Specification for unbacked flexible PVC flooring.

IS:4971 Recommendations for selection of industrial floor finishes.

IS:5318 Code of practice for laying of flexible PVC sheet and tile
flooring.

IS:8042 Specification for white portland cement.

IS:13801 Specification for chequered cement concrete flooring tiles.

Painting and Allied Works

IS:162 Specification for fire resisting silicate type, brushing, for use on
wood, colour as required.

IS:1477 Code of practice for painting of ferrous metals in buildings.

Part-I Pretreatment.

Part-II Painting.

IS:1650 Specification for colours for building and decorative finishes.

IS:2074 Specification for red oxide-zinc chrome, priming, ready mixed

paint air drying.

IS:2338 Code of practice for finishing of wood and wood based

materials.

Part-I Operations and workmanship

Part-II Schedules

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 CEMS FOR CHIMNEY & INLET GAS
RSTPP ANALYSERS PACKAGE FOR FGD (Supply, GENERAL TECHNICAL
STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

IS:2395 Code of practice for painting concrete, masonry and plaster

surfaces.

Part-I Operations and workmanship.

Part-II Schedule.

IS:2524 Code of practice for painting of nonferrous metals in buildings.

Part-I Pretreatment.

Part-II Painting.

IS:2932 Specification of synthetic enamel paint, exterior, under-coating

and finishing.

IS:2933 Specification enamel paint, under coating and finishing.

IS:4759 Code of practice for hot dip zinc coating on structural steel and
other allied products.

IS:5410 Specification for cement paint

IS:5411(Part-I) Specification for plastic emulsion paint-for exterior use.

IS:6278 Code of practices for white washing and colour washing.

IS:10403 Glossary of terms relating to building finishes.

Piling and Foundation

IS:1080 Code of practice for design and construction of simple spread

foundations.

IS:1904 Code of practice for design and construction of foundations in

Soils; General Requirements.

IS:2911 Code of practice for designs and construction of Pile

foundations (Relevant Parts).

IS:2950(Part-I) Code of practice for designs and construction of Raft

foundation.

IS:2974(Part-I TO V) Code of practice for design and construction of machine

foundations.

IS:6403 Code of practice for determination of Allowable Bearing

pressure on Shallow foundation.

IS:8009 Code of practice for calculation of settlement of foundation

subjected to symmetrical vertical loads.

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 CEMS FOR CHIMNEY & INLET GAS
RSTPP ANALYSERS PACKAGE FOR FGD (Supply, GENERAL TECHNICAL
STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

Part-I Shallow foundations.

Part-II Deep foundations.

IS:12070 Code of practice for design and construction of shallow

foundations on rocks.

DIN:4024 Flexible supporting structures for machines with rotating

machines.

VDI:2056 Criteria for assessing mechanical vibrations of machines.

VDI:2060 Criteria for assessing rotating imbalances in machines.

Stop Log and Trash Rack

IS:4622 Recommendations for fixed - wheel gates structural design.

IS:5620 Recommendations for structural design criteria for low head slide
gates.

IS:11388 Recommendations for design of trash rack for intakes.

IS:11855 General requirements for rubber seals for hydraulic gates.

Roads

IRC:5 Standard specifications and Code of practice for road bridges,

section-I general Features of Design.

IRC:14 Recommended practice of 2cm thick bitumen and tar carpets.

IRC:16 Specification for priming of base course with bituminous

primers.

IRC:19 Standard specifications and code of practice for water bound

macadam.

IRC:21 Standard specifications and Code of practice for road bridges,

section-III - Cement concrete (plain and reinforced).

IRC:34 Recommendations for road construction in waterlogged areas.

IRC:36 Recommended practice for the construction of earth

embankments for road works.

IRC:37 Guidelines for the Design of flexible pavements.

IRC:56 Recommended practice for treatment of embankment slopes for

erosion control.

IRC:73 Geometric design standards for rural (non-urban) highways.

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 CEMS FOR CHIMNEY & INLET GAS
RSTPP ANALYSERS PACKAGE FOR FGD (Supply, GENERAL TECHNICAL
STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

IRC:SP:13 Guidelines for the design of small bridges & culverts.

IRC – Publication Ministry of Surface Transport (Roads Wing), Specifications for road
and bridge works.

IS:73 Specification for paving bitumen

Loadings

IS:875(Pt. I to V Code of practice for design loads other than earthquake) for
buildings and structures.

IS:1893 Criteria for earthquake resistant design of structures.

IS:4091 Code of Practice for design and construction of foundation for

transmission line towers & poles.

IRC:6 Standard specifications & code of practice for road bridges,

Section-II Loads and stresses.

M.O.T. Deptt. of railways Bridge Rules.

Safety

IS:3696(Part I & II) Safety code for scaffolds and ladders.

IS:3764 Safety code for excavation work.

IS:4081 Safety code for blasting and related drilling operations.

IS:4130 Safety code for demolition of buildings.

IS:5121 Safety code for piling and other deep foundations.

IS:5916 Safety code for construction involving use of hot bituminous

materials.

IS:7205 Safety code for erection on structural steelwork.

IS:7293 Safety code for working with construction machinery.

IS:7969 Safety code for handling and storage of building materials

IS:11769 Guidelines for safe use of products containing asbestos.

----- Indian Explosives Act. 1940 as updated.

Architectural design of buildings

SP:7 National Building Code of India

SP:41 Hand book on functional requirements of buildings (other than

industrial buildings)

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 CEMS FOR CHIMNEY & INLET GAS
RSTPP ANALYSERS PACKAGE FOR FGD (Supply, GENERAL TECHNICAL
STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

Miscellaneous

IS:802 Code of practice for use of structural steel in (Relevant parts)

overhead transmission line towers.

IS:803 Code of practice for design, fabrication and erection of vertical

mild steel cylindrically welded in storage tanks.

IS:10430 Criteria for design of lined canals and liner for selection of type of
lining.

IS:11592 Code of practice for selection and design of belt conveyors.

IS:12867 PVC handrails covers.

CIRIA Publication Design and construction of buried thin-wall pipes.

REFERENCE CODES AND STANDARDS FOR CONTROL AND

INSTRUMENTATION

The design, manufacture, inspection, testing & installation of all equipment and
system covered under this specification shall conform to the latest editions of codes and
standards mentioned below and all other applicable VDE, IEEE, ANSI, ASME, NEC, NEMA,
ISA AND Indian Standards and their equivalents.

Temperature Measurements

1. Instrument and apparatus for temperature measurement - ASME PTC 19.3 (1974).

2. Temperature measurement - Thermocouples ANSI MC 96.1 - 1982.

3. Temperature measurement by electrical Resistance thermometers - IS:2806.

4. Thermometer - element - Platinum resistance - IS:2848.

Pressure Measurements

1. a) Instruments and apparatus for pressure measurement - ASME PTC 19.2

(1964).

b) Electronic transmitters BS:6447.

2. Bourdon tube pressure and vacuum gauges - IS:3624 - 1966.

3. Process operated switch devices (Pr. Switch) BS-6134.

Flow Measurements

Instruments and apparatus for flow measurements - ASME PTC 19.5 (1972) Interim
supplement, Part-II.

Measurement of fluid flow in closed conduits - BS-1042.

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 CEMS FOR CHIMNEY & INLET GAS
RSTPP ANALYSERS PACKAGE FOR FGD (Supply, GENERAL TECHNICAL
STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

Electronic Measuring Instrument & Control Hardware/ Software

1. Automatic null balancing electrical measuring instruments - ANSI C 39.4 (Rev.

1973): IS:9319.

2. Safety requirements for electrical and electronic measuring and controling

instrument - ANSI C 39.5 - 1974.

3. Compatibility of analogue signals for electronic industrial process instruments - ISA

- S 50.1 (1982) ANSI MC 12.1 - 1975.

4. Dynamic response testing of process control instrumentation ISA - S 26 (1968).

5. Surge Withstand Capability (SWC) tests - ANSI C 37.90 a/IEEE-472 or

suitable class of IEC-255-4 equivalent to ANSI C37.90a/IEEE-472.

6. Printed circuit boards - IPC TM - 650, IEC 326 C.

7. General requirement and tests for printed wiring boards - IS 7405 (Part-I)
1973.

8. Edge socket connectors - IEC 130-11.

9. Requirements and methods of testing of wire wrap terminations DIN 41611 Part-2.

10. Dimensions of attachment plugs & receptacles - ANSI C 73 - 1973

(Supplement ANSI C 73 a - 1980).

11. Direct acting electrical indicating instrument - IS:1248 - 1968 (R).

12. Standard Digital Interface for Programmable Instrumentation - IEEE-488.2 - 1990.

13. Information Processing Systems - Local Area Networks - Part 2 : Logical Link
Control - IEEE-802.2 - 1989.

14. Standard for Local Area Networks : Carrier Sense Multiple Access with
Collision Detection - IEEE-802.3 - 1985.

15. Supplements A, B, C and E to Carrier Sense Multiple Access with Collision

Detection - IEEE-802.3 - 1988.

16. Standard for Local Area Networks : Token - Passing Bus Access Method - IEEE-
802.4 - 1985.

17. Standard for Local Area Networks : Token - Ring Access Method and
Physical Layer Specification - IEEE-802.5 - 1985.

18. IEEE Guide to Software Requirements Specifications - IEEE-830 - 1984.

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 CEMS FOR CHIMNEY & INLET GAS
RSTPP ANALYSERS PACKAGE FOR FGD (Supply, GENERAL TECHNICAL
STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

19. Hardware Testing of Digital Process Computers - ISA RP55.1 - 1983.

20. Electromagnetic Susceptibility of Process Control Instrumentation - SAMA

PMC 33.1 - 1978.

21. Interface Between the Data Terminal Equipment and Data Circuit -
Terminating Equipment Employing Serial Binary Data Interchange - EIA-232- D-
1987.

22. Electromagnetic Compatibility for Industrial Process Measurement and

Control Equipment, Part 3 : Radiated Electromagnetic Field Requirements - IEC
801-3-1984.

Instrument Switches and Contact

1. Contact rating - AC services NEMA ICS 2 - 1978 (with revision through May 1983),
Part - 2-125, A6000.

2. Contact rating - DC services NEMA ICS 2-1978 Part-2 125, N600.

Enclosures

1. Type of Enclosures - NEMA ICS Part - 6 - 1978 (with Rev. 1 4/80) through 110.22
(Type 4 to 13).

2. Racks, panels and associated equipment - EIA : RS - 310 C- 1983 (ANSI C 83.9 -
1972).

3. Protection class for Enclosures, cabinets, control panels & desks - IS:2147 - 1962.

Apparatus, enclosures and installation practices in hazardous area

1. Classification of hazardous area - NFPA 70 - 1984, Article 500.

2. Electrical Instruments in hazardous dust location - ISA - 512.11, 1973.

3. Intrinsically safe apparatus - NFPA 493 1978.

4. Purged and pressurised enclosure for electrical equipment in hazardous

location - NFPA 496-1982.

5. Enclosures for Industrial Controls and Systems - NEMA IS 1.1 - 1977.

Sampling System

1. Stainless steel material of tubing and valves for sampling system - ASTMA 296-82,
Grade 7 P 316.

2. Submerged helical coil heat exchangers for sample coolers ASTM D11 92- 1977.

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 CEMS FOR CHIMNEY & INLET GAS
RSTPP ANALYSERS PACKAGE FOR FGD (Supply, GENERAL TECHNICAL
STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

3. Water and steam in power cycle - ASME PTC 19.11.

4. Standard methods of sampling system - ASTM D 1066-99.

Annunciators

1. Specifications and guides for the use of general purpose annunciators - ISA S 19.1,
1979.

2. Surge withstand capability tests - ANSI C 37.90a - 1989/IEEE-472 or suitable class

of IEC 255-4 equivalent to ANSI C37.90a 1989/IEEE-472

3. Damp heat cycling test - IS:2106

4. Specification for Electromagnetic Susceptibility - SAMA DMC 33, 1/78

Protections

1. Relays and relay system associated with electric power apparatus. ANSI C 37.90, 1 -
1989.

2. General requirements & tests for switching devices for control and auxiliary circuits
including contactor relays - IS:6875 (Part-I) - 1973.

3. Turbine water damage prevention - ASME TDP-1-1980.

4. Boiler safety interlocks - NFPA 85 - 2011 or latest version.

UPS System

1. Practices and requirements for semi-conductor power rectifiers - ANSI C 34.2,

1973.

2. Relays and relays system associated with electrical power apparatus - ANSI C 3.90 -
1983.

3. Surge withstand capability test - ANSI C 37.90 1 -1989.

4. Performance testing of UPS - IEC 146.

5. Stationary cells & Batteries Lead Acid type (with tubular positive
plates)specification IS-1651-1991.

6. Recommended practice for sizing large lead storage batteries for generating stations
& sub-stations - IEEE-485-1985.

7. Printed Circuit Board - IPC TM 650, IEC 326C.

8. General Requirements & tests for printed wiring boards, IS:7405 (Part-I) 1973.

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RSTPP ANALYSERS PACKAGE FOR FGD (Supply, GENERAL TECHNICAL
STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

Control Valves

1. Control valve sizing - Compressible & Incompressible fluids - ISA S 75.01-

1985.

2. Face to face dimensions of control valves - ANSI B 16.00 - 1973.

3. ISA Hand Book of Control Valves - (ISBN : B: 1047-087664-234-2).

4. Codes for pressure piping - ANSI B 31.1

5. Control Valve leak class - ISA RP 39.6

Process Connection & Piping

1. Codes for pressure piping "power piping" - ANSI B 31.1.

2. Seamless carbon steel pipe ASTM - A - 106.

3. Forged & Rolled Alloy steel pipe flanges, forged fittings and valves and parts -
ASTM - A - 182.

4. Material for socket welded fittings - ASTM - A - 105.

5. Seamless ferritic alloy steep pipe - ASTM - A - 335.

6. Pipe fittings of wrought carbon steel and alloy steel - ASTM - A - 234.

7. Composition bronze of ounce metal castings - ASTM - B - 62.

8. Seamless Copper tube, bright annealed - ASTM - B - 168.

9. Seamless copper tube - ASTM - B - 75.

10. Dimension of fittings - ANSI - B - 16.11.

11. Valves flanged and butt welding ends - ANSI - B - 16.34.

Instrument Tubing

1. Seamless carbon steel pipe - ASTM - A 106.

2. Material of socket weld fittings - ASTM - A105.

3. Dimensions of fittings - ANSI - B - 16.11.

4. Code for pressure piping, welding, hydrostatic testing - ANSI B 31.1.

Cables

1. Thermocouples extension wires/cables - ANSI MC 96.1 - 1992.

2. Requirements for copper conductor-Wiring cables for telecommunications

&information processing system - VDE:0815.

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 CEMS FOR CHIMNEY & INLET GAS
RSTPP ANALYSERS PACKAGE FOR FGD (Supply, GENERAL TECHNICAL
STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

3. Colour coding of single or multi-pair cables - ICEA - S - 61-402 (third edition)

NEMA WCS - 1979 with revisions thorugh 2/83.

4. Insulation & Sheathing compounds for cables : VDE 0207 (Part-4, 5 & 6).

5. Guide design and installation of cable systems in power generating stations

(insulation, jacket materials) - IEEE Std. 422-1977.

6. Rules for Testing insulated cables and flexible cables : VVDE - 0472

7. Requirements of vertical flame propagation test - IEEE 383 - 1974 (R 1980)

8. Standard specification for tinned soft or annealed copper wire for electrical
purpose - ASTM B-33-81.

9. Oxygen index and temperature index test - ASTM D - 2863.

10. Smoke density measurement test - ASTMD - 2843.

11. Acid gas generation test - IEC - 754 - 1.

12. Swedish Chimney test - SEN - 4241475 (F3).

13. Teflon (FEP) insulation & sheath test - ASTMD - 2116.

14. Thermocouple compensating cables - Testing requirements & sampling plan

IS:8784.

15. PVC insulated electric cables for working voltage upto and including 1100 V -
IS:1554 (Part-I).

Cable Trays, Conduits

1. Guide for design and installation of cable systems in power generating station
(Cable trays, support systems, conduits) - IEEE Std. 422, 1977, NEMA VE-1
1979, NFPA 70-1984.

2. -do- Test Standards. NEMA VE-1-1979.

3. Zinc coating "hot dip" on assembled products for galvanising of carbon steel cable
trays - ASTMA - 386-78.

Public Address System

1. Specifications for loud speakers - IS:7741 (Part-I, II and III)

2. Code of safety requirement for electric mains operated audio amplifiers -

IS:1301

3. Specification for Public Address Amplifiers - IS:10426.

4. Code of practice for outdoor installation of PA system - IS:1982.

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RSTPP ANALYSERS PACKAGE FOR FGD (Supply, GENERAL TECHNICAL
STAGE - III Commissioning & Supervision of Erection) – REQUIREMENTS (GTR)
FGD System

5. Code of practice for installation for indoor amplifying and sound distribution
system - IS:1881.

6. Basic environmental testing procedures for electronic and electrical items -

IS:9000.

7. Characteristics and methods of measurements for sound system equipment -

IS:9302

8. Code of practice of electrical wiring installations (System voltage not

exceeding 650 volts) - IS:732

9. Rigid steel conduits for electric wiring - IS:9537 (Part-I and II)

10. Fittings for rigid steel conduits for electrical wiring - IS:2667

11. Degree of protection provided by enclosure for low voltage switchgear and
control gear - IS:2147.
Vibration Monitoring System

1. API 670 - 1994

2. BS : 4675 Part-2

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System

ANNEXURE- I

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System

ANNEXURE- II

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System

ANNEXURE- III

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System

ANNEXURE- IV

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System

ANNEXURE- V

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 CEMS FOR CHIMNEY & INLET GAS
RSTPP ANALYSERS PACKAGE FOR FGD (Supply, GENERAL TECHNICAL
STAGE - III Commissioning and Supervision of REQUIREMENTS (GTR)
Erection) – FGD System

ANNEXURE- VI

VOLUME-II SECTION -
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VII
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RSTPP ANALYSERS PACKAGE FOR FGD (Supply, GENERAL TECHNICAL
STAGE - III Commissioning and Supervision of REQUIREMENTS (GTR)
Erection) – FGD System

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RSTPP STAGE - III FGD (Supply, Commissioning and Supervision of Erection) – FGD GENERAL TECHNICAL REQUIREMENTS (GTR)
System

ANNEXURE- VII

VENDOR TO RECOMMEND AND FURNISH THE TRAINING MODULES FOR O&M AND ENGINEERING EXECUTIVES

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 CEMS FOR CHIMNEY & INLET GAS ERECTION
RSTPP ANALYSERS PACKAGE FOR FGD (Supply,
Commissioning & Supervision of Erection ) –
CONDITIONS OF
STAGE - III
FGD System CONTRACT

SECTION VIII—INDEX
ERECTION CONDITIONS OF CONTRACT

1.00.00 GENERAL ........................................................................................................................ 3

2.00.00 REGULATION OF LOCAL AUTHORITIES AND STATUTES ................................. 3
3.00.00 WELDING OF PRESSURE PARTS AND HIGH PRESSURE PIPING ....................... 3
4.00.00 HEAT TREATMENT ....................................................................................................... 4
5.00.00 WELD EDGE PREPARATION ...................................................................................... 5
6.00.00 CLEANING AND SERVICING ..................................................................................... 5
7.00.00 FIELD WELDING SCHEDULE ...................................................................................... 6
8.00.00 SITE RUN MISCELLANEOUS PIPING ....................................................................... 6
9.00.00 THERMAL EXPANSIONS ............................................................................................. 7
10.00.00 PIPING SUPPORTS ......................................................................................................... 7
11.00.00 PRESSURE TESTING ...................................................................................................... 7
12.00.00 THERMOWELLS AND FLOW NOZZLES .................................................................. 8
13.00.00 INSULATION, LAGGING AND CLADDING ........................................................... 8
14.00.00 CODE REQUIREMENTS.............................................................................................. 10
15.00.00 ELECTRICAL SAFETY REGULATIONS ................................................................... 10
16.00.00 REMOVAL OF MATERIAL ......................................................................................... 11
17.00.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES ............................. 11
18.00.00 ACCESS TO SITE AND WORKS ON SITE ................................................................ 11
19.00.00 CONTRACTOR'S SITE OFFICE ESTABLISHMENT ............................................... 11
20.00.00 CO-OPERATION WITH OTHER CONTRACTORS ................................................ 12
21.00.00 DISCIPLINE OF WORKMEN ...................................................................................... 12
22.00.00 CONTRACTOR'S FIELD OPERATION ..................................................................... 12
23.00.00 PHOTOGRAPHS AND PROGRESS REPORT .......................................................... 13
24.00.00 MAN-POWER REPORT ............................................................................................... 13
25.00.00 PROTECTION OF WORK ............................................................................................ 13
26.00.00 EMPLOYMENT OF LABOUR ..................................................................................... 14
27.00.00 FACILITIES TO BE PROVIDED BY THE CLIENT (EPIL)/ NTPC ........................ 14
28.00.00 FACILITIES TO BE PROVIDED BY THE CONTRACTOR ....................................... 15
29.00.00 LINES AND GRADES .................................................................................................. 16
30.00.00 FIRE PROTECTION ...................................................................................................... 16

VOLUME-II
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SECTION - VIII
 CEMS FOR CHIMNEY & INLET GAS ERECTION
RSTPP ANALYSERS PACKAGE FOR FGD (Supply,
Commissioning & Supervision of Erection ) –
CONDITIONS OF
STAGE - III
FGD System CONTRACT

31.00.00 SECURITY ...................................................................................................................... 17

32.00.00 CONTRACTOR'S AREA LIMITS ................................................................................ 17
33.00.00 CONTRACTOR'S CO-OPERATION WITH THE CLIENT (EPIL)/ NTPC .......... 17
34.00.00 PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES ......................... 18
35.00.00 MATERIALS HANDLING AND STORAGE ............................................................ 20
36.00.00 CONSTRUCTION MANAGEMENT.......................................................................... 22
37.00.00 FIELD OFFICE RECORDS ........................................................................................... 26
38.00.00 CONTRACTOR'S MATERIALS BROUGHT ON TO SITE ...................................... 26
39.00.00 PROTECTION OF PROPERTY AND CONTRACTOR'S LIABILITY .................... 27
40.00.00 PAINTING...................................................................................................................... 28
41.00.00 INSURANCE .................................................................................................................. 28
42.00.00 UNFAVOURABLE WORKING CONDITIONS........................................................ 29
43.00.00 PROTECTION OF MONUMENTS AND REFERENCE POINTS ........................... 29
44.00.00 WORK & SAFETY REGULATIONS ........................................................................... 30
45.00.00 FOREIGN PERSONNEL............................................................................................... 42
46.00.00 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/
EQUIPMENT BASES .................................................................................................... 43
47.00.00 SHAFT ALIGNMENTS ................................................................................................ 45
48.00.00 DOWELLING ................................................................................................................. 45
49.00.00 CHECK OUT OF CONTROL SYSTEMS ..................................................................... 45
50.00.00 COMMISSIONING SPARES ........................................................................................ 45
51.00.00 CABLING ....................................................................................................................... 46
52.00.00 EQUIPMENT DELIVERY AND ERECTION ............................................................ 47
53.00.00 WELDING - SPECIAL REQUIREMENTS ................................................................. 55
54.00.00 DEVIATIONS DISPOSITIONING .............................................................................. 55
55.00.00 NON-DESTRUCTIVE TESTING (NDT) .................................................................... 55
56.00.00 TESTING EQUIPMENT & FACILITIES ...................................................................... 55
ANNEXURE-I ..................................................................................................................................... 56
ANNEXURE-II ................................................................................................................................... 63
ANNEXURE - III ................................................................................................................................ 64

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CONDITIONS OF
STAGE - III
FGD System CONTRACT

1.00.00 GENERAL
1.01.00 The following provisions shall supplement the conditions already contained in
the other parts of these specifications and documents and shall govern that portion
of the work of this contract which is to be performed at site. The erection requirements
and procedures not specified in these documents shall be in accordance with the
recommendations of the equipment manufacturer, or as mutually agreed to between
the Client (EPIL) and the Contractor prior to commencement of erection work.
1.02.00 The Contractor upon signing of the Contract shall, in addition to a Project
coordinator, nominate another responsible officer as his representative at Site suitably
designated for the purpose of overall responsibility and co-ordination of the Works to
be performed at Site. Such a person shall function from the Site office of the
Contractor during the pendency of Contract.
2.00.00 REGULATION OF LOCAL AUTHORITIES AND STATUTES
2.01.00 In addition to the local laws and regulations, the Contractor shall also comply with
the Minimum Wages Act and the Payment of Wages Act (both of the Government of
India) and the rules made there under in respect of its labour and the labour of its
sub-contractors currently employed on or connected with the contract.
2.02.00 All registration and statutory inspection fees, if any, in respect of his work pursuant to
this Contract shall be to the account of the Contractor. However, any registration,
statutory inspection fees lawfully pay-able under the provisions of the Indian Boiler
Regulations and any other statutory laws and its amendments from time to time
during erection in respect of the plant equipment ultimately to be owned by
the Client (EPIL)/ NTPC, shall be to the account of the Client (EPIL)/ NTPC. Should
any such inspection or registration need to be re-arranged due to the fault of the
Contractor or his Sub- Contractor, the additional fees for such inspection and/or
registration shall be borne by the Contractor.
3.00.00 WELDING OF PRESSURE PARTS AND HIGH PRESSURE PIPING
The welding of all pressure parts and high pressure piping shall be in accordance with
the following requirements:
3.01.00 Qualification of Weld Procedures
Only qualified welding procedures as per ASME Section IX shall be used by
contractor at site. Procedure qualification records along with WPS shall be submitted
to NTPC for review. Welding procedure shall indicate all essential and non-essential
parameters as per ASME Section IX. Makes of welding consumables shall be subject
to Client (EPIL)/ NTPC's approval.

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3.02.00 Welder's Qualification

Only welders, who are qualified in accordance with the latest applicable requirements
of the Indian Boiler Regulations, shall be permitted to perform any welding work on
the pressure parts and its attachment welding. In addition to such statutory
qualification requirements, the welders shall also undergo a pre-
production qualification test to be conducted by the Contractor at site as per
ASME Sec IX in presence of Client (EPIL)/ NTPC's representative(s), prior to
performing work under these specifications. The services of an independent testing
laboratory shall be retained by the Contractor to perform welder qualification tests for
welders. All the welders carrying out welding at site shall carry an identification
badge, which shall indicate the category and the grade of welding for which they have
been tested and authorized to carry out welding.
3.03.00 Records
Welders performance shall be monitored regularly and record of their performance
shall be maintained by contractor in a manner acceptable to the Client
(EPIL)/ NTPC. Contractor shall maintain such records including record of procedure
qualification & welder qualification and hand-over to the Client (EPIL)/ NTPC at the
end of work.
3.04.00 MARKING
On completion of each welded joint, the welder shall mark his regularly
assigned identification mark near the joint. The welder's identification numbers,
inspection stamps or code symbol stamps and any other information shall not be
directly stamped on any alloy steel piping. In alloy steel piping, all such information
shall be stamped on separate marking plate which shall be tack welded on pipe
near the weld.
4.00.00 HEAT TREATMENT
4.01.00 Pre-heating, post-heating and post-weld stress relief operations of all welds, shall be
performed in accordance with the requirements of applicable code. Local post weld
stress relieving heat treatments shall be adopted only in cases where it is normally
impracticable to subject the entire assembly as such for stress relieving operations.
Heating may be by means of electric induction coils or electric resistance coils. Oxy-
acetylene flame heating or exothermic chemical heating methods will not be
permitted. Complete recording of the temperatures throughout the stress relieving
cycle of the material and the weld subjected to heat treatment shall be made by
means of a potentiometric recorder. Recorders other than those of potentiometric
type shall not be used for such temperature recording during stress relieving

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FGD System CONTRACT

operations. The contractor & Client (EPIL)/ NTPC's representative, at start and at the
end of HT Cycle shall sign the time and temperature charts for heat-treatment.
4.02.00 Not Used.
4.03.00 After setting up the weld joint for heat treatment operation, the Client (EPIL)/ NTPC's
signature shall be obtained on the strips chart of the recorder prior to starting of heat
treatment cycle. The right hand corner of the strip chart at the starting point of
the heat treatment cycle shall contain details like the weld number, material,
diameter and thickness, method of heating adopted, prescribed ranges of
heat treatment temperatures, date of heat treatment, reference to item number of the
Field welding Schedule (as specified at clause no 7.00.00- of this Section) etc.
5.00.00 WELD EDGE PREPARATION
Preparation at site of weld joint shall be in accordance with details acceptable to the
Client (EPIL)/ NTPC. Wherever possible, machining or automatic flame cutting shall
be used for edge preparation. Hand flame cutting will be permitted only
where edge preparation otherwise is impractical. All slag shall be removed from cuts
and all the hand cuts shall be ground smooth to the satisfaction of the Client (EPIL)/
NTPC. Flame cutting of alloy steel pipe shall be avoided. Wherever such cutting is
done, a 200mm length at the cut face shall be removed by machining. Pneumatic hand
tools such as edge preparation, tube cutting machine can be used.
6.00.00 CLEANING AND SERVICING
6.01.00 The inside of all tubes, pipes, valves and fittings shall be free from dirt, and loose
scales before being erected. All the pipelines shall be thoroughly blown and/or
flushed. Each steam and water tubes shall be blown with compressed air and shall be
subjected to 'ball test' before erection to ensure that no obstructions exist. A
system for recording of all such operations shall be developed and maintained in a
manner to ensure that no obstructions are left inside the tubes and no tubes are left
uncleaned and untested.
6.02.00 All valves and valve actuators, and dampers and damper actuators, if any, shall be
thoroughly cleaned and serviced prior to pre-commissioning tests and/or Initial
Operations of the plant. A system for recording of such servicing operation shall be
developed and maintained in a manner acceptable to the Client (EPIL)/ NTPC and to
ensure that no valves or dampers including their actuators are left unserviced.
6.03.00 All interior surfaces of the turbine shall be thoroughly cleaned prior to boxing - up to
remove all traces of oil preservations.

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FGD System CONTRACT

7.00.00 FIELD WELDING SCHEDULE

The Contractor shall submit to the Client (EPIL)/ NTPC, a certified and complete field
welding schedule for all the field welding activities to be carried out in respect of the
pressure parts involved in the equipment furnished and erected by him, at least 90
days prior to the scheduled start of erection work at site. Such schedule will be strictly
followed by the Contractor during the process of erection. The above field-welding
schedule to be issued by the Contractor shall contain the following:
(a.) Drawing No (s)
(b.) Location of the weld
(c.) Size of the weld (outside diameter and thickness)
(d.) Type of joints
(e.) Material specifications
(f.) Size of fillet on backing ring, when the type of joint is with backing ring.
(g.) Electrode/ filler metal specifications
(h.) Number of welds per unit
(i.) Quantity of filler metal per weld
(j.) Indication of required Non-destructive Examination (NDE) for each weld.
(k.) Pre-heat temperatures for welding.
(l.) Process of welding.
(m.) Post-welding heat treatment temperature ranges, duration, under as
specified at clause no 4.00.00 of this chapter entitled "Heat Treatment".
(n.) Qualification details of weld procedures to be adopted as specified at clause
no 3.01.00 of this Section entitled 'Qualification of Weld Procedures'.
8.00.00 SITE RUN MISCELLANEOUS PIPING
Sketches or diagrams of the proposed routings of all piping, not already indicated
and routed on the shop drawings which were reviewed by the Client (EPIL)/
NTPC, shall be submitted to the Client (EPIL)/ NTPC for review, Client (EPIL)/
NTPC's acceptance of such site routings shall be obtained before the piping is
erected. All these site run piping shall be installed in such a manner as to present an
orderly and neat installation. They shall be located as to avoid obstruction of access
and passages. Valves, instruments or any other special items shall be located
convenient for operation by the operating personnel. Pipe runs shall be plumb or
level except where pitch for drainage is required. Pipe runs that are not parallel
to the building structure, walls or column rows shall be avoided so that deflection

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FGD System CONTRACT

of pipes between hangers does not exceed 6 mm. No miscellaneous pipe shall be
routed and installed above or adjacent to electrical equipment.
9.00.00 THERMAL EXPANSIONS
All piping installation shall be such that no excessive or destructive expansion forces
exist either in the cold condition or under condition of maximum temperature.
All bends, expansion joints and any other special fittings, necessary to provide proper
expansion, shall be incorporated. During installation of expansion joints and
anchors, care must be taken to make sure that full design movement is available at all
times for maximum to minimum temperature and vice-versa.
10.00.00 PIPING SUPPORTS
10.01.00 Hangers, supports and anchors shall be installed as required to obtain a safe,
reliable and complete pipe installation. All supports shall be properly levelled and
anchored when installed. The anchors shall be so placed that thermal expansion will
be absorbed by bends without subjecting the valves or equipment to excessive
strains.
10.02.00 The hanger assemblies shall not be used for the attachment of rigging to hoist the pipe
into place. Other means shall be used to securely hold the pipe in place till the
structures and spring support is set to accommodate the pipe way. All
temporary rigging shall be removed in such a way that the pipe support is not
subjected to any sudden load. All piping, having variable spring type supports, shall
be held securely in place by temporary means during the hydraulic test of pipe
system. Constant support type spring hangers used during hydraulic test shall be
pinned or blocked solid during the test. After complete installation and insulation of
the piping and filling of the piping with its normal operating medium, the pipe
support springs shall be adjusted to the cold positions. If necessary, the spring
support shall be re-adjusted to the hot positions after the line has been placed for
service at its normal maximum operating temperature conditions. Electric arc welding
only shall be used to weld all pipe supports to structural steel members that form
part of the building supporting structure. The structural beams shall not be heated
more than necessary during welding of supports and such welds shall run parallel to
the axis of the span. All lugs or any other attachments welded to the piping shall be of
the same material as the pipe.
11.00.00 PRESSURE TESTING
11.01.00 On completion of erection of pressure parts, a hydraulic test in accordance with the
requirements of the Indian Boiler Regulations shall be performed by the Contractor.
11.02.00 All the valves, high pressure pipes and inter-connected pipes connecting the
pressure parts shall be tested along with pressure parts. All blank flanges or

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any removable plugs required for openings not closed by the valves, and
piping provided, shall be furnished by the Contractor. The pressurization
equipment including water piping from the supply, needed for the above test
shall also be furnished by the Contractor. Any defects noticed during the testing are
to be rectified and the unit re-tested. If any welding is done on the pressure
parts after the Hydraulic test, the Hydraulic test for that portion of pressure parts
shall be repeated. Water as required for such pressure testing shall be provided by the
Client (EPIL)/ NTPC.
11.03.00 The hydraulic test shall be considered successful only on certification to that effect by
the concerned inspecting Authority as per the provisions of the Indian Boiler
Regulations and the Client (EPIL)/ NTPC.
12.00.00 THERMOWELLS AND FLOW NOZZLES
12.01.00 All the thermowells and flow nozzles in the equipment furnished under the technical
specifications shall be installed as a part of this work.
12.02.00 All thermowell connections incorporated in the steam service shall be plugged during
the pressure testing and the blow out of steam piping systems. Upon completion of the
blow out operation, all thermowells shall be installed and seam welded. Similarly, all
flow nozzles in the steam lines shall also be installed only on completion of steam
blowing operations unless otherwise agreed to by the Client (EPIL)/ NTPC,
depending upon the sequence of cleaning and purging operations to be adopted by
the Contractor at the field.
13.00.00 INSULATION, LAGGING AND CLADDING
The provision of insulation, lagging and cladding of the various equipments and
portion of the equipment covered under the Contract, shall be furnished by
Contractor as specified elsewhere or agree to separately in writing. Welds required for
holding insulation on pressure parts shall be carried out by IBR qualified welder.
13.01.00 Piping, Pipe Fittings & Valves
All piping insulation and metal cladding furnished with the equipment to be erected
shall be applied as specified herein.
13.01.01 Piping
The insulation on piping shall be applied using wire loops on 150mm centres. These
wire loops shall be thoroughly embedded into the outer insulation surface and
all cracks, voids and depressions shall be filled with insulating cement suitable for the
piping temperature so as to form a smooth base for application of cladding.
The wires used for piping insulation shall be of 16 SWG. The surface shall be

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FGD System CONTRACT

smooth and uniform before applying the outer covering. All piping insulation ends
shall be terminated at a sufficient distance from flanges to facilitate removal of bolts.

13.01.02 Flanges
Insulation on flanges shall be by means of blocks of insulating material securely
bound to the flange by wire loops. Such blocks of insulation shall be long enough to
overlap the adjacent pipe insulation by an amount equal to the thickness of adjacent
pipe insulation. Smooth finish shall be obtained by the application of insulating
cement. Alternatively, sectional pipe insulation of proper diameter may be used.
Insulation on flanges shall not be done until the pipe and equipment have been in
service during the initial operation and till all the flange bolts have been retightened.
13.01.03 Bends and Elbows
Insulation on bends and elbows shall be cut into sections sufficiently short to form a
reasonable smooth external surface. After the application of insulation material in
place, it shall be smoothly coated with insulating cement. Elbows may be insulated as
above or alternatively by means of specially moulded insulation enclosures.
13.01.04 Cladding
Cladding shall be of aluminium sheet of thickness as per details given in detail
Technical Specification or will be provided during detail engineering shall
be machine rolled and formed to accurately fit insulation curvatures. Cladding shall be
secured using self-tapping screws. Screws shall be adequate number and so
located as to produce tight joints. The spacing of screws shall be as far as possible
uniform and on centres not exceeding 150 mm. For outside diameters less than 230
mm, spacing of screws shall be on centres not exceeding 100 mm. adequate
number of screws shall be provided for fixing the cladding and be so placed in such
locations, as to produce a smooth cladding finish without bellying'. Insulated elbows
having insulated diameters less than 330 mm shall be provided with preformed
smooth aluminium elbow jackets. Wherever possible, all joints should be lapped a
minimum of 50 mm with joints facing downwards and so placed that they are
obscured from normal points of vision. All the joints in the cladding shall be made
with suitable provisions for expansions. All butt joints such as those shall be made
using rolled seams. In addition, to prevent galvanic corrosion, suitable action, as
specified at clause no 13.02.00 of this Section, shall be taken.
13.01.05 Valves and Fittings
All valves and fittings (above valve size of 2 inches) installed in the steam pipelines
shall also be applied with insulation and furnished with suitably shaped boxes so as to

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FGD System CONTRACT

facilitate easy dismantling of the fittings. The insulation thickness for valves, valve
fittings etc shall be same as that used on the line on which they are installed. All
voids shall be properly filled up with insulating material and as per the directions of
the Client (EPIL)/ NTPC.
13.02.00 Protection of Equipment during Insulation Applications
All equipment and structures shall be suitably protected from damage while applying
insulation after completion of insulation. All equipment and structures shall be
thoroughly cleaned and remove insulating materials which might have fallen on
them.
14.00.00 CODE REQUIREMENTS
The erection requirements and procedures to be followed during the installation of
the equipment shall be in accordance with the relevant Indian Electricity Rules
& Codes, Indian Boiler Regulations, ASME codes and accepted good practices,
the Client (EPIL)/ NTPC's Drawings and other applicable Indian recognised codes
and laws and regulations of the Government of India.
15.00.00 ELECTRICAL SAFETY REGULATIONS
15.01.00 In no circumstances will the Contractor interfere with fuses and electrical equipment
belonging to the other Contractor or Client (EPIL)/ NTPC.
15.02.00 Before the Contractor connects any electrical appliances to any plug or socket
belonging to the other Contractor or Client (EPIL)/ NTPC, he shall:
(a) Satisfy the Client (EPIL)/ NTPC that the appliance is in good working
condition.
(b) Inform the Client (EPIL)/ NTPC of the maximum current rating, voltage and
phase of the appliances.
(c) Obtain permission of the Client (EPIL)/ NTPC detailing the socket to
which the appliances may be connected.
The Client (EPIL)/ NTPC will not grant permission to connect unitl he is
satisfied that :-
(d) The appliance is in good condition and is fitted with suitable plug.
(e) The appliance is fitted with a suitable cable having two earth conductors, one
of which shall be an earthened metal sheath surrounding the cores.
15.03.00 No electric cable in use by the other Contractor/Client (EPIL)/ NTPC will be
disturbed without permission. No weight of any description will be imposed on
any such cable and ladder or similar equipment will rest against or to be attached
with it.

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15.04.00 No reapir work shall be carried out on any live equipment. The equipment must be
declared safe by the Client (EPIL)/ NTPC and a permit to work issued before
any work is carried out.
15.05.00 The Contractor shall employ the necessary number of qualified, full time electricians
to maintain his temporary electrical installation.
16.00.00 REMOVAL OF MATERIAL
No material brought to the Site shall be removed from the Site by the
Contractor and/or his Sub-Contractors without the prior written approval of the
Client (EPIL)/ NTPC.
17.00.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES
The provisions of the clause entitled Inspection, Testing and Inspection Certificates
given in Section-VII (GTR) of the Technical Specification, shall also be applicable
to the erection portion of the Works. The Client (EPIL)/ NTPC shall have the right
to re-inspect any equipment though previously inspected and approved by him
at the Contractor's works, before and after the same are erected at Site. If by the above
inspection, the Client (EPIL)/ NTPC rejects any equipment, the Contractor shall make
good for such rejections either by replacement or modification/ repairs as may
be necessary to the satisfaction of the Client (EPIL)/ NTPC. Such replacements will
also include the replacements or re-execution of such of those works of other
Contractors and/or agencies, which might have got damaged or affected by the
replacements or re-work done to the Contractor's work.
18.00.00 ACCESS TO SITE AND WORKS ON SITE
18.01.00 Suitable access to site and permission to work at the Site shall be accorded to the
Contractor by the Client (EPIL)/ NTPC in reasonable time.
18.02.00 In the execution of the Works, no person other than the Contractor or his duly
appointed representative, Sub-Contractor and workmen, shall be allowed to do work
on the Site, except by the special permission, in writing by the Client (EPIL)/
NTPC or his representative.
19.00.00 CONTRACTOR'S SITE OFFICE ESTABLISHMENT
The Contractor shall establish a Office at the Site and keep posted an authorized
representative for the purpose of the Contract. Any written order or instruction of the
Client (EPIL)/ NTPC or his duly authorised representative shall be communicated to
the said authorized resident representative of the Contractor and the same shall be
deemed to have been communicated to the Contractor at his legal address.

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FGD System CONTRACT

20.00.00 CO-OPERATION WITH OTHER CONTRACTORS

20.01.00 Client (EPIL)/ NTPC, who may be performing other works on behalf of the
Client (EPIL)/ NTPC and the workmen who may be employed by the Client (EPIL)/
NTPC and doing work in the vicinity of the works under the Contract. The Contractor
shall also arrange to perform his work as to minimise, to the maximum extent possible,
interference with the work of other Contracts and their workmen. Any injury or
damage that may be sustained by the employees of the other Contractors and the
Client (EPIL)/ NTPC, due to the Contractor's work shall promptly be made good at
his own expense. The Client (EPIL)/ NTPC shall determine the resolution of any
difference or conflict that may arise between the Contractor and other
Contractors or between the Contractor and the workmen of the Client (EPIL)/
NTPC in regard to their work. If the work of the Contractor is delayed because of the
any acts of omission of another Contractor, the Contractor shall have no claim
against the Client (EPIL)/ NTPC on that account other than an extension of time for
completing his works. Client (EPIL)/ NTPC shall have full access to visit the
contractor's site at any time for inspection and surveillance checks.
20.02.00 The Client (EPIL)/ NTPC shall be notified promptly by the Contractor of any defects
in the other Contractor’s works that could affect the Contractor's Works. The Client
(EPIL)/ NTPC shall determine the corrective measures if any, required to rectify
this situation after inspection of the works and such decisions by the Client (EPIL)/
NTPC shall be binding on the Contractor.
21.00.00 DISCIPLINE OF WORKMEN
The Contractor shall adhere to the disciplinary procedure set by the Client
(EPIL)/ NTPC in respect of his employees and workmen at Site. The Client (EPIL)/
NTPC shall be at liberty to object to the presence of any representative or
employee of the Contractor at the Site, if in the opinion of the Client (EPIL)/ NTPC
such employee has misconducted himself or is incompetent, negligent or otherwise
undesirable then the Contractor shall remove such a person objected to and provide
in his place a competent replacement.
22.00.00 CONTRACTOR'S FIELD OPERATION
22.01.00 The Contractor shall keep the Client (EPIL)/ NTPC informed in advance
regarding his field activity plans and schedules for carrying out each part of the
works. Any review of such plan or schedule or method of work by the Client
(EPIL)/ NTPC shall not relieve the Contractor of any of his responsibilities
towards the field activities. Such reviews shall also not be considered as an
assumption of any risk or liability by the Client (EPIL)/ NTPC or any of his
representatives and no claim of the Contractor will be entertained because of the

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failure or inefficiency of any such plan or schedule or method of work reviewed. The
Contractor shall be solely responsible for the safety, adequacy and efficiency of plant
and equipment and his erection methods.
22.02.00 The Contractor shall have the complete responsibility for the conditions of the Work-
Site including the safety of all persons employed by him or his Sub-Contractor and all
the properties under his custody during the performance of the work. This
requirement shall apply continuously till the completion of the Contract and shall not
be limited to normal working hours. The construction review by the Client (EPIL)/
NTPC is not intended to include review of Contractor's safety measures in, on or near
the Work- Site, and their adequacy or otherwise.
23.00.00 PHOTOGRAPHS AND PROGRESS REPORT
23.01.00 The Contractor shall furnish three (3) prints each to the Client (EPIL)/ NTPC of
progress photographs of the work done at Site. Photographs shall be taken as and
when indicated by the Client (EPIL)/ NTPC or his representative. Photographs shall
be adequate in size and number to indicate various stages of erection. Each
photograph shall contain the date, the name of the Contractor and the title of the
photograph.
23.02.00 The above photographs shall accompany the monthly progress report detailing out
the progress achieved on all erection activities as compared to the schedules. The
report shall also indicate the reasons for the variance between the scheduled and
actual progress and the action proposed for corrective measures, wherever
necessary.
23.03.00 The Contractor shall submit the progress of work in soft and hard form (as decided by
Client (EPIL)/ NTPC) quarterly highlighting the progress and constraints at site.
24.00.00 MAN-POWER REPORT
24.01.00 The Contractor shall submit to the Client (EPIL)/ NTPC, on the first day of every
month, a man hour schedule for the month, detailing the man hours scheduled for the
month, skill- wise and area-wise.
24.02.00 The Contractor shall also submit to the Client (EPIL)/ NTPC on the first day of every
month, a man power report of the previous month detailing the number of persons
scheduled to have been employed and actually employed, skill- wise and the
areas of employment of such labour.
25.00.00 PROTECTION OF WORK
The Contractor shall have total responsibility for protecting his works till it is finally
taken over by the Client (EPIL)/ NTPC. No claim will be entertained by the Client
(EPIL)/ NTPC or the representative of the Client (EPIL)/ NTPC for any damage or

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loss to the Contractor's works and the Contractor shall be responsible for complete
restoration of the damaged works to original conditions to comply with the
specification and drawings. Should any such damage to the Contractor's Works occur
because of other party not being under his supervision or control, the Contractor
shall make his claim directly with the party concerned. If disagreement or conflict
or dispute develops between the Contractor and the other party or parties concerned
regarding the responsibility for damage to the Contractor's Works the same shall be
resolved as per the provisions of the as specified at clause no 21.00.00 of this
chapter entitled "Co-operation with other Contractors." The Contractor shall not
cause any delay in the repair of such damaged Works because of any delay in
the resolution of such disputes. The Contractor shall proceed to repair the Work
immediately and no cause thereof will be assigned pending resolution of such
disputes.
26.00.00 EMPLOYMENT OF LABOUR
26.01.00 In addition to all local laws and regulations pertaining to the employment of labour to
be complied with by the Contractor pursuant to GCC, the Contractor will be expected
particular work. No female labour shall be employed after darkness. No person
below the age of eighteen years shall be employed.
26.02.00 All travelling expenses including provisions of all necessary transport to and
from Site, lodging allowances and other payments to the Contractor's employees shall
be the sole responsibility of the Contractor.
26.03.00 The hours of work on the Site shall be decided by the Client (EPIL)/ NTPC and the
Contractor shall adhere to it. Working hours will normally be eight (8) hours per day -
Monday through Saturday.
26.04.00 Contractor's employees shall wear identification badges while on work at Site.
26.05.00 In case the Client (EPIL)/ NTPC becomes liable to pay any wages or dues to the
labour or any Government agency under any of the provisions of the Minimum
Wages Act, Workmen Compensation Act, Contact Labour Regulation Abolition Act or
any other law due to act of omission of the Contractor, the Client (EPIL)/ NTPC
may make such payments and shall recover the same from the Contractor's Bills.
27.00.00 FACILITIES TO BE PROVIDED BY THE CLIENT (EPIL)/ NTPC
27.01.00 Electricity
Refer clause 3.20(d) (Construction Power) in Section –I of Technical Specification.
27.02.00 Water
Contractor shall make all arrangements himself for the supply of construction water as
well as potable water for labour and other personnel at the worksite/colony.

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However, drawl of construction/potable water from bore-well shall be permitted

if found suitable. Any statutory clearance required shall be obtained by the contractor.
Assistance, if required shall be provided by the Client (EPIL)/ NTPC.
27.03.00 Communication
The Client (EPIL)/ NTPC will extend the telephone facilities, if available at Site, for
purposes of Contract. The Contractor shall be charged at actual for such facilities.
27.04.00 Railway Siding
Railway siding shall be provided by Client (EPIL)/ NTPC (up to plant entry
point) for coal transportation to site. However the same may not be available to
the bidder for material/supplies transport etc. Bidder has to plan its own
arrangement for movement of ODC consignment to plant site.
28.00.00 FACILITIES TO BE PROVIDED BY THE CONTRACTOR
28.01.00 Contractor's site office Establishment
The Contractor shall establish a site office at the site and keep posted an authorized
representative for the purpose of the contract, pursuant to GCC. The site office will
include one conference meeting room for site meetings between the Contractor and the
Client (EPIL)/ NTPC.
28.02.00 Tools, tackles and scaffoldings
The Contractor shall provide all the construction equipments, tools, tackles and
scaffoldings required for pre-assembly, installation, testing, commissioning and
conducting Guarantee tests of the equipments covered under the Contract. He shall
submit a list of all such materials to the Client (EPIL)/ NTPC before the
commencement of pre- assembly at Site. These tools and tackles shall not be removed
from the Site without the written permission of the Client (EPIL)/ NTPC. The
Contractor shall arrange Dozer, Hydra, Cranes, Trailer, etc. for the purpose of
fabrication, erection and commissioning.
28.03.00 Testing Equipment and Facilities:
The contractor shall provide the necessary testing, equipment and facilities.
28.04.00 Site laboratory for civil works
Contractor shall provide and maintain a site laboratory for the testing of construction
material under the direction and general supervision of Client (EPIL)/ NTPC.
28.05.00 First-aid
28.05.01 The Contractor shall provide necessary first-aid facilities for all his employees,
representatives and workmen working at the Site. Enough number of Contractor's
personnel shall be trained in administering first-aid.

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28.05.02 The Client (EPIL)/ NTPC will provide the Contractor, in case of any emergency, the
services of an ambulance for transportation to the nearest hospital.
28.06.00 Cleanliness
28.06.01 The Contractor shall be responsible for keeping the entire area allotted to him clean
and free from rubbish, debris etc. during the period of Contract. The Contractor shall
employ enough number of special personnel to thoroughly clean his work-area
at least once in a day. All such rubbish and scrap material shall be stacked or disposed
in a place to be identified by the Client (EPIL)/ NTPC. Materials and stores shall be so
arranged to permit easy cleaning of the area. In areas where equipment might drip oil
and cause damage to the floor surface, a suitable protective cover of a flame resistant,
oil proof sheet shall be provided to protect the floor from such damage.
28.06.02 Similarly the offices shall be kept clean and neat to the entire satisfaction of
the Client (EPIL)/ NTPC. Proper sanitary arrangements shall be provided by the
Contractor, in the work-areas and office areas of the Contractor.
29.00.00 LINES AND GRADES
All the Works shall be performed to the lines, grades and elevations indicated on the
drawings. The Contractor shall be responsible to locate and layout the Works.
Basic horizontal and vertical control points will be established and marked by
the Client (EPIL)/ NTPC at Site at suitable points. These points shall be used as
datum for the works under the Contract. The Contractor shall inform the Client
(EPIL)/ NTPC well in advance of the times and places at which he wishes to do work
in the area allotted to him so that suitable datum points may be established and
checked by the Client (EPIL)/ NTPC to enable the Contractor to proceed with his
works. Any work done without being properly located may be removed and/or
dismantled by the Client (EPIL)/ NTPC at Contractor's expense.
30.00.00 FIRE PROTECTION
30.01.00 The work procedures that are to be used during the erection shall be those which
minimise fire hazards to the extent practicable. Combustible materials, combustible
waste and rubbish shall be collected and removed from the Site at least once each day.
Fuels, oils and volatile or flammable materials shall be stored away from the
construction and equipment and materials storage areas in safe containers.
Untreated canvas, paper, plastic or other flammable flexible materials shall not at all
be used at Site for any other purpose unless otherwise specified. If any such
materials are received with the equipment at the Site, the same shall be removed
and replaced with acceptable material before moving into the construction or storage
area.

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30.02.00 Similarly corrugated paper fabricated cartons etc will not be permitted in the
construction area either for storage or for handling of materials. All such materials
used shall be of water proof and flame resistant type. All the other materials such as
working drawings, plans etc. which are combustible but are essential for the works to
be executed shall be protected against combustion resulting from welding
sparks, cutting flames and other similar fire sources.
30.03.00 All the Contractor's supervisory personnel and sufficient number of workers shall be
trained for fire-fighting and shall be assigned specific fire protection duties. Enough of
such trained personnel must be available at the Site during the entire period of the
Contract.
30.04.00 The Contractor shall provide enough fire protection equipment of the types and
number for the warehouses, office, temporary structures, labour colony area etc.
Access to such fire protection equipment, shall be easy and kept open at all time.
31.00.00 SECURITY
The Contractor shall have total responsibility for all equipment and materials in his
custody stores, loose, semi-assembled and/or erected by him at Site. The
Contractor shall make suitable security arrangements including employment of
security personnel to ensure the protection of all materials, equipment and
works from theft, fire, pilferage and any other damages and loss. All materials of
the Contractor shall enter and leave the Client (EPIL)/ NTPC Site only with the
written permission of the Client (EPIL)/ NTPC in the prescribed manner.
32.00.00 CONTRACTOR'S AREA LIMITS
The Client (EPIL)/ NTPC will mark-out the boundary limits of access roads,
parking spaces, storage and construction areas for the Contractor and the
Contractor shall not trespass the areas not so marked out for him. The Contractor
shall be responsible to ensure that none of his personnel move out of the areas
marked out for his operations. In case of such a need for the Contactor's personnel to
work out of the areas marked out for him the same shall be done only with the written
permission of the Client (EPIL)/ NTPC.
33.00.00 CONTRACTOR'S CO-OPERATION WITH THE CLIENT (EPIL)/ NTPC
In case where the performance of the erection work by the Contractor affects
the operation of the system facilities of the Client (EPIL)/ NTPC, such erection
work of the Contractor shall be scheduled to be performed only in the manner
stipulated by the Client (EPIL)/ NTPC and the same shall be acceptable at all
times to the Contractor. The Client (EPIL)/ NTPC may impose such restrictions on
the facilities provided to the Contractor such as electricity, etc. as he may think fit
in the interest of the Client (EPIL)/ NTPC and the Contractor shall strictly adhere

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to such restrictions and co-operate with the Client (EPIL)/ NTPC. It will be
the responsibility of the Contractor to provide all necessary temporary
instrumentation and other measuring devices required during start-up and operation
of the equipment systems which are erected by him. The Contractor shall also be
responsible for flushing and initial filling of all the oil and lubricants required for the
equipment furnished and installed by him, so as to make such equipment ready
for operation. The Contractor shall be responsible for supplying such flushing oil and
other lubricants unless otherwise specified elsewhere in documents and
specifications.
34.00.00 PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES
34.01.00 GENERAL
34.01.01 The Contractor upon completion of installation of equipments and systems, shall
conduct pre-commissioning and commissioning activities, to make the
equipment/systems ready for safe, reliable and efficient operation on sustained
basis. All pre-commissioning/commissioning activities considered essential for such
readiness of the equipment/systems including those mutually agreed and included in
the Contractor’s quality assurance programme as well as those indicated in clauses
elsewhere in the technical specifications shall be performed by the contractor.
34.01.02 The pre-commissioning and commissioning activities including Guarantee/
demonstration/ acceptability tests, checks and trial operations of the
equipment/systems furnished and installed by the contractor shall be the
responsibility of the Contractor as detailed in relevant clauses in Technical
Specification. The Contractor shall provide, in addition, test instruments, calibrating
devices etc. and labour required for successful performance of these operations. If it is
anticipated that the above test may prolong for a long time, the Contractor's
workmen required for the above test shall always be present at site during such
operations.
34.01.03 The following activities shall be carried out by the contractor, 18 month prior to
schedule date of commissioning of the equipment/systems installed by him.
(a.) The contractor shall furnish the organization chart of his operation and
commissioning engineers for the acceptance of Client (EPIL)/ NTPC. Adequate
number of operation and commissioning engineers shall be deployed
by the contractor to effectively meet the requirement of round the clock
operation in shifts also, till the plant is taken over by the Client (EPIL)/ NTPC.
(b.) The contractor shall submit the bio-data containing the details of experience of
his operation and commissioning engineers for the acceptance of Client
(EPIL)/ NTPC.

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(c.) The contractor shall furnish the deployment schedule of his operation and
commissioning engineers for the acceptance of the Client (EPIL)/ NTPC.
(d.) Apart from above, contractor shall ensure deployment of sufficient
skilled/semi-skilled/unskilled manpower during pre-commissioning and
commissioning activities.
34.01.04 It shall be the responsibility of the Contractor to provide all necessary temporary
instrumentation and other measuring devices required during start-up and initial
operation of the equipment/systems which are installed by him.
34.01.05 The Contractor shall also be responsible for flushing and initial filling of all oils and
lubricants required for the equipment furnished and installed by him so as to make
such equipment ready for operation. The Contractor shall be responsible for
supplying such flushing oil and other lubricants unless otherwise specified elsewhere
in these specifications and documents.
34.02.00 COMMISSIONING DOCUMENTATION
34.02.01 The contractor shall submit the commissioning documentation, comprising of
Standard checklists, pre-commissioning procedures, testing schedules, commissioning
schedules and commissioning networks for various equipment/systems covered
under the contract, for the approval of Client (EPIL)/ NTPC.
34.02.02 Standard checklist, as the name suggests, shall be a fairly general documents,
containing the list of all checks required to be carried out for similar and repetitive
type of equipment to ensure consistent and thorough checking. An indicative list of
such equipment is enclosed as Annexure-I.
34.02.03 The testing schedule is a document, designed for safe and systematic
commissioning of individual equipment/sub-system (for example compressor
etc.) Commissioning schedule is a document envisaged for commissioning of a
system (for example Compressed Air system, Unit commissioning etc.).
The testing/Commissioning schedule shall have a standard format in order to
maintain consistency of presentation, content and reporting. A brief write up on the
contents of the Testing /Commissioning Schedule is enclosed as Annexure-II.
34.02.04 The contractor shall submit the list of commissioning documentation to be submitted
by him, along with their submission schedule for various equipment/systems covered
under the contract, with in 6(six) month from the date of award of contract, for the
acceptance of Client (EPIL)/ NTPC.
34.02.05 The Contractor shall submit the commissioning documentation, for various
equipment/covered under the contract, for the approval of Client (EPIL)/ NTPC,

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at least 18 months before the scheduled date of commissioning of the

equipment/systems.
34.03.00 COMMISSIONING ACTIVITIES
34.03.01 Upon completion of pre-commissioning activities/tests, the contractor shall
initiate commissioning of facilities. During commissioning the Contractor shall
carry out system checking and reliability trials on various parts of the facilities.
34.03.02 Contractor shall carry out the checks/tests at site to prove to the Client (EPIL)/ NTPC
that each equipment of the supply complies with requirements stipulated and is
installed in accordance with requirements specified.
34.03.03 Before the plant is put into initial operation the Contractor shall be required
to conduct test to demonstrate to the Client (EPIL)/ NTPC that each item of the plant
is capable of correctly performing the functions for which it was specified and its
performance, parameters etc. are as per the specified/approved values. These
tests may be conducted concurrently with those required under commissioning
sequence.
34.03.04 The Contractor shall also demonstrate the performance of all C&I equipment, the
tests on main equipment of prior to that as the case may be.
34.03.05 Other tests shall be conducted, if required by the Client (EPIL)/ NTPC, to
establish that the plant equipment are in accordance with requirements of the
specifications.
34.03.06 The Contractor shall conduct all the commissioning tests and undertake
commissioning activities pertaining to all other auxiliaries and equipments including
all electrical and C&I equipment/systems not specifically brought out above but are
within the scope of work and facilities being supplied and installed by the Contractor
and follow the guidelines indicated above or elsewhere in these Technical
Specifications.
34.05.00 Initial Operation
Upon completion of system checking/Tests as above and as a part of commissioning
of facilities, complete plant/facilities shall be put on initial operation as stipulated in
General Technical Requirements.
35.00.00 MATERIALS HANDLING AND STORAGE
35.01.00 All the equipments furnished under the Contract and arriving at Site shall be
promptly received, unloaded and transported and stored in the storage spaces by
the Contractor.
35.02.00 Contractor shall be responsible for examining all the shipment and notify the
Client (EPIL)/ NTPC immediately of any damage, shortage, discrepancy etc. for the

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purpose of Client (EPIL)/ NTPC's information only. The Contractor shall submit
to the Client (EPIL)/ NTPC every week a report detailing all the receipts during
the week. However, the Contractor shall be solely responsible for any shortages or
damage in transit, handling and / or in storage and erection of the equipment at
Site. Any demurrage, wharf age and other such charges claimed by the transporters,
railways etc. shall be to the account of the Contractor.
35.03.00 The Contractor shall maintain an accurate and exhaustive record detailing out the
list of all equipment received by him for the purpose of erection and keep such
record open for the inspection of the Client (EPIL)/ NTPC.
35.04.00 All equipment shall be handled very carefully to prevent any damage or loss.
No bare wire ropes, slings, etc. shall be used for unloading and/or handling of
the equipment without the specific written permission of the Client (EPIL)/ NTPC.
The equipment stored shall be properly protected to prevent damage either to the
equipment or to the floor where they are stored. The equipment from the store shall be
moved to the actual location at the appropriate time so as to avoid damage of such
equipment at Site.
35.05.00 All electrical panels, controls gear, motors and such other devices shall be properly
dried by heating before they are installed and energised. Motor bearings, slip rings,
commutators and other exposed parts shall be protected against moisture ingress
and corrosion during storage and periodically inspected. Heavy rotating parts in
assembled conditions shall be periodically rotated to prevent corrosion due to
prolonged storage.
35.06.00 All the electrical equipment such as motors, etc shall be tested for insulation
resistance at least once in three months from the date of receipt till the date of
commissioning and a record of such measured insulation values maintained by the
Contractor. Such records shall be open for inspection by the Client (EPIL)/ NTPC.
35.07.00 The Contractor shall ensure that all the packing materials and protection devices
used for the various equipments during transit and storage are removed before the
equipment are installed.
35.08.00 The consumables and other supplies likely to deteriorate due to storage must be
thoroughly protected and stored in a suitable manner to prevent damage or
deterioration in quality by storage.
35.09.00 All the materials stored in the open or dusty location must be covered with suitable
weatherproof and flame-proof covering material wherever applicable.
35.10.00 If the materials belonging to the Contractor are stored in areas other than those
earmarked for him, the Client (EPIL)/ NTPC will have the right to get it moved
to the area earmarked for the Contractor at the Contractor's cost.

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35.11.00 The Contractor shall be responsible for making suitable indoor storage facilities to
store all equipment which require indoor storage. Normally, all the
electrical equipments such as motors, control gear, generators, exciters and
consumables like electrodes, lubricants etc shall be stored in the closed
storage space. The Client (EPIL)/ NTPC, in addition, may direct the Contractor
to move certain other materials, which in his opinion will require indoor storage,
to indoor storage areas which the Contractor shall strictly comply with.
36.00.00 CONSTRUCTION MANAGEMENT
36.01.00 The field activities of the Contractors working at Site, will be coordinated by
the Client (EPIL)/ NTPC and the Client (EPIL)/ NTPC decision shall be final in
resolving any disputes or conflicts between the Contractor and other Contractors
and tradesmen of the Client (EPIL)/ NTPC regarding scheduling and co-
ordination of work. Such decision by the Client (EPIL)/ NTPC shall not be a cause
for extra compensation or extension of time for the Contractor.

36.02.00 The Client (EPIL)/ NTPC shall hold weekly meetings of all the Contractors working at
Site, at a time and place to be designated by the Client (EPIL)/ NTPC. The Contractor
shall attend such meetings and take notes of discussions during the meeting and the
decisions of the Client (EPIL)/ NTPC and shall strictly adhere to those decisions
in performing his Works. In addition to the above weekly meeting, the Client
(EPIL)/ NTPC may call for other meeting either with individual Contractors or with
selected number of Contractors and in such a case the Contractor if called, will also
attend such meetings.

36.03.00 Time is the essence of the Contract and the Contractor shall be responsible for
performance of his works in accordance with the specified construction schedule. If at
any time, the Contractor is falling behind the schedule, he shall take necessary
action to make good for such delays by increasing his work force or by
working overtime or otherwise accelerate the progress of the work to comply
with the schedule and shall communicate such actions in writing to the Client (EPIL)/
NTPC, satisfying that his action will compensate for the delay. The Contractor
shall not be allowed any extra compensation for such action.

36.04.00 The Client (EPIL)/ NTPC shall however not be responsible for provision of
additional labour and/or materials or supply or any other services to the Contractor
except for the co- ordination work between various Contractors as set out earlier.

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36.05.00 Site management during construction phase till handing over of plant

Bidder shall ensure that the plant site within the plant boundary is managed in
a coordinated and professional way all through the construction phase till handing
over of plant, ensuring safe, easy & unhindered working conditions and a
healthy & hygienic working environment at site. He shall ensure the following
measures at site while executing the project.

a) Proper housekeeping by systematic and proper disposal of earth from

excavations (separately for usable & surplus earth), muck (from pile bores or
otherwise), wastes (from dismantling of pile tops, concrete works etc),
packing & insulation wastes, steel scrap, cable wastes etc generated during
construction / erection works. Suitable disposal sites for each of above shall be
identified in the layout and at site in the beginning of the project itself. It shall be
ensured that all agencies engaged by the bidder follow the discipline to
dispose off of earth spoils and wastes at the designated places. Preferably
once in a week suitable time slot will be identified for housekeeping by all
agencies and suitable instructions shall be issued in this regard. Bidder may
engage a separate agency or identify a gang for collection of wastes and
disposal to designated places. Suitable arrangement / tie-up will also be made
for periodic disposal of wastes/ scrap from the designated places.

b) All fabrication areas shall be suitably hard crusted to provide a water free and
proper working platforms. Suitable sheds preferably pre engineered
structures to be provided for paint shops, fabrication workshops etc for
ensuring all weather work conditions for onsite structural works. For the
main plant and auxiliary buildings, bidder should preferably plan the works
in such a way that structural fabrication is done in suppliers' offsite works /
workshops and onsite fabrication works are avoided / kept minimum.

c) Suitable onsite maintenance workshop for day to day breakdown

maintenance heavy plant and equipment like batching plants, cranes, earth
moving equipment, poclains, welding equipment etc. The workshop shall
have stock of frequently needed spares and suitable repair facilities with
experienced technicians/mechanics. A central test laboratory equipped with test
equipment for routine tests like tests on soil, concrete, bricks, aggregates,

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welds etc with experienced staff shall be established at the start of the
project itself.

d) All office and covered store buildings of the bidder and its agencies shall
be of prefab/ pre-engineered / porta cabin construction. Shabby semi -
finished constructions in brickwork/ GI / asbestos roof etc shall not be
permitted.

e) First aid facilities and amenities like rest rooms, suitable pre engineered
toilets ( separate for men and women), drinking water fountains/tanks,
canteen, crèche for women workers shall be planned and established at the
beginning of the project itself. These facilities shall be located distributed over
the plant area to enable easy access by the construction workers and staff
and shall be marked on the plant layout. Suitable treatment for toilet
discharge, like bio digesters etc shall be planned and conventional septic tanks /
soak pits etc shall be avoided.

f) Proper lighting of all construction/ erection areas:

Bidder shall erect adequate number of high lighting masts in main plant, offsite,
office and store areas for lighting during night. DG sets of adequate capacity
shall be provided for emergency backup. The street lighting along the
roads shall also be prioritised along with road construction. The
construction power ring main shall be planned and erected immediately after
the award.

g) Well planned and coordinated storage and movement of plant, equipment

and construction materials. System wise / agency wise storage / laydown areas
shall be planned and marked on the plant layout at the beginning itself. Bidder
shall ensure that all its agencies comply to the areas allocated to them and follow
the designated storage and movement plans. Adequate covered storage shall
be constructed for storage of critical equipments like switchgears, MCCs,
insulation etc.

h) Proper access control for construction workers, staff and visitors. Bidder shall
ensure that suitable electronic based gate pass system is in place from start of
project itself to keep record and track of all workers, staff and visitors
entering/exiting the plant premises shift wise on daily basis.

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i) Compliance to all safety requirements as specified elsewhere in the

tender documents. Bidders shall establish a safety centre at the start of the
project itself. It shall have a 24X7 manned safety control room in addition
to a permanent safety equipment display room, separate training / lecture hall
with AV facilities for safety training, store room with adequate stock of
specified safety equipment, a first aid room and other amenities. Bidder
shall install CCTV cameras at all strategic locations in the plant area which shall
be linked to the safety control room.

j) Compliance to all environment and other conditions stipulated by the

concerned statutory authorities while according clearance / NOC to the
project. Bidder shall ensure adequate sprinkling of water by deploying
water tankers to prevent the fugitive dust nuisance during construction.

k) Development of suitable landscape & green belt areas and rainwater

harvesting within the plant premises. Bidder shall plan to develop the landscape
& green belt areas and rainwater harvesting from the start of the project itself.
The landscape and rainwater harvesting plan shall be finalized immediately
after award of work and suitable work plan with priority and schedule shall
also be finalized thereafter. Top soil before excavation shall be suitably
preserved and stacked for landscape and green belt development.

l) Provision of adequate shelters, water supply, sanitation and lighting in

construction workers and staff camps. No camps for workers and staff shall be
permitted within the plant premises and Bidder shall make separate
arrangement outside the plant premises for locating and development of camps
for construction workers and staff. The designated areas shall be suitably
developed with infrastructure like roads, drains, water supply and sewerage
and shall be free from water logging. Suitable low cost shelters will be
provided for the workers. Complete area shall be secured by fencing and shall be
provided adequate area lighting. Suitable waste disposal, shopping and
recreation facilities will be developed in these camps.

Contractor shall ensure that due importance is given to site management

as discussed above and a detailed work plan considering the above aspects is
finalized immediately after the award. A senior level executive shall be

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identified who shall be responsible for implementation of the work plan.

Suitable format for progress reporting on site management plan shall be
developed and made part of the project progress report. The progress on
implementation of above work plan shall be reviewed along with project
progress in the monthly project review meetings with Client (EPIL)/ NTPC.
In case the progress on site management plan is unsatisfactory, Engineer-in
Charge may withhold upto 1% of the monthly running bill for civil and site
erection works) till such time the required progress is demonstrated. In case in
the opinion of Engineer-in-charge, bidder's actions on site management aspects
is not adequate, Engineer-in- charge may get the relevant work executed through
a separate agency and deduct the expenses incurred from Bidder's bill along
with overheads @10 %.

37.00.00 FIELD OFFICE RECORDS

The Contractor shall maintain at his Site Office up-to- date copies of all
drawings, specifications and other Contract Documents and any other
supplementary data complete with all the latest revisions thereto. The Contractor
shall also maintain in addition the continuous record of all changes to the above
Contract Documents, drawings, specifications, supplementary data, etc. effected at
the field and on completion of his total assignment under the Contract shall
incorporate all such changes on the drawings and other Engineering data to
indicate as installed conditions of the equipment furnished and erected under
the Contract. Such drawings and Engineering data shall be submitted to the
Client (EPIL)/ NTPC in required number of copies.

38.00.00 CONTRACTOR'S MATERIALS BROUGHT ON TO SITE

38.01.00 The Contractor shall bring to Site all equipment, components, parts, materials,
including construction equipment, tools and tackles for the purpose of the
Works under intimation to the Client (EPIL)/ NTPC. All such goods shall, from the
time of their being brought vest in the Client (EPIL)/ NTPC, but may be used for the
purpose of the Works only and shall not on any account be removed or taken away
by the Contractor without the written permission of the Client (EPIL)/ NTPC. The
Contractor shall nevertheless be solely liable and responsible for any loss or
destruction thereof and damage thereto.

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38.02.00 The Client (EPIL)/ NTPC shall have a lien on such goods for any sum or sums which
may at any time be due or owing to him by the Contractor, under, in respect of
or by reasons of the Contract. After giving a fifteen (15) days notice in writing
of his intention to do so, the Client (EPIL)/ NTPC shall be at liberty to sell and dispose
off any such goods, in such manner as he shall think fit including public auction or
private treaty and to apply the proceeds in or towards the satisfaction of such sum or
sums due as aforesaid.

38.03.00 After the completion of the Works, the Contractor shall remove from the Site under the
direction of the Client (EPIL)/ NTPC the materials such as construction equipment,
erection tools and tackles, scaffolding etc. with the written permission of the Client
(EPIL)/ NTPC. If the Contractor fails to remove such materials, within fifteen (15)
days of issue of a notice by the Client (EPIL)/ NTPC to do so then the Client (EPIL)/
NTPC shall have the liberty to dispose off such materials as detailed under as specified
at clause no 39.02.00 of this Section and credit the proceeds thereto to the account of
the Contractor.

39.00.00 PROTECTION OF PROPERTY AND CONTRACTOR'S LIABILITY

39.01.00 The Contractor shall be responsible for any damage resulting from his operations. He
shall also be responsible for protection of all persons including members of
public and employees of the Client (EPIL)/ NTPC and the employees of other
Contractors and Sub- Contractors and all public and private property including
structures, building, other plants and equipments and utilities either above or below
the ground.

39.02.00 The Contractor will ensure provision of necessary safety equipment such as barriers,
sign- boards, warning lights and alarms, etc. to provide adequate protection to persons
and property. The Contractor shall be responsible to give reasonable notice to the
Client (EPIL)/ NTPC and the Client (EPIL)/ NTPCs of public or private property and
utilities when such property and utilities are likely to get damaged or
injured during the performance of his Works and shall make all necessary
arrangements with such Client (EPIL)/ NTPCs, related to removal and/or
replacement or protection of such property and utilities.

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40.00.00 PAINTING
For painting refer Part-A, sub section-III, Section VI of Technical specification.
Painting for structures shall conform to the painting specification specified in Part-B
under Civil. Painting for Electrical equipments/systems shall conform to the painting
specification given in Electrical portion of Part-A and Part-B of technical specifications.

41.00.00 INSURANCE
41.01.00 In addition to the conditions covered under the Clause entitled "Insurance" in Section
General Conditions of Contract (GCC), the following provisions will also apply to the
portion of works to be done beyond the Contractor's own or his Sub-
Contractor's manufacturing Works.

41.02.00 Workmen's Compensation Insurance

This insurance shall protect the Contractor against all claims applicable under
the Workmen's Compensation Act, 1948 (Government of India). This policy shall
also cover the Contractor against claims for injury, disability disease or death of his or
his Sub-Contractor's employees, which for any reason are not covered under the
Workmen’s Compensation Act, 1948. The liabilities shall not be less than the
following:

Workmen's Compensation - As per Statutory Provisions

Employee's Liability - As per Statutory Provisions

41.03.00 Comprehensive Automobile Insurance

This insurance shall be in such a form to protect the Contractor against all claims for
injuries, disability, disease and death to members of public including the Client
(EPIL)/ NTPC's men and damage to the property of other arising from the use
of motor vehicles during on or off the Site operations, irrespective of the Client
(EPIL)/ NTPCship of such vehicles. The liability covered shall be as herein indicated:

Fatal Injury : Rs.100,000 each person

: Rs.200,000 each occurrence

Property Damage : Rs.100,000 each occurrence

41.04.00 Comprehensive General Liability Insurance

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41.04.01 The insurance shall protect the Contractor against all claims arising from
injuries, disabilities, disease or death of members of public or damage to property of
others, due to any act or omission on the part of the Contractor, his agents, his
employees, his representatives and Sub-Contractors or from riots, strikes and civil
commotion. This insurance shall also cover all the liabilities of the Contractor arising
out of the Clause entitled "Defence of Suits" in Section “General Conditions of
Contract (GCC).”

41.04.02 The hazards to be covered will pertain to all the Works and areas where the
Contractor, his Sub-Contractors, his agents and his employees have to perform work
pursuant to the Contract.

41.05.00 The above are only illustrative list of insurance covers normally required and it will be
the responsibility of the Contractor to maintain all necessary insurance coverage to the
extent both in time and amount to take care of all his liabilities either direct or indirect,
in pursuance of the Contract.

42.00.00 UNFAVOURABLE WORKING CONDITIONS

The Contractor shall confine all his field operations to those works which can
be performed without subjecting the equipment and materials to adverse effects
during inclement weather conditions, like monsoon, storms, etc. and during
other unfavourable construction conditions. No field activities shall be performed
by the Contractor under conditions which might adversely affect the quality and
efficiency thereof, unless special precautions or measures are taken by the
Contractor in a proper and satisfactory manner in the performance of such
Works and with the concurrence of the Client (EPIL)/ NTPC. Such unfavourable
construction conditions will in no way relieve the Contractor of his responsibility
to perform the Works as per the schedule.

43.00.00 PROTECTION OF MONUMENTS AND REFERENCE POINTS

The Contractor shall ensure that any finds such as relic, antiquity, coins, fossils, etc.
which he may come across during the course of performance of his Works either
during excavation or elsewhere, are properly protected and handed over to the
Client (EPIL)/ NTPC. Similarly the Contractor shall ensure that the bench marks,
reference points, etc., which are marked either with the help of Client (EPIL)/ NTPC
or by the Client (EPIL)/ NTPC shall not be disturbed in any way during the

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performance of his Works. If, any work is to be preformed which disturb such
reference, the same shall be done only after these are transferred to other suitable
locations under the direction of the Client (EPIL)/ NTPC. The Contractor shall
provide all necessary materials and assistance for such relocation of reference points
etc.

44.00.00 WORK & SAFETY REGULATIONS

44.01.00 General

i) The contractor shall comply with all the requirements of "The Building
and Other Construction Workers (Regulation of Employment & Conditions
of Service) Act," 1996 and its Central Rule 1998 / State Rules and any other
statutory requirements as applicable.

ii) The Contractor shall follow NTPC Safety Rules as issued from time to time with
respect to safety in construction & erection.

iii) The contractor shall have the approved Safety, Health and Environment
(SHE) Policy in respect of Safety and health of Building Workers and it shall be
circulated widely and displayed at conspicuous place in Hindi and local
language understood by the majority of the workers. A copy of the safety
policy should be submitted to Engineer in charge.

iv) The contractor shall submit the safety plan comprising of methods to
implement the Safety Policy/ Rules, Risk assessment and ensuring Safety at
work areas, Safety audits, inspections and its compliance, Supervision and
responsibility to ensure Safety at various levels, Safety training to
employees, review of Safety and accident analysis, ensure Health and Safety
Procedures to prevent accidents to Engineer-in Charge for approval as per
the format of Safety plan as annexed at Annexure - III.

v) The Contractors shall ensure proper safety of all the workmen, materials,
plant and equipment belonging to him or to the Client (EPIL)/ NTPC or to
others, working at the Site.

vi) All equipments used in construction and erection by the contractor shall meet
BIS / International Standards and where such standards do not exist, the
Contractor shall ensure these to be absolutely safe. All equipments shall be

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strictly operated and maintained by the contractor in accordance with

manufacturer's operation manual. The contractor should also follow
Guidelines / Rules of the Client (EPIL)/ NTPC in this regard.

vii) The Contractors shall provide suitable latest Personal Protective Equipments of
prescribed standard to all their employees and workmen according to the need.
The Engineer-in Charge shall have the right to examine these safety
equipments to determine their suitability, reliability, acceptability and
adaptability. The contractor should also ensure these before their use at
worksite.

viii) The Contractor shall provide safe working conditions to all workmen and
employees at his workplace including safe means of access, railings, stairs, and
ladders, scaffolding, work platforms, toe boards etc. The scaffoldings shall
be erected under the control and supervision of an experienced and
competent person. For erection of scaffolds, access, work platforms etc. shall
be good and the contractor shall use standard quality of material.

ix) The Contractor shall follow and comply with all the Safety Rules, standards,
code of practices of NTPC and relevant provisions of applicable laws
pertaining to the safety of workmen, employees, plant and equipment as may be
prescribed from time to time without any protest or contest or reservation. In
case of any unconformity between statutory requirement and the Safety
Rules of the Client (EPIL)/ NTPC referred above, the latter shall be binding
on the Contractor unless the statutory provisions are more stringent. As and
when required he can refer / obtain copy of NTPC safety documents as
stated above.

x) The contractor shall have his own arrangements with nearby hospitals for
shifting and treatment of sick and injured.

The medical examination of the workers employed in hazardous areas shall be

conducted as per Rule 223 0f The Building and Other Construction Worker
(Regulation of Employment and Condition of Service) Central Rule 1998
Their health records shall be maintained accordingly and to be
submitted to Engineer-in Charge when asked for. If any worker found suffering
from occupational health hazard, the worker should be shifted to suitable place

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of working and properly treated under intimation to Engineer-in Charge. The

medical fitness certificate to be submitted to Engineer-in Charge.

xi) First Aid boxes equipped with requisite articles as specified in the Rule 231 of
The Building and Other Construction Worker (Regulation of Employment and
Condition of Service) Central Rule 1998 shall be provided at construction sites
for the use of workers. Training has to be provided on first aid to workmen
& office bearers working at site.

xii) Bidder also requested to refer the safety rules under

http://www.ntpctender.com/ applicable for FGD package. Safety rules shall be
followed as per the safety rules indicated under http://www.ntpctender.com/

44.01.01 Emergency Action Plan

The contractor shall prepare an emergency action plan approved by his competent
authority to handle any emergency occurred during construction work. Regular mock
drills shall be organized to practice this emergency plan. The Emergency Action
Plan should be widely circulated to all the employees and suitable infrastructure
shall be provided to handle the emergencies.

44.01.02 Scaffolding

The contractor shall take all precautions to prevent any accidental collapse of
scaffolding or fall of persons from scaffolding. The contractor should ensure that
scaffolding are designed by a competent person and it erection and repairs should be
done under the expert supervision. The scaffolding shall meet the required
strength and other requirements for the purpose for which the scaffold is
erected. The material used for scaffold should conform to the BIS / International
standards.

44.01.03 Opening

The contractor shall ensure that there is no opening in any working

platform/any floor of the building, which may cause fall of workers or material.
Whenever an opening on a platform/any floor of the building is unavoidable, the
opening should be suitably fenced and necessary measures for protection against
falling objects or building workers from such platform are taken by providing
suitable safety nets, safety belts or other similar means. The contractor shall take

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all precautions while handling, using, storing or transporting of all explosives.

Before usage of any explosive necessary warning / danger signals be erected at
conspicuous places to warn the workers and general public. The contractor should
strictly ensure that all measures and precautions required to be complied for
use, handling, storing or transportation of explosives under the rules framed under
the Explosives Act, 1884.

44.02.00 Fencing of Machinery

The contractor shall provide suitable fencing or guard to all dangerous and moving
parts of machinery.

The contractor shall not allow any of the employees to clean, lubricate, repair, adjust or
examine during machinery in motion, which may cause injury to the person.

44.03.00 Carrying of Excessive Weight by a Worker

The worker shall not be allowed to lift by hand or carry over his head, back or
shoulder more than the maximum limit set by the prescribed rules for
the construction Workers.

44.04.00 Dangerous and Harmful Gases / Equipment

The contractor shall ensure that the workers are not exposed to any harmful gases
during any construction activity including excavation, tunnelling, confined spaces etc.

The contractor should not allow any worker to go into the confined space unless it is
certified by Engineer-in Charge to be safe and fit for the entry to such work place.
Proper record and work permits should be followed to carry out such works.

44.05.00 Overhead Protection

The contractor shall ensure that any area exposed to risk of falling materials, articles or
objects is roped off or cordoned off or otherwise suitably guarded from inadvertent
entry of any person.

Wherever there is a possibility of falling of any material, equipment or construction

workers while working at heights, a suitable and adequate safety net should be
provided. The safety net should be in accordance with BIS Standards.

44.06.00 Working at Heights

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All working platforms, ways and other places of construction work shall be free from
accumulations of debris or any other material causing obstructions and tripping.

Wherever workers are exposed to the hazard of falling into water, the
contractor shall provide adequate equipment for saving the employees from
drowning and rescuing from such hazards. The contractor shall provide boat or
launch equipped with sufficient number of life buoys, life jackets etc. manned with
trained personnel at the site of such work.

Every opening at elevation from ground level through which a building worker,
vehicle, material equipment etc may fall at a construction work shall be covered
and/or guarded suitably by the contractor to prevent such falls.

Wherever the workers are exposed to the hazards of falling from height, the
contractor shall provide full harness safety belts fitted with fall arresting systems to
all the employees working at higher elevations and life line of 8 mm diameter wire
rope with turn buckles for anchoring the safety belts while working or moving
at higher elevations. Safety nets shall also be provided for saving them from fall from
heights and such equipment should be in accordance with BIS standards.

Wherever there is a possibility of falling of any material, equipment or construction

workers while working at heights, a suitable and adequate safety net should be
provided. The safety net should be in accordance with BIS Standards.

The contractor shall provide standard prefabricated ladders on the columns

where the workers are required to use them as an access for higher elevations
till permanent staircase is provided. The workers shall be provided with safety
belts fitted with suitable fall arresting system (Fall arrestors) for climbing/getting
down through ladders to prevent fall from height.

44.07.00 Handling of Hazardous Chemicals

The Contractor will notify well in advance to the Engineer-in Charge of his intention to
bring to the Site any container filled with liquid or gaseous fuel or explosive or
petroleum substance or such chemicals which may involve hazards. NTPC shall have
the right to prescribe the conditions, under which such container is to be stored,
handled and used during the performance of the works and the Contract shall strictly
adhere to and comply with such instructions. The Engineer I/c shall have the right at
his sole discretion to inspect any such container or such construction plant /

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equipment for which material in the container is required to be used and if in his
opinion, its use is not safe; he may forbid its use. No claim due to such prohibition
shall be entertained by NTPC and NTPC shall not entertain any claim of the
Contractor towards additional safety provisions / conditions to be provided for /
constructed.

Further, any such decision of the Engineer-in Charge (Engineer I/c) shall not, in
any way, absolve the Contractor of his responsibilities and in case, use of such
a container or entry thereof into the Site area is forbidden by NTPC, the Contractor
shall use alternative methods with the approval of the NTPC without any cost
implication to the NTPC or extension of work schedule.

Where it is necessary to provide and / or store petroleum products or

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

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

The contractor shall provide suitable personal protective equipments to the workers
who are handling the hazardous and corrosive substances including alkalis and
acids.

As a precautionary measure the contractor should keep the bottles filled with distilled
water in cupboard / Boxes near work place for emergency eye wash by worker
exposed to such hazardous chemicals.

44.08.00 Eye Protection

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The contractor shall provide suitable personal protective equipment to his workmen
depending upon the nature of hazards and ensure their usage by the workers
engaged in operations like welding, cutting, chipping, grinding or similar operations
which may cause injuries to his eyes.

44.09.00 Excavation

The contractor shall take all necessary measures during excavation to prevent the
hazards of falling or sliding material or article from any bank or side of such
excavation which is more than one and a half meter above his footing by providing
adequate piling, shoring, bracing etc. against such bank or sides.

Adequate and suitable warning signs shall be put up at conspicuous places at the
excavation work to prevent any persons or vehicles falling into the excavation
trench. No worker should be allowed to work where he may be stuck or endangered
by excavation machinery or collapse of excavations or trenches.

44.10.00 Electrical Hazards

The contractor should ensure that all electrical installations at the construction work
comply with the requirements of latest electricity acts / rules.

The contractor shall take all adequate measures to prevent any worker from coming
into physical contact with any electrical equipment or apparatus, machines or
live electrical circuits which may cause electrical hazards during the construction
work. The contractor shall provide the sufficient ELCBs / RCCBs for all the
portable equipments, electrical switchboards, distribution panels etc to prevent
electrical shocks.

The contractor should ensure use of single / double insulated hand tools or
low voltage i.e., 110 volts hand tools.

The contractor should also ensure that all temporary electrical installations at
the construction works are provided with earth leakage circuit breakers.

44.11.00 Vehicular Traffic

The contractor should employ vehicle drivers who hold a valid driving license under
the Motor Vehicles Act, 1988.

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44.12.00 Lifting Appliances, Tools & Tackles, Lifting Gear and Pressure Plant & Equipment
etc.

The contractor shall ensure all the lifting appliances, tools & tackles including cranes
etc., lifting gear including fixed or movable and any plant or gear, hoists, Pressure
Plant and equipment etc. are in good condition and shall be examined by competent
person and only certified shall be used at sites. Periodical Examination and the
tests for all lifting / hoisting equipment & tackles shall be carried out. A register of
such examinations and tests shall be properly maintained by the Contractor and will
be promptly produced as and when desired by the Engineer I/c or by the
person authorized by him.

44.13.0 Excessive Noise, Vibration

The contractor shall take adequate measures to protect the workers against the
harmful effect of excessive noise or vibration. The noise should not exceed the
limits prescribed under the concerned rules, Noise Pollution (Regulation
and Control) Rules, 2000.

44.14.00 Electrical Installations

44.14.01 The Contractor shall not interfere or disturb electric fuses, wiring and other electrical
equipment belonging to the Client (EPIL)/ NTPC or other contractors under any
circumstances, whatsoever, unless expressly permitted in writing by the Engineer I/c
to handle such fuses, wiring or electrical equipment.

Before the Contractor connects any electrical appliances to any plug or socket
belonging to the other contractor or the NTPC, he shall,

i) Satisfy the Engineer I/C that the appliance is in good working condition;
ii) Inform the Engineer I/C of the maximum current rating, voltage and phases of
the appliances;
iii) Obtain permission of the Engineer I/C detailing the sockets to which the
appliances may be connected.
iv) The Engineer I/C will not grant permission to connect until he is satisfied that:

- The appliance is in good condition and is fitted with suitable plug;

having earth connection with the body.

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- Wherever armoured / metallic sheathed multi core cable is used,

the same armoured / sheathed should be connected to earth.

iv) No repair work shall be carried out on any live equipment. The Engineer I/c
must declare the equipment safe and a permit to work shall be issued by the
NTPC / contractor as the case may be to carry out any repair / maintenance
work. While working on electric lines / equipments whether live or
dead, suitable type and sufficient quantity of tools will have to be provided by
the contractor to electricians / workmen / Officers.

v) The contractor shall employ necessary number of qualified, full time

Electricians /Electrical Supervisors to maintain his temporary electrical
installation.

vi) The installations are provided with suitable ELCBs and RCCBs wherever
required.

44.15.00 Safety Organisation

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

In case of contractor deploying less than 250 workmen he should designate one of his
Engineer / supervisor or the contractor himself (if he is directly supervising the work)
as safety officer in addition to his existing responsibilities. The Engineer /
supervisor should get atleast 2days safety training from any reputed organization or
from NTPC before resuming the work. If already trained in past the declaration
along with training certificate to be furnished to NTPC safety officer.

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44.15.02 The name and address of such Safety Officer of the Contractor will be promptly
informed in writing to the EIC with a copy to the Project Safety Officer before
he starts work or immediately after any change of the incumbent is made
during currency of the Contract.

44.16.00 Reporting of Accident and Investigation

In case any accident occurs during the construction / erection or other associated
activities undertaken by the Contractor thereby causing any near miss, minor or
major or fatal injury to his employees due to any reason, whatsoever, it shall be the
responsibility of the Contractor to promptly inform the same to the Engineer
I/C, NTPC Safety Officer with a copy to NTPC Head of Project in the prescribed
form and also to all the authorities envisaged under the applicable laws.

44.17.00 Right to stop Work

44.17.01 The Engineer I/C shall have the right at his sole discretion to stop the work, if in his
opinion the work is being carried out in such a way that it may cause accidents and
endanger the safety of the persons and / or property, and / or equipments. In such
cases, the contractor shall be informed in writing about the nature of hazards and
possible injury / accident and he shall comply to remove shortcomings
promptly. The Contractor after stopping the specific work can, if felt necessary appeal
against the order of stoppage of work to the Project Manager within 3 days of such
stoppage of work and decision of the Project Manager in this respect shall be
conclusive and binding on the Contractor.

44.17.02 The Contractor shall not be entitled for any damages / compensation for stoppage of
work, {Sub-Clause 17.01 } due to safety reasons and the period of such stoppage of
work shall not be taken as an extension of time for Completion of the Facilities
and will not be the ground for waiver of levy of liquidated damages.

44.18.00 Fire Protection

The contractor shall provide sufficient fire extinguishers at place /s of work. The fire
extinguishers shall be properly maintained as per relevant BIS Standards. The
employees shall be trained to operate the fire extinguishers / equipment.

44.19.00 Penalties

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i) If the Contractor fails in providing safe working environment as per the Safety
Rules of NTPC or continues the work even after being instructed to stop the
work by the Engineer-I/C as provided in Clause 17.01 above, the
Contractor shall be penalized at the rate of Rs. 25,000/- per day or part
thereof till the instructions are complied with and so certified by the Engineer
I/C. However, in case of accident, the provisions contained in Sub-Clause 19(II)
below shall also apply in addition to the penalties mentioned in this sub-clause.

ii) If the Contractor does not take all safety precautions and / or fails to comply
with the Safety Rules as prescribed by the Client (EPIL)/ NTPC or under the
applicable law for the safety of the plant and equipment and for the safety of
personnel and the contractor does not prevent hazardous conditions which
cause injury to this own employees or employees of other contractors, or
NTPC's employees or any other person who are at the Site or adjacent thereto,
the Contractor shall be responsible for payment of penalty to NTPC as per the
following schedule:-

a) Fatal injury or accident causing death:

Penalty @10% of contract value or Rs. 5,00,000/- per person, whichever is

less.

b) Major injuries or accident causing 25% or more permanent

disablement to workmen or employees:

Penalty @2.5% of contract value or Rs. 1,00,000/- per person whichever is

less.

Permanent disablement shall have the same meaning as indicated in The

Workmen's Compensation Act' 1923. The penalty mentioned above
shall be in addition to the compensation payable to the workmen /
employees under the relevant provisions of the Workmen's Compensation
Act' 1923 and rules framed there under or any other applicable laws as
applicable from time to time.

iii) If any contractor worker found working without using the safety
equipment like safety helmet, safety shoes, safety belts, etc. or without
anchoring the safety belts while working at height the Engineer I/c / Safety
Officer of NTPC shall have the right to penalize the contractor for Rs. 200/-

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per person per day and such worker shall be sent out of the workplace
immediately and shall not be allowed to work on that day. Engineer I/c /
Safety Officer of NTPC will also issue a notice in this regard to the contractor.

iv) If two or more fatal accidents occur at same NTPC site under the control of
contractor during the period of contract and he has:

(1) not complied with keeping adequate PPEs in stock or

(2) defaulted in providing PPEs to his workmen.

(3) not followed statutory requirements / NTPC safety rules.

(4) been issued warning notice/s by NTPC head of the project on non-
observance of safety norms.

(5) not provided safety training to all his workmen, the contractor can be
debarred from getting tender documents in NTPC for two years from
the date of last accident.

The safety performance will also be one of the overriding criteria for
evaluation of overall performance of the contractors by NTPC. The
contractor shall submit the accident data including fatal / non-fatal accidents for
the last 3 years where he has undertaken the construction activities Projects-
wise along with the tender documents. This will also be considered for
evolution of tender documents. If the information given by the contractor found
incorrect, his contract will be liable to be terminated.

44.20.00 The Contractor will make available minimum quantity of all safety equipments and
safety personal protection equipments (PPEs) of required specifications as per
suggestive list included bidding documents as a part of "List of minimum T &
P". Further Contractor will ensure availability of additional requirement for
individual worker and safety equipment as per site requirement during execution
of the contract till its completion.

44.21.00 Award

If the Contractor's performance on safety front is found satisfactory i.e. without any
fatal/reportable accident in the year of consideration; he may be considered for
suitable award "ACCIDENT FREE SAFETY MERITORIOUS AWARD" as per
scheme of the Client (EPIL)/ NTPC.

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44.22.00 The Contractor shall abide by the following during Construction and Erection
activities:

I. Chain pulley block shall not be used for loads more than 2 (Two) tonne.
II. Hydra shall not be used for material transport.
III. Cage shall necessarily be provided to Monkey ladders of height more than 4 m.
IV. Fencing shall be provided to all Electrical Distribution boards and
transformers etc.

45.00.00 FOREIGN PERSONNEL

45.01.00 The Contractor shall submit to the Client (EPIL)/ NTPC data on all personnel he
proposes to bring into India from abroad for the performance of the Works under the
Contract, at least sixty (60) days prior to their departure to India. Such data will
include for each person the name, his present address, his assignment and
responsibility in connection with the works, and a short resume of his qualification,
experience etc. in relation to the work to be performed by him.
45.02.00 Any person unsuitable and unacceptable to the Client (EPIL)/ NTPC shall not be
brought to India. Any person brought to India, if found unsuitable or
unacceptable by the Client (EPIL)/ NTPC, the Contractor shall within a
reasonable time make alternate arrangements for providing a suitable
replacement and repatriation of such unsuitable personnel.
45.03.00 No person brought to India for the purposes of the works shall be repatriated without
the consent of the Client (EPIL)/ NTPC in writing, based on a written request
from the Contractor for such repatriation giving reasons for such an action to the
Client (EPIL)/ NTPC. The Client (EPIL)/ NTPC may give permission for such
repatriation provided he is satisfied that the progress of work will not suffer due to
such repatriation.
45.04.00 The cost of passports, visas and all other travel expenses to and from India, incurred
by the Contractor shall be to his account. The Client (EPIL)/ NTPC will not
provide any residential accommodation and/or furniture for any of the
Contractor's personnel including foreign personnel and Contractor shall make his
own arrangements for such facilities in the area allotted at Site, to him by the Client
(EPIL)/ NTPC for that purpose.
45.05.00 The Contractor and his expatriate personnel shall respect all Indian Acts, Laws,
rules and regulations and shall not in any way interfere with Indian political

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and religious affairs and shall conform to any other rules and regulations which
the Government of India and the Client (EPIL)/ NTPC may establish from time to
time, on them. The Contractor's expatriate personnel shall work and live in close co-
operation and coordination with their co-workers and the community and
shall not engage themselves in any other employment neither part-time nor
full-time nor shall they take part in any local politics.
45.06.00 The Client (EPIL)/ NTPC shall assist the Contractor, to the extent possible, in
obtaining necessary permits to travel to India and back, by issue of necessary
certificates and other information needed by the Government agencies.

46.00.00 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/ EQUIPMENT

BASES
46.01.00 The surfaces of foundations shall be dressed to bring the top surface of the
foundations to the required level, prior to placement of equipment/equipment bases
on the foundations.
46.02.00 All the equipment/ equipment bases, shall be grouted and finished by bidder as per
these specifications unless otherwise recommended by the equipment
manufacturer.
46.03.00 The concrete foundation surfaces shall be properly prepared by bidder by chipping,
grinding as required to bring the top of such foundation to the required level,
to provide the necessary roughness for bondage and to assure enough bearing
strength.
46.04.00 Grout
The grout for equipment foundation shall be high strength grout having a minimum
characteristic compressive strength of 60 N/mm2 at 28 days. The grout shall be ready
mix non-shrink, chloride - free, cement based, free flowing, non-metallic grout as
recommended by equipment manufacturer. The ready- mix grout shall be of reputed
make as approved by the Client (EPIL)/ NTPC.

The Grout shall have good “flowability” even at very low water/ grout powder ratio.

The Grout shall have characteristics of controlled expansion to be able to occupy its
original volume to fill the voids and to compensate for shrinkage. Grout shall be of
pre-mix variety so that only water needs to be added before use.

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The mixing of the Grout shall conform to the recommendations of the manufacturer of
the Grout.
46.05.00 Placing of Grout
46.05.01 After the base has been prepared, its alignment and level has been checked and
approved and before actually placing the grout, a low dam shall be set around the
base at a distance that will permit pouring and manipulation of the grout. The height
of such dam shall be at least 25mm above the bottom of the base. Suitable size and
number of chains shall be introduced under the base before placing the grout,
so that such chains can be moved back & forth to push the grout into every part of the
space under the base.
46.05.02 The grout shall be poured either through grout holes if provided or shall be poured at
one side or at two adjacent sides to make the grout move in a solid mass under the
base and out in the opposite side. Pouring shall be continued until the entire space
below the base is thoroughly filled and the grout stands at least 25 mm higher all
around than the bottom of the base. Enough care should be taken to avoid any air or
water pockets beneath the bases.
46.05.03 In addition to the above, recommendations of Grout manufacturer shall also be
followed.
46.06.00 Finishing of the Edges of the Grout
The poured grout should be allowed to stand undisturbed until it is well set.
Immediately thereafter, the dam shall be removed and grout which extends beyond
the edges of the structural or equipment base plates shall be cut off, flushed and
removed. The edges of the grout shall then be pointed and finished with 1:2 cement
mortar pressed firmly to bond with the body of the grout and smoothened with a tool
to present a smooth vertical surface. The work shall be done in a clean and scientific
manner and the adjacent floor spaces, exposed edges of the foundations, and
structural steel and equipment base plates shall be thoroughly cleaned of any
spillage of the grout.
46.07.00 Checking of Equipment after Grouting
After the grout is set and cured, the Contractor shall check and verify the alignment of
equipments, alignment of shafts of rotating machinery, the slopes of all bearing
pedestals, centering of rotors with respect to their sealing bores, couplings, etc. as
applicable and the like items to ensure that no displacement had taken place

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during grouting. The values recorded prior to grouting shall be used during
such post grouting check- up and verifications. Such pre and post grout records
of alignment details shall be maintained by the Contractor in a manner acceptable
to the Client (EPIL)/ NTPC.

47.00.00 SHAFT ALIGNMENTS

All the shafts of rotating equipment shall be properly aligned to those of the matching
equipments to as perfect an accuracy as practicable. The equipment shall be free from
excessive vibration so as to avoid overheating of bearings or other conditions which
may tend to shorten the life of the equipment. The vibration level of rotating
equipments measured at bearing housing shall conform to Zone A of ISO 10816. All
bearings, shafts and other rotating parts shall be thoroughly cleaned and
suitably lubricated before starting.

48.00.00 DOWELLING
All the motors and other equipment shall be suitably doweled after alignment
of shafts with tapered machined dowels as per the direction of the Client (EPIL)/
NTPC.

49.00.00 CHECK OUT OF CONTROL SYSTEMS

After completion of wiring, cabling furnished under separate specification and
laid and terminated by the Client (EPIL)/ NTPC, the Contractor shall check out the
operation of all control systems for the equipment furnished and installed under these
specifications and documents.

50.00.00 COMMISSIONING SPARES

50.01.00 It will be the responsibility of the Contractor to provide all commissioning
spares including consumable spares required for initial operation till the
Completion of Facilities. The Contractor shall furnish a list of all commissioning
spares within 60 days from the date of Notification of Award and such list shall be
reviewed by the Client (EPIL)/ NTPC and mutually agreed to. However. such
review and agreement will not absolve the Contractor of his responsibilities to
supply all commissioning spares so that initial operation do not suffer for
want of commissioning spares. All commissioning spares shall be deemed to be
included in the scope of the Contract at no extra cost to the Client (EPIL)/ NTPC.

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50.02.00 These spare will be received and stored by the Contractor atleast 3 months prior to the
schedule date of commencement of initial operation of the respective equipment and
utilised as and when required. The unutilised spares and replaced parts, if any, at the
end of successful completion of guarantee tests shall be the property of the Contractor
and he will be allowed to take these parts back at his own cost with the permission of
Client (EPIL)/ NTPC.

51.00.00 CABLING
51.01.00 All cables shall be supported by conduits or cable tray run in air or in cable channels.
These shall be installed in exposed runs parallel or perpendicular to dominant
surfaces with right angle turn made of symmetrical bends or fittings. When cables are
run on cable trays, they shall be clamped at a minimum interval of 2000mm or
otherwise as directed by the Client (EPIL)/ NTPC.
51.02.00 Each cable, whether power or control, shall be provided with a metallic or plastic tag
of an approved type, bearing a cable reference number indicated in the cable and
conduit list (prepared by the Contractor), at every 5 meter run or part thereof and at
both ends of the cable adjacent to the terminations. Cable routing is to be done in
such a way that cables are accessible for any maintenance and for easy
identification.
51.03.00 Sharp bending and kinking of cables shall be avoided. The minimum radii for PVC
insulted cables 1100 V grade shall be 15 D where D is the overall diameter of the cable.
Installation of other cables like high voltage, coaxial, screened,
compensating, mineral insulated shall be in accordance with the cable
manufacturer’s recommendations. Wherever cables cross roads and water, oil,
sewage or gaslines, special care should be taken for the protection of the cables in
designing the cable channels.
51.04.00 In each cable run some extra length shall be kept at a suitable point to enable one or
two straight through joints to be made, should the cable develop fault at a later date.
51.05.00 Control cable terminations shall be made in accordance with wiring diagrams, using
identifying codes subject to the Client (EPIL)/ NTPC's approval. Multi-core control
cable jackets shall be removed as required to train and terminate the conductors.
The cable jacket shall be left on the cable, as far as possible, to the point of the first
conductor branch. The insulated conductors from which the jacket is removed shall
be neatly twined in bundles and terminated. The bundles shall be firmly but not

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tightly tied utilising plastic or nylon ties or specifically treated fungus protected
cord made for this purpose. Control cable conductor insulation shall be securely and
evenly cut.
51.06.00 The connectors for control cables shall be covered with a transparent insulating
sleeve so as to prevent accidental contact with ground or adjacent shall
preferably terminate in Elmex terminals and washers. The insulating sleeve shall
be fire resistant and shall be long enough to over pass the conductor insulation. All
control cables shall be fanned out and connection made to terminal blocks and test
equipment for proper operation before cables are corded together.

52.00.00 EQUIPMENT DELIVERY AND ERECTION

52.01.00 General Requirements
(a.) This part covers Contractor's responsibilities for packing, shipping, ware-
housing and the installation of all equipment and materials furnished and
installed under this specification.
(b.) The Contractor shall submit for Client (EPIL)/ NTPC's approval draft
manual for Equipment Delivery and Erection (EDE Manual) covering
detailed instructions, write up, technical data, drawings, check-lists,
documentation formats for all activities after equipment manufacture upto
installation of equipment. This manual shall cover general instructions for all
equipment and specific instructions for individual equipment wherever required
and shall include at least the following :
(1.) Instructions for packing, shipping, receiving handling, ware-housing and
storage.
(2.) Instructions for location and installation of equipment furnished by this
specification.
(3.) Installation drawings for field mounted equipment, panels, cubicles and
other equipment covered under this specification.
(4.) Instruction relating installation of piping/ tubing, support and routing
drawings of impulse pipes/signal tubes and tube/cable trays.
(5.) Check lists and quality assurance hold points.
(6.) Format for all related documentation.

(c.) The EDE Manual shall conform to the requirements of this specification, all
applicable codes and standards, recommendations of equipment manufacturers

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and accepted good engineering practices and shall be subject to Client (EPIL)/
NTPC approval during detailed engineering.

(d.) The Contractor shall ensure that all work under this part shall be performed as
per the requirements of this specification, Client (EPIL)/ NTPC approved
EDE Manual and drawing/documents approved by the Client (EPIL)/ NTPC
during detailed engineering.

52.02.00 Crating

(a.) All equipment and materials shall be suitably coated, wrapped, or covered
and boxed or crated for moist humid tropical shipment and to prevent
damage or deterioration during handling and storage at the site.

(b.) Equipment shall be packed with suitable desiccants, sealed in water proof
vapour-proof wrapping and packed in lumber of plywood enclosures, suitably
braced, tied and skidded. Lumber enclosures shall be solid, not slatted.

(c.) Desiccants shall be either silica gel or calcium sulphate, sufficiently ground to
provide the required surface area and activated prior to placing in the
packaging. Calcium sulphate desiccants shall be of a chemical nature to absorb
moisture. In any case, the desiccant shall not be of a type that will absorb
enough moisture to go into solution. Desiccants shall be packed in porous
containers, strong enough to withstand handling encountered during normal
shipment. Enough desiccants shall be used for the volumes enclosed in
wrapping.

(d.) Review by the Client (EPIL)/ NTPC of the Contractor's proposed packaging
methods shall not relieve the Contractor of responsibility for damage or
deterioration to the equipment and materials specified.

(e.) All accessory items shall be shipped with the equipment. ; Boxes and crates
containing accessory items shall be marked so that they are identified with the
main equipment. The contents of each box and crates shall be indicated by
markings on the exterior.

(f.) All boxes, crates, cases bundles, loose pieces, etc shall be marked
consecutively from No.1 upward throughout all shipments from a given port to
completion of the order without repeating the same number.

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(g.) An itemized list of contents shall be enclosed inside each case and one other
copy securely fastened to the outside of the case in a tin or light weight sheet
metal envelope or pocket. The lists shall be plainly marked and placed in
accessible locations to facilitate receipt and inspection. The packing list shall
indicate whether shipment is partial or complete and shall incorporate the
following information on each container, etc., according to its individual
shipping number:

i) Export case markings

ii) Case number

iii) Gross weight and net weight in Kilograms

iv) Dimensions in centimetres

v) Complete description of material

(h.) Packaging or shipping units shall be designed within the limitations of

unloading facilities and the equipment which will be used for transport.
Complications involved with ocean shipment and the limitations of ports,
railways and roads shall be considered. It shall be the responsibility
to investigate these limitations and to provide suitable packaging to
permit safe handling during transit and at the job site.

(i.) Electrical equipment, control and instrumentation shall be protected against

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

(j.) Equipment having antifriction or sleeve bearings shall be protected by

weather tight enclosures.

(k.) Coated surfaces shall be protected against impact, abrasion, discolouration and
other damage. Surfaces which are damaged shall be repaired.

(l.) All exposed threaded parts shall be greased and protected with metallic or
other substantial type protectors. All female threaded openings shall be
closed with forged steel plugs. All pipings, tubing, and conduit equipment

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and other equipment openings shall be sealed with metallic or other rough
usage covers and tapped to seal the interior of the equipment piping, tubing, or
conduit.

(m.) Provisions shall be made to ensure that water does not enter any equipment
during shipment or in storage at the plant site.

(n.) Returnable containers and special shipping devices shall be returned by the
manufacturer's field representative at the Contractor's expense.

(o.) While packaging the material, care shall be taken for the limitation from the
point of view of availability of railway wagon sizes in India.

52.03.00 Factory Assembly

(a.) Instrument enclosures shall be supplied and erected completely in the factory
with instrument, air supply and blow down piping with necessary valves,
fittings, etc. and also all electrical wiring between the instruments and the
enclosure terminal blocks. Control panel and cubicles shall also be fully wired
in the factory. Control panel mounted equipments are to be dismounted from
the panels before shipment and individually packed for shipment. Electronic
control modules of the plug-in type are to be removed from equipment
racks after factory checkout are individually packed for shipment. Other
equipment shall be fully assembled at the factory, except for necessary shipping
splits in panels.

(b.) All separately packaged accessories items and parts shall be shipped with the
equipment. Containers for separately packaged items shall be marked so that
they are identified with the main equipment. An itemized packing slip,
indicating what is in that carton only, shall be attached to the outside and
inside of each container used for packing.

A master packing slip covering all accessories items for a given piece of
equipment which are shipped in separate containers, shall be attached to
one container.

52.04.00 Equipment Installation

(a.) General Requirements

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(1.) The Contractor shall furnish all construction materials, tools and
equipment and shall perform all work required for complete
installation of all control and instrument equipment furnished under
this specification.

(2.) Contractor shall prepare detailed installation drawings for each

equipment furnished under this specification for Client (EPIL)/ NTPC’s
approval. Installation of all equipment/systems furnished by this
specification shall be as per Client (EPIL)/ NTPC's approval.

(3.) Erection procedures not specified herein shall be in accordance with the
recommendations of the equipment manufacturers. The procedures
shall be acceptable to the Client (EPIL)/ NTPC.

(4.) The Contractor shall coordinate his work with other suppliers where their
instruments and devices are to be installed under specifications.

(b.) Installation Materials

All materials required for installation, testing and commissioning of the

equipment shall be furnished by the Contractor.

(c.) Regulatory Requirements

All installation procedures shall confirm with the accepted good engineering
practice and with all applicable governmental laws, regulations and codes.

(d.) Cleaning

All equipment shall be cleaned of all sand, dirt and other foreign materials
immediately after removal from storage and before the equipment is brought
inside the power plant building or to other installation sites. All piping
and tubes shall be air blown.

(e.) Equipment Assembly

Equipment installed under these specifications shall be assembled if shipped

unassembled. The equipment shall be dismantled and reassembled as
required to perform the installation and commissioning work described in
these specifications.

(f.) Equipment Setting

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Field mounted instruments and accessories shall be bracket or sub panel

mounted on the nearest suitable firm steel work or masonry. The brackets,
stands, supports and other miscellaneous hardware required for mounting
instruments and accessories such as receiver gauge, air set, valve manifold,
purge-meter etc. shall be furnished and installed. No field mounted
instruments shall be installed such that it depends for support or rigidity on the
impulse piping or on electrical connection to it.

Indicating type field mounted instruments shall be installed in such a way that
centre of indicating dial shall be about 1600-1800mm from operating floor
level. Non-indicating type field instruments shall be installed such that
operating handle of manifold block / isolating cock comes within 1600
mm from operating floor level.

(g.) Free-Standing Equipment

Free-standing Cabinets shall be attached to the floor, concrete equipment

bases or supporting steel as indicated on the manufacturer's drawings and
the Client (EPIL)/ NTPC's Plant Arrangement Drawings. The cabinets
shall be shimmed for proper alignment before bolting them to the floor.
Adjacent enclosures shall be shimmed to maintain mutually level appearance
before they are attached to floor. Vibration dampening mounts shall be
installed between supporting structures and panels when specified.

(h.) Non-free Standing Equipment

(1.) Non-free standing local enclosures and cabinets shall be mounted in

accessible locations on columns, walls, or stands in locations as
indicated on the Client (EPIL)/ NTPC's Plant Arrangement Drawings.
Bracket and stands shall be fabricated as required to install the
local enclosures and cabinets in a workman like manner.

(2.) Rough edges and welds on all fabricated supports shall be ground
smooth. The supports shall be finished with two coats of primer and two
coats of paint as specified in this part.

(i.) Equipment Location

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(1.) All individual items of equipment not located in cabinets or on panels and
racks are located approximately according to the floor elevation and the
nearest building column designated by the Client (EPIL)/ NTPC.

(2.) Solenoid valves not located in enclosures or mounted on valves shall be

mounted in easily accessible protected locations near the
components with which they are associated.

(3.) All brackets, stands, supports and other miscellaneous hardware required
for mounting devices shall be furnished and installed.

(4.) Thermometers shall be installed in the process lines and ducts as

required and adjusted for ease in reading.

(5.) Permanent temperature wells on the main steam, hot reheat and cold reheat
piping shall not be installed until steam blowing has been completed.
Temporary temperature wells shall be installed in the main and reheat
steam piping during steam blow and discarded after completion.

(6.) Any required adapting hardware such as pipe bushings, nipples, drilled
caps and the like shall be provided for complete installation of control
devices into process connections.

For location of C&I related equipment/devices, the requirement

specified elsewhere in the technical specification may be referred.

(j.) Installation of Field Mounted Instruments and Devices

The Contractor shall submit installation drawings for all field mounted
equipment furnished under this specification for Client (EPIL)/ NTPC's
approval. These drawings shall meet the requirements of this
specification, installation drawings, applicable codes and standards and
recommendations of manufacturers of instruments/devices. All
installation work under this specification shall be strictly as per
installation drawings approved by the Client (EPIL)/ NTPC during detailed
engineering stage.

In addition to above relevant Portion as specified elsewhere in technical

specification may be referred.

(k.) Piping Connections

VOLUME-II
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SECTION - VIII
 CEMS FOR CHIMNEY & INLET GAS ERECTION
RSTPP ANALYSERS PACKAGE FOR FGD (Supply,
Commissioning & Supervision of Erection ) –
CONDITIONS OF
STAGE - III
FGD System CONTRACT

(1.) All equipment having piping connections shall be levelled, aligned

and wedged in place but shall not be grouted or bolted prior to the
initial fitting and alignment of connecting piping. All equipment shall,
however, be grouted or bolted to its foundation prior to final bolting or
welding of the connection piping.

(2.) All flanged joints shall be checked and retightened after

approximately 10 days of operation at normal operating temperature.

(l.) Equipment Checkout

(1.) All equipment shall be cleaned after installation. Equipment subject to

pressure differentials shall be checked for leakage.

(2.) After erection, all equipment having moving parts, having electrical
apparatus, or subject to pressure differentials shall be trial-operated.

(m.) Defects

(1.) All defects in erection shall be corrected to the satisfaction of the

Client (EPIL)/ NTPC and the Project Manager. The dismantling and
reassembly of Contractor furnished equipment to remove defective parts,
replace parts, or make adjustments shall be included as a part of the
work under these specifications.

(2.) The removal of control and instrument equipment in order to allow

bench calibration, if required, and the re-installation of the said
equipment after calibration shall also be included as a part of the work
under these specifications.

(n.) Equipment Protection

(1.) All equipment to be erected under these specifications shall be

protected from damage of any kind from the time of contract award
until commissioning of each unit.

(2.) The equipment shall be protected during storage as described herein.

(3.) Equipment shall be protected from weld spatter during construction.

(4.) Suitable guards shall be provided for protection of personnel on all

exposed rotating or moving machine parts. All such guards with

VOLUME-II
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SECTION - VIII
 CEMS FOR CHIMNEY & INLET GAS ERECTION
RSTPP ANALYSERS PACKAGE FOR FGD (Supply,
Commissioning & Supervision of Erection ) –
CONDITIONS OF
STAGE - III
FGD System CONTRACT

necessary spares and accessories shall be designed for easy

removal and maintenance.

(5.) Equipment having glass components such as gauges, or equipment

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

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

surfaces which are not to be painted, such as machinery shafts and
couplings shall be provided temporary protection during storage and
constructional periods by a coating of a suitable non- drying, oily type, rust
preventive compound.

53.00.00 WELDING - SPECIAL REQUIREMENTS

If the manufacturer has special requirements relating to the welding procedures for
welds at the terminals of the equipments to be performed under separate
specifications, the requirements shall be submitted to the Project Manager in
advance of commencement of erection work.

54.00.00 DEVIATIONS DISPOSITIONING

Any deviation to the contract and Client (EPIL)/ NTPC approved documents shall be
properly recorded in the format prescribed by NTPC. All the deviations shall be
bought to the knowledge of Client (EPIL)/ NTPC's representative for suitable
dispositioning.

55.00.00 NON-DESTRUCTIVE TESTING (NDT)

The contractor shall record results of NDTs carried out at site in the format
acceptable to Client (EPIL)/ NTPC. All the radiographs & its report duly signed &
correlated to the job shall be handed over to the Client (EPIL)/ NTPC. Sensitivity of
all the test equipment shall be compatible to the job & acceptance norms agreed.

56.00.00 TESTING EQUIPMENT & FACILITIES

Contractor shall provide the testing equipment and facilities necessary to carry out
tests & inspections.

VOLUME-II
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SECTION - VIII
 CEMS FOR CHIMNEY & INLET GAS ERECTION
RSTPP ANALYSERS PACKAGE FOR FGD (Supply,
Commissioning & Supervision of Erection ) –
CONDITIONS OF
STAGE - III
FGD System CONTRACT

ANNEXURE-I
STANDARD CHECKLIST

This is an indicative list of items. The actual list shall depend on the Equipment / System
being supplied by the contractor.

MECHANICAL

VALVES

1. Manually Operated Valve

2. Electrically Operated Valve

3. Pneumatically Actuated Valve

4. Hydraulically Actuated Valve

5. Safety Valve

6. Electromatic Relief Valve

7. Steam Trap

8. Non Return Valve (including Hydraulic/ Pneumatic QCNRVS)

9. Control Valve

10. Relief Valve

11. Differential Pressure Regulating Valve

12. Pinch valve

TANKS & PRESSURE VESSELS

1. Limestone silos

2. Gypsum storage silos

3. Limestone slurry tanks

4. Filtrate tank

5. Waste water tank

6. Secondary hydrocyclone feed tank

7. Lime dosing tank

VOLUME-II
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SECTION - VIII
 CEMS FOR CHIMNEY & INLET GAS ERECTION
RSTPP ANALYSERS PACKAGE FOR FGD (Supply,
Commissioning & Supervision of Erection ) –
CONDITIONS OF
STAGE - III
FGD System CONTRACT

8. Process water tank

9. Absorber

10. Auxiliary absorbent tank

11. Mill circuit tank

12. Any other tank not covered above

13. Vacuum tanks

14. Air Receiver(if any)

PUMPS

1. Slurry recirculation pumps

2. Gypsum bleed pumps

3. Limestone slurry pumps

4. Process water pumps

5. All other slurry pumps

6. Vacuum pumps

7. Sump pumps

PIPE WORK SYSTEM

1. Steam services

2. Water services

3. Slurry services

4. Air services

5. Constant load support

6. Spring supports

7. Hangers and other Supports

STRAINER AND FILTER

1. Strainer / Filter Basket Type

2. Strainer Rotary (Low Pressure)

VOLUME-II
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SECTION - VIII
 CEMS FOR CHIMNEY & INLET GAS ERECTION
RSTPP ANALYSERS PACKAGE FOR FGD (Supply,
Commissioning & Supervision of Erection ) –
CONDITIONS OF
STAGE - III
FGD System CONTRACT

3. Filter & Strainers Centrifugal Separators

4. Filter & Strainer Y-Type

5. Filter & Strainer (Plate Type)

6. Purifier

7. Filter – Compressed Air Line

FANS & COMPRESSORS

1. Booster Fans – Axial Flow pressure Lubricated

2. Oxidation Blowers/Compressors-General

DAMPERS & GATES

1. Manually Operated Damper

2. Pneumatically Operated Damper

3. Electrically Operated Damper

4. Manually Operated Gates

5. Pneumatically Operated Gate

6. Electrically Operated Gate

DUCT WORK

1. Flue Gas Ducting

2. Expansion Joints

3. Observation & Access Door

CRANES AND ELEVATORS

1. Crane

2. Hoists

3. Passenger cum goods elevator

POWER TRANSMISSION

1. Power Transmission Gear Box

2. Bearings

VOLUME-II
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SECTION - VIII
 CEMS FOR CHIMNEY & INLET GAS ERECTION
RSTPP ANALYSERS PACKAGE FOR FGD (Supply,
Commissioning & Supervision of Erection ) –
CONDITIONS OF
STAGE - III
FGD System CONTRACT

3. Couplings

FGD & AUX.SYSTEM

1. Agitators

2. Air Motor

3. Process trustle

4. Limestone feeder

5. Vacuum belt filter

6. Limestone ball mill

7. Limestone Hydrocyclones

8. Primary Hydrocyclones

9. Secondary Hydrocyclones

10. Absorber internals

11. Absorber Auxiliaries

ELELCTRICAL

1. D.C. Motor

2. HV Squirrel Cage Induction Motor

3. 415 V Squirrel Cage Induction Motor

4. Motor Operated Actuators

5. Soot Blower (GGH)

6. Aux. Control and Relay Panel Desk

7. SWITCHGEARS/MCC

(I) STANDARD CHECLISTS FOR ALL TYPES OF RELAYS USED IN

SWITCHGEARS PROTECTION SYSTEM

(II) PT CARRIAGE AND CUBICLES

(III) CABLE/BUS DUCT/BUS BARS

(IV) CONTRACTOR MODULE

VOLUME-II
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SECTION - VIII
 CEMS FOR CHIMNEY & INLET GAS ERECTION
RSTPP ANALYSERS PACKAGE FOR FGD (Supply,
Commissioning & Supervision of Erection ) –
CONDITIONS OF
STAGE - III
FGD System CONTRACT

(V) SWITCH FUSE MODULE

(VI) MASTER PANEL OF LUBE OIL PANEL

(VII)FEEDER PANEL OF LUBE OIL PANEL

(VIII)SPACE HEATER AND CABLE MODULE

(IX) HT CIRCUIT BREAKER

(X) 415 V CIRCUIT BREAKER

POWER CABLE

AUXILIARY CABLE

D.C. CABLE

EXPLOSION PROOF ELECTRICAL EQUIPMENT

JUNCTION BOX

CONTROL TRANSFORMER MODULE

BRUSH GEAR ASSEMBLY

AUX. CONTROL AND RELAY PANEL DESK

INDICATING INSTRUMENT

RECORDING INSTRUMENT

INTEGRATING INSTRUMENT

CONTROL & INSTRUMENTATION

1. Conductivity Measuring Equipment Including Test Procedures

2. pH Analyser Including Test procedure

3. Silica Analyser

4. Level Switch (Float Actuated)

5. Level Switch (Electrode Type)

6. Level Switch (Displacer Actuated)

7. Transmitter (Float Operated Pneumatic Output including Testing procedures

8. Level indicator (Float/Pulley Type)

VOLUME-II
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SECTION - VIII
 CEMS FOR CHIMNEY & INLET GAS ERECTION
RSTPP ANALYSERS PACKAGE FOR FGD (Supply,
Commissioning & Supervision of Erection ) –
CONDITIONS OF
STAGE - III
FGD System CONTRACT

9. Local Temperature Indicator Including Test Procedure

10. Resistance Thermometer Element Including Test procedure

11. Thermocouple Element and Connecting Cable

12. Thermocouple and Resistance Thermometer Convertor/Transmitter Including Test

Procedures

13. Temperature Switch Including Test Procedure

14. Cold Junction Boxes

15. O2Analyser

16. S O2 analyzer

17. 02 in Hydrogen including Test procedures

18. Pressure and Vacuum Gauge

19. Pressure and Vacuum Switch Including Test procedures

20. Differential Pressure Transmitter including Test Procedures

21. Differential pressure switch including Test procedures

22. Flow indicator (Variable Area)

23. Orifice plate

24. Flow Switch

25. Nozzle

26. Flow Integrator (pneumatic input) including test procedure

27. Flow indicator (Float Operated) Including Test Procedure

28. Venturi (Fluid)

29. Flow Switch (Magnetic Type)

30. Limit Switches

31. Turbine Supervisory Measuring System

32. Position Measurement & Indication Including Test procedures

33. Vibration Measurement

VOLUME-II
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SECTION - VIII
 CEMS FOR CHIMNEY & INLET GAS ERECTION
RSTPP ANALYSERS PACKAGE FOR FGD (Supply,
Commissioning & Supervision of Erection ) –
CONDITIONS OF
STAGE - III
FGD System CONTRACT

34. Digital Indicator

35. Moving Coil Indicator Including Test Procedures

36. Recorder Including Test procedure

37. Flame Scanner

38. Electrical Auto Manual Control Station

39. Push Button Module

40. Test Procedure for Electronic Modules of DDCMIS

41. Alarm Annunciator Equipment Including Test Procedure

42. Test procedure for Adjustment of Modulating Controller-PID Term

43. Test Procedure Indicating Controller-Electrical Input & Pneumatic Output

44. Density monitors

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

VOLUME-II
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SECTION - VIII
 CEMS FOR CHIMNEY & INLET GAS ERECTION
RSTPP ANALYSERS PACKAGE FOR FGD (Supply,
Commissioning & Supervision of Erection ) –
CONDITIONS OF
STAGE - III
FGD System CONTRACT

ANNEXURE-II
BRIEF WRITE UP ON THE CONTENTS OF TESTING SCHEDULE / COMMISSIONING
SCHEDULE

Testing Schedules should be designed to ensure that the plant area, equipment or apparatus
are tested and commissioned and will operate as per the Client (EPIL)/ NTPC's
specifications and good engineering practices.

Testing Schedule/Commissioning Schedule is required to be of a standard format in order

to maintain consistency of presentation, content and reporting.

Testing Schedule/Commissioning Schedule should contain the following sections to make

the document a self contained one:

1. Plant Details/Design data

2. Testing Objective/Proposals

3. State of the Plant

a) Erection Status with respect to Mech. Elect and C&I

b) Availability of the services required

c) Safety requirements as per Manufacturer's

4. Test method including completion/acceptance criteria

5. Results

6. Appendix

a) Testing Programme

b) Mech/Elect/C&I -Plant item completing list

c) List of Drawing/documents required for carrying out the testing.

VOLUME-II
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SECTION - VIII
 CEMS FOR CHIMNEY & INLET GAS ERECTION
RSTPP ANALYSERS PACKAGE FOR FGD (Supply,
Commissioning & Supervision of Erection ) –
CONDITIONS OF
STAGE - III
FGD System CONTRACT

ANNEXURE - III
SAFETY PLAN

01. Safety Policy of the Contractor to be enclosed:

02. When was the Safety Policy last reviewed:

03. Details of implementation procedure / methods to implement Safety Policy /

Safety Rules:

04. Name, Qualification, experience of Safety Officer

05. Review of Accidents Analysis Method, Methods to ensure Safety and Health:

06. Unit executive responsible to ensure Safety at various levels in work area:

07. List of employees trained in safety employed before execution of the job. Give the
details of training:

08. Safety Training Targets, Schedules, methods Adopting to providing safety training
to all employees:

09. Details of checklist for different jobs / work and responsible person to ensure
compliance (copy of checklist to be enclosed):

10. Regular Safety Inspection Methods and Periodicity and list of members to be
enclosed:

11. Risk Assessment, Safety Audit by Professional Agencies, Periodicity:

12. Implementation of Recommendations of Audit /Inspections. Procedures for

implementation and follow up:

13. Provision for treatment of injured persons at work site:

14. Review of overall safety by top Management and Periodicity:

15. System for Implementation of Statutory legislations:

16. Issue of PPEs to employees, Periodicity / stock on hand etc:

Signature

Head of the Organisation

with date & stamp

VOLUME-II
Tender Doc No.: SRO/CON/ETS-040 Page 64 of 64
SECTION - VIII
TENTATIVE LOCATION OF TAPPING POINTS AT ELEVATION 257 M
FOR SO2/NOx/CO/CO2/O2 & MERCURY ANALYSERS &
PRESSURE.TEMP, FLOW & DUST/OPACITY MEASUREMENT. STUBS,
OTHER FITTINGS, IMPULSE LINES ETC., REQUIRED TO BE
SUPPLIED BY CEMS SUPPLIER. HOLES & STUB WELDING IN THE
SHELL & ERECTION OF INSTRUMENTS WILL BE DONE BY CHIMNEY
CONTRACTOR
SEPERATE PORTA CABINS FOR CEMS & INLET RAW GAS ANALYSERS SHALL BE SUPPLIED
AND LOCATED AT FGL AT A SUITABLE LOCATION FOR ROUTING THE SAMPLING LINES &
CABLES ETC.,
 :
Project : C&I ITEMS- INDICATIVE SUB-VENDOR LIST Doc No

:
Package : FGD Package Rev No

:
LIST OF ITEMS REQUIRING QUALITY PLAN AND SUB-
Supplier : Date
SUPPLIER APPROVAL
:
Contract No.: Page

QP / QP QP Sub- Sub-
QP
Sl No ITEM Insp. Sub. approval Proposed sub-supplier Place Supplier supplier Remark
No:
Cat. Sch. Sch. approval Details
CEMS System

1. SOX,NOX & CO2 Analyser will be from M/S

YOKOGAWA India Ltd Banglore A
Yokogawa Electric Corporation Japan .
ADAGE AUTOMATION PVT. 1. SOX,NOX &CO2 analysers will be imported
GOA A
LTD. from M/S SIEMENS Germany .
Only for Dilution Extractive Technique
1)Analyser (SOX,NOX,CO,CO2,Mercury
),sampling probe
M/s Thermo Fisher Scientific ,sample handling system ,umbical cord etc to
Mumbai A
India Pvt. Ltd be supplied from M/S Thermo Fisher USA .
2) Opacity monitor to be supplied from M/S
Durag ,
Germany .

Emerson Process Analysers from their prinipals i.e M/S Emerson

Flue Gas Analyser Panel Pawane A
Management Pvt Ltd USA
1.0 (CEMS)
Hot Extractive Type /
Envoirenment SA India Pvt Navi
A 1.Multipoint gas Analyzers MIR-9000 for SO2,
Ltd Mumbai
NOX,CO2 & CO ,Probe ,Nafyon drier & heater
Analyser Instrument Co Pvt
Kota A Analysers from Fuji Japan
Ltd
Chemtrols Engineering Ltd Goa A Analysers from SICK AG Germany
Land Instruments
UK A Optical Transreceiver type
International
Codel UK A Optical Transreceiver type

Durag Germany A Optical Transreceiver type

2.0 Dust Emision Monitor
Emerson Process
Ireland A Optical Transreceiver type
Management

SICK AG Germany A Optical Transreceiver type

Emerson Process Analyser from principals M/S Emerson

Pawane A
Management Germany/ USA
Codel UK A
Land Instruments
UK A
International
Sick AG Germany A
3.0 Flue Gas Analyser (CO)
Siemens Germany A

Envoirenment SA France A For Hot Extractive

Fuji Electric Japan A

Servo max Group UK A

Yokogawa Electric
Japan A IR-400 SERIES
Corporation
SIEMENS Ltd China A

Sick AG Germany A Hot Extractive Type

4.0 Flue Gas Analyser (CO2)
Fuji Electric Japan A

Envoirenment SA France A Hot Extractive Type

Emerson Process Analyser from principals M/S Emerson

Pawane A
Management Germany/ USA
Hot Extractive Type For So2 & Nox and In situ
SICK AG Germany A type for
So2 analyser

Fuji Electric Japan A

Flue Gas Analyser (SOX and Siemens Germany A

5.0
Nox)
 Flue Gas Analyser (SOX and
5.0
Nox)
Yokogawa Electric
Japan A IR-400 SERIES
Corporation
For In Situ Type So2 analyser /
Sick India Pvt Ltd Mumbai A 1. Analyser will be from Sick AG Germany
2. Other components like ,Whether proof
Envoirenment SA France A For Hot Extractive

Servo max Group UK A

DURAG Banglore A Analyser from M/S Verewa Umwelt Germany

M/S Mercury Instruments

Germany A
GMBH
6.0 Mercury Analyser
SICK AG Germany A

Themofisher USA A

For In Situ Type /

Sick India Pvt Ltd Mumbai A 1. Analyser will be from Sick AG Germany
2. Other components like ,Whether proof

For In Situ Type /

1.Main parts like Sample probe & Analyser will
be supplied by M/S Enotec Germany.
Analyser Instruments Co Pvt
Kota A 2. Other components like auto calibration
Ltd
unit ,probe protector ,enclosure panel &
calibration kit will be supplied
Flue Gas Analyser {O2 & integrated M/S AIC kota.
7.0 Analyser (LT)}
Emerson Process For In Situ Type / Analyser from principals M/S
Management Pawane A Emerson
Ltd USA
ABB Bengaluru A For In Situ Type /Make ABB UK

Yokogawa India Bengaluru A For In Situ Type / Make Yokogawa Japan

Enotech GMBH Germany A For In Situ Type

For In Situ Type /Shall be supplied through

Ametek USA A
ICE Mumbai
Yokogawa Electric
Japan A For In Situ Type
Corporation

Servo max Group UK A For In Situ Type

Sick AG Germany A For In Situ Type

Ultrasonic type flow meter will be from Sick AG

Sick India Pvt ltd Mumbai A
Germany

Ultrasonic type Stack Flow SICK AG Germany A

8.0
measurement
Durag Germany A

Teledyne USA A

Emerson Process Procured from USA, assembly & testing in

Pawane A
Management pawane

Hach USA A
9 Conductivity Analyser
ABB UK A

Yokogawa Japan A

Emerson Process Procured from USA, assembly & testing in

Pawane A
Management Pvt Ltd pawane
ABB UK A
10 PH Analyser
Hach USA A

Yokogawa Japan A
NOTE - 1 : Approval is conditional and subject to Sub QR / Provennes clearance as specified in the contract specification. Further for any change in the Technical specificaiton at later
stage vendor approval will be reviewed accordingly.
Data Policy for Technology Provider: -
CPCB does not register any agency as Technology Provider. Any firm either
Instrument Supplier or combination of Instrument Supplier and Software Developer
can become a Technology Provider and submit data to CPCB on behalf of any
industry. Before data submission, Technology Provider has to ensure that it provides
the data as per CPCB requirements/formats.

Ownership of Real Time Online Continuous Emission/Effluent Monitoring Stations

data collected at the web portals of Technology Provider lies with CPCB and SPCB.

Once an industry started data submission through any one of the Technology
Provider, it is the responsibility of the Technology Provider to collect, display and
forward the Online Continuous Emission/Effluent Monitoring Stations Real Time
data to CPCB Central Portal and SPCB's or any other Govt. Agency's Portal without
delay.
Technology Provider will not charge any additional cost to the industry for
transferring this data to any other Govt. Agency or SPCB etc.

Data Policy for Industry: -

Industry has to make arrangement of data submission through Technology provider
which are submitting data to CPCB as per CPCB laid down requirements given on
http://cpcb.nic.in/Online-Monitoring-Industrial-Emission-Effluent/

Sole responsibility of Real Time data submission to CPCB lies with the industry.
Industry has to ensure that data is received at CPCB Portal on Real Time Basis
without any interruption and if interruptions are observed, Technology Providers
should be immediately informed and corrective actions have to be taken by Industry
and Technology Provider.

Each Industry has to ensure 85% data availability every month for all its stations and
parameters to be monitored as per C.T.O. given by SP CB and Environmental
Clearance given by MOEF & CC.
Industry can migrate to one Technology Provider to other while it has to ensure:
� All previous data available with old Technology Provider is on boarded
in the database of New Technology Provider.
� Migration information is shared with CPCB along with data details.
� New Technology Provider follows the CPCB requirements/procedure.

o1\09t.\�
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\4.C.
 Location of CEMS
Analysers
Porta cabin

SKETCH SHOWING THE LOCATION OF

PORTA CABINS IN THE FGD LAYOUT_
Location of Inlet Gas SKETCH-1 OF F-044
Analyzer Porta cabin