STANDARD SPECIFICATION STANDARD SPECIFICATION No.

FOR COOLING TOWER & CWTP

PACKAGE 6-65-0091 REV. 0
Page 1 of 207

STANDARD SPECIFICATION
FOR COOLING TOWER & COOLING
WATER TREATMENT PLANT (CWTP)
PACKAGE

0 16.04.12 ISSUED AS STANDARD SPECIFICATION GYAS VG RBB VK DM

Standards GM Standards
committee (Engg.) Bureau
Rev. Prepared Checked
Convener Chairman
Date Purpose by by
No
Approved by

Copyright EIL – All rights reserved

Format No . 8-00-0001-F1 Rev. 0
 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 2 of 207

Abbreviations:
ATC : Acceptance Test Code
APP : Atactic PolyPropylene
BASEEFA : British Approvals Service for Electrical Equipments in Flammable Atmosphere
CS : Carbon Steel
CCOE : Chief Controller of Explosives
CIMFR : Central Institute of Mining and Fuel Research
CPRI : Central Power Research Institute
CI : Cast Iron
CWTP : Cooling Water Treatment Plant
CENELEC : Comite Europeen de Normalisation Electrotechnique
DCS : Distributed Control System
ERC : Electrical Road Crossing
EOT : Electric Operated Trolley
ERTL : Electronic Regional Test Laboratory
ELCB : Earth Leakage Circuit Breaker
FM : Factory Mutual
FLP : Flame Proof
GI : Galvanized Iron
HOT : Hand Operated Trolley
HSE : Health Safety and Environment
IRC : Instrument Road Crossing
ITP : Inspection Test Plan
LCIE : Laboratoire Central des Industries Electriques
LED : Light Emitting Diode
LCP : Local Control Panel
MS : Mild Steel
MCC : Motor Control Centre
MCB : Miniature Circuit Breaker
OWS : Oily Water Sewer
OD : Outer Diameter
OISD : Oil Industry Safety Directorate
PESO : Petroleum Explosive Safety Organisation
PLC : Programmable Logic Controller
PVC : Polyvinyl Chloride
PCC : Plain Cement Concrete
PTB : Physikalisch Technische Bundesanstalt
QA/QC: Quality Aussurance / Quality Control
RCC : Reinforced Cement Concrete
SCRC : Street Cable Road Crossing
UL : Underwriter Laboratory
WC : Water Closet

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 3 of 207

General Civil Standards Committee

Convener: Mr. R.B. Bhutda

Members: Mr. Vipan Goel
Mr. R.K. Sharma
Mr. S.K. Naskar
Mr. D.C. Brahma
Mr. Gyasuddin
Mr. P.K. Mittal (Structure)
Mr. A.T. Dharmik (Piping)
Mr. U.A. Patro (Electrical)
Mr. J.K. Joshi (Environment)
Mr. S. Mukherjee (Construction)
Mr. M.P. Jain (Projects)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 4 of 207

CONTENTS

SECTION NO. DESCRIPTION PAGE

A SCOPE OF WORK & SUPPLY 5

B DESIGN BASIS & PHILOSOPHY 15

C MANDATORY SPARE PARTS 30

D DOCUMENTS / DRAWINGS FOR OWNER’S / 33

PMC’S REVIEW

E SPECIFICATIONS 46

F GEOTECHNICAL SPECIFICATIONS 150

G PRE-COMMISSIONING, COMMISSIONING
& START-UP GUIDELINES 153

H CONSTRUCTION SUPERVISION AND

MANAGEMENT 172

I HEALTH, SAFETY AND ENVIRONMENT

(HSE) MANAGEMENT DURING CONSTRUCTION 187

J QUALITY ASSURANCE / QUALITY CONTROL

(QA/QC) DURING CONSTRUCTION 192

K LIST OF ATTACHMENTS 202

ANNEXURE-A INDICATIVE LAYOUT COOLING WATER

TREATMENT PLANT

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 5 of 207

SECTION – A
(SCOPE OF WORK & SUPPLY)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 6 of 207

1.0 SCOPE
This specification covers the requirement of scope of work, supply, design, engineering,
fabrication, erection, construction, painting, testing and commissioning of cooling tower &
CWTP Package. The no. of cooling tower cells, capacity and other requirements shall be as
per Process data sheet, P&ID & scope drawing attached in tender document.
1.1 ORDER OF PRECEDENCE
In case of any conflict following order of precedence shall be followed
i. P&ID, Process data sheet/ Package/ Job specification/scope drawing
ii. This specification
iii. Other International / national codes and standards referred to
However, contactor shall bring out the conflict to notice of the Owner/ PMC. Owner/
PMC decision shall be final.
2.0 SCOPE OF WORK & SUPPLY
2.1 GENERAL
The scope of work includes design, Engineering, procurement, manufacture, shop testing &
inspection, supply of all items including all materials and equipments, mandatory and
commissioning spares, consumables and chemicals, special tools & tackles, transportation,
receipt, storage and handling at site, installation, painting, pre commissioning and
commissioning, trial runs and performance guarantee test run of complete cooling tower
and Cooling water treatment Plant.
The scope shall also include preparation of all drawings and documents & obtaining
approval from Owner/PMC.
The detailed scope of work shall be as follows:

2.2 GENERAL CIVIL

The General Civil Works for this package shall include following:
2.2.1 Cooling Tower, Cooling water Sump and Pump House

i. Mechanical induced draft, RCC counter flow Cooling Towers with PVC film type fill for fresh
water service/Cross flow cooling tower in Timber construction with splash type bar for sea
water service.
ii. The cooling tower cells shall be designed such that each of them can be repaired,
maintained and cleaned while the other cells are operating. Oil skimming arrangement in
the channel at entry for sump shall be provided to remove floating oil to OWS.
iii. The basin shall be provided with an overflow and de-sludging arrangement from each cell,
which shall be suitably connected, to the nearest storm water drain. Drains shall be of RCC
construction.
iv. Partition of cell shall be provided from the basin bottom to the bottom of fan deck. End walls
of cooling tower shall be kept closed.
v. A chain pulley block of suitable capacity with all necessary lifting arrangement shall be
provided for maintenance work on cooling tower fan, gearbox and motor as per
specifications.
vi. The cold water from the basin shall be conveyed through a sluice gate to the sump through
cold-water channel covered with pre-cast RCC slabs. Cold water channel shall be designed

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 7 of 207

considering the water requirement of the cells. The sluice gate (as per IS: 3042) shall be
provided at a level such that full flow occurs through the gate at minimum water level.
vii. Return hot water header shall be laid underground from battery limit up to cooling towers
and further taken into the cooling tower as per contractor's design requirements for each
cell.
viii. The top slab of sump shall be provided with two number of 0.6m x 0.6m manholes with
RCC covers for maintenance of each sump. Each manhole shall be provided with a ladder
for access inside the sump up to bottom level. Suction pipe nozzles for all pumps shall be
provided in sump as per P&ID, scope drawing. Puddle flanges shall be provided in sump
and basin wall for pump suction pipes, sludge outlet pipes, overflow pipes and level
transmitter nozzles. Monkey ladder shall be provided for access to sump top.
ix. Additional manhole of 0.5m x 0.5m with removable RCC covers shall be provided on the top
of each slab of sump just above each suction line of the cooling water pumps for inspection.
These manholes shall be provided with access ladders.
x. Sufficient number of vents of CS pipe with insect screen shall be provided on the top slab of
each sump.
xi. The sump shall be provided with scour valve/ drain valve at the bottom and overflow shall
be suitably connected with the nearest storm water drain through CS pipe. The overflow
pipe in cold water basin shall be minimum 2 nos. of 300 mm diameter.
xii. Puddle pipes in sump wall, suction pipes in sump as per the scope drawing.
xiii. Cooling Water Pump House shall be as per Scope Drawing requirements.
xiv. Contractor shall check minimum pressure requirement in return header and fan deck height
with return header pressure available at cooling tower grade as specified in process data
sheet. Contractor to finalise Cooling Tower height accordingly & design the hot water riser
to suit the battery limit pressure conditions. Each hot water riser shall be provided with
isolation valve.
xv. Contractor to note that area available for proposed cooling tower, cooling water sump and
CWTP is marked on scope drawing and no extra space shall be made available to put up
the same. Contractor is required to visit site and make himself aware of actual site
conditions.
xvi. Area below cooling tower basin & cold water channel shall be provided with 100 mm thick
PCC M20. Area upto 5.0m all around the cooling tower basins and cold channel shall be
provided with RCC Pavement Type-III.
xvii. Corrosion probe and corrosion coupon shall be installed by the contactor in the return
header near the cooling tower.
2.2.2 Cooling Water Treatment Plant

i) Cooling Water Treatment Plant (CWTP) shall include acid dosing system, biocide &
formulation dosing system, Chlorine di Oxide generation and dosing system and side stream
filtration.

ii) Cooling water treatment Plant shall be designed & engineered by the specialist vendor who
has similar type of experience, the same shall be got approved from EIL/Owner prior to his
engagement.

iii) Plumbing, building drainage, drinking water, joining the sewer line from building to plant
sanitary sewer system, Safety shower & eye wash units and hook up with drinking water
header.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 8 of 207

iv) H2SO4 storage, pumping & dosing, Formulation dosing & Biocide dosing area shall be
provided with acid proof tile lining as per specifications. The area shall be kerbed & drained to
neutralization pit. Overflow from neutralization pit shall be routed to nearest storm water drain.
H2SO4 unloading / Transfer pumps, dosing pumps shall be provided in a shed.

v) The cooling water treatment plant area shall be RCC paved type-III.

2.2.3 Miscellaneous
i) The graded area shall be handed over to contractor. However, micro grading of the entire
area, drainage and footpaths within the battery limit shall be in the scope of this contactor.
Extra earth required to make up to finished grade levels shall be arranged by the contractor at
his own cost from the approved borrow areas. Contractor shall have to bear the cost of
royalties etc. as applicable. Unserviceable material / debris shall be disposed off anywhere
outside the Plant complex to the areas identified by the bidder.
ii) All under ground CS piping shall be provided with tape coating as per specifications.
iii) Cutting of existing road & other facilities, if required, making good the same at no extra cost to
the Owner. Footpaths shall be provided between CWTP & dosing point in cooling water
channel.
iv) Contractor’s scope shall also include providing approach roads to H 2SO4 dosing block, side
stream filter, Treatment Plant building, pump house
v) Providing ERC/IRC/SCRC for cable crossing and Pipe culvert for storm drains on approach
roads.
2.3 ENVIRONMENT
The Environment works for this Package shall include following
2.3.1 Chlorine dioxide Generation and Dosing System including
 Automatic Chlorine dioxide Generators
 Bulk Chemical Storage for Hydrochloric Acid and Sodium Chlorite.
 Acid (HCl) and NaClO2 unloading and dosing pumps for unloading the Acid and
Sodium Chlorite as per Job Specifications.
 Ejectors and dosing facilities including diffusers in the Cooling Tower Sump.
 All instrumentation including analyzers and detectors
 Dedicated PLC based control system.
 ClO2 Generator room and Control room
2.3.2 Side Stream Filtration System
 Side Stream Filter Unit including Filter and support media.
 All Piping and Instrumentation as per the P&ID including Manual Backwash provision.
2.4 STRUCTURES
The Structure works for this package shall include following:-
i) Foundation and super structure
ii) Pipe supports, cable supports, operating/ maintenance platforms, walkways, cross-overs,
monorails/ EOT crane/ HOT crane (as applicable), stairs, ladders, handrail, trenches, pits,
channels, embedment (bolts/ inserts/ sleeves).

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 9 of 207

iii) Water proofing and damp proofing wherever specified/ directed by Engineer-in-charge.
iv) Protective lining/ coatings on RCC surfaces wherever required.
v) One side machined sliding plates, embedded in grout over sliding support, under horizontal
equipment.
vi) Preparation of fabrication drawings for all structural steel works and bar bending schedules for
all RCC works.
vii) Anti-termite treatment for buildings.
viii) Laying 50 mm thick Anti-corrosive layer under tanks.
ix) Water-proofing compound (Approve make) in concrete as per manufacturer’s specification for
all leak-proof RCC structures.
x) Concrete penetrating corrosion inhibiting admixture (approved make) in concrete as per
manufacturer’s specification for protection of reinforcement against corrosion.
2.5 ARCHITECTURE
The Architecture works for this package shall include for following buildings:-
i) CWTP Building
ii) Cooling Water Pump House
iii) Equipment Sheds
2.6 ELECTRICAL
The electrical works for this package shall include following:
i) Motor Control Centre (MCC) for dosing, transfer pump motors, cooling tower fans and other
loads of the package.
ii) MCC shall be located in Owner’s substation. Supply, installation, testing & commissioning of
MCC shall be by contractor.
iii) All the motors within the package rated upto 55 kW are to be fed from above MCC.
However, motors rated above 55 kW shall be fed from Owners’ Power Control centers
located in Owner’s substation.
iv) All MV motors along with respective Local control stations for motors including emergency
push buttons.
v) 415V Welding receptacles.
vi) Carryout soil resistivity test to ascertain the soil resistivity value for earthing system design
vii) Lighting system including lighting and power panels, fixtures with lamps, platform/ floor
mounted lighting poles, lighting cables and accessories.
viii) Earthing & lightning protection system including earth electrodes in test pits, earth strips, earth
plates, earthing cables etc. and interconnection of earth grid of the package with the main
plant grid.
ix) All electrics for EOT cranes, as applicable.
x) Cable accessories/installation materials such as double compression cable glands, adapters,
tag numbers, cable markers, cable ferrules, lugs etc., supports, saddles and all other
associated accessories and hardware.
xi) Complete cable work, cable trench / above ground cable trays, supports, racks including
provision of cable trays as required for power, control, fire alarm, communication cables.
However cable works from Owner’s substation to Package battery limit will be provided by

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 10 of 207

Owner.
xii) Installation of plant communication equipment (to be free issued by owner) such as field call
stations, loud speakers, acoustic hood, etc. within the battery limit of the package.
xiii) Supply and installation of Public address junction box (PAJB), installation materials e.g.
conduits and accessories, as required; including laying and termination of all cables from
PAJB onwards to all equipment.
xiv) Installations of Fire Alarm Manual call stations (to be free issued by owner) within the battery
limit of the package.
xv) Supply and installation of Fire alarm junction box (FAJB), installation materials, as required;
including laying and termination of all cables from FAJB onwards.
xvi) Telephone wiring including supply and laying of telephone cables inside operator room/PLC
room from telephone Junction box onward, including supply and installation of Telephone
Junction box (TJB), conduits, wires, telephone socket outlets etc.
2.7 INSTRUMENTATION
The instrumentation works for this package shall include but not limited to the following:
i) All field-mounted instruments as shown in P&IDs.
ii) Local panels with all instruments and accessories duly mounted on them.
iii) Local gauge board/s with all instruments and accessories, duly mounted on them.
iv) PLC based control system for Chlorine di-oxide generation and dosing system.
v) Junction boxes:
 For interconnection between field and local panels.
 For interconnection between field/ local panels and Control Room.
 Three way junction boxes in field for connection to loop powered indicators in local panels,
wherever required
vi) Armoured cables (signal, alarm, control, thermocouple extension, RTD, power supply):
 Between field instruments and junction boxes.
 Between field instruments and local panels.
 Between junction boxes and local panels.
 All other special cables from field to Control Room.
vii) All installation materials such as impulse tubes, pipes, valves, pipe & tube and fittings for all
field instruments and instrument air supply distribution.
viii) Cable glands and PVC sleeves (cable shrouds) for different types of single pair /triads cables
as well as multipair/triad side of junction boxes.
ix) Canopies for field mounted electronic /electrical instruments and junction boxes.
x) Sunshield/Weather hood for local panels.
xi) Cable trays, perforated trays, angle trays and RCC trenches for cable laying within the
package battery limit.
xii) All erection materials such as instrument supports, stanchions, consumables required for
mounting of instruments, local panels, gauge boards, structural supports.
xiii) Complete field earthing including GI/ copper earthing strip, earth pit & earthing cables for
earthing of all instrumentation items including junction boxes, field instruments etc.
xiv) Carrying out/ witnessing shop testing, calibration of all special instruments like analysers

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 11 of 207

supplied by Vendor and inspection & testing of all other instruments.

xv) Installation, Field Calibration/ Testing, Loop Checking:
 All package instruments & accessories including local panels, local gauge boards, cable
tray including installation of free issue items like gas detectors, Hooter / beacon,
corrosion probe.
 Instrument cable trays.
 Laying, termination, ferruling and glanding of all cables supplied by Vendor up to junction
boxes.
 Instrument air distribution within package.
xvi) Coordination with Owner /PMC, Owner’s DCS / PLC vendor and owner’s instrumentation
erection contractor for successful commissioning of the package.
2.8 ROTATING EQUIPMENT
The Rotating Equipment works for this package shall include following:
Centrifugal Pumps, Controlled Volume Pumps, Rotary Pumps (Screw/ Gear type/Archimedean
screw type) as per Process Package.
The item as defined herein means as a minimum of the driven equipment, its driver, couplings,
coupling guards, common base plate, foundation bolts, local instruments, local gauge board
(as required), local control panel (as required) and other associated auxiliaries / accessories,
as specified in the bid package and as required to make the package ready for safe & smooth
operation.
2.9 STATIC EQUIPMENT
The scope of Static Equipment shall include Complete mechanical design and detailed
engineering of equipment including all mountings, accessories & bought-out items for vessels
and tanks.
2.10 PACKAGED EQUIPMENT
The Packaged Equipment works for this package shall include as specified below:
 EOT Cranes
 HOT cranes
 Chain pulley Blocks
 Air Conditioning system for operator room and control room
2.11 PIPING
The Piping scope covers the design requirements, materials and guidelines for the design and
engineering of piping systems inside package battery limit of Cooling Tower & CWTP. The
design and engineering shall conform to the following standards as applicable:
 ASME B 31.3 “Process Piping”
 IBR “ Indian Boiler regulations”

2.12 Painting
Contractor’s scope shall include shop and field painting of following items as per the painting
specification:
i. Painting on all Structural Steel surfaces confirming to environmental exposure conditions.
ii. Painting of all above ground piping and equipment.
iii. Painting of instruments, instruments supports and installation material/ impulse lines (as

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 12 of 207

applicable).
iv. External and internal painting of vessels and tanks.
v. Painting of Buildings
2.13 Commissioning
i) Commissioning of the entire system within package battery limit including testing and trial
runs for 30 days and removal of unserviceable material.
ii) Owner or his authorised representative will have the right to inspect at any stage of
manufacture and construction, all materials, components and workmanship and testing of
materials. The contractor shall provide all facilities of inspection and testing without any
extra cost to the owner.
iii) Supply of chemicals and consumables including first fill required for equipment & lubricants
required during commissioning, trial runs for 30 days, performance guarantee test run and
six months consumption of plant operation after commissioning.
2.14 Performance Guarantee & tests
i) The cooling tower shall be tested and guaranteed to meet the performance requirement
when tested in accordance with the procedure set forth in the latest revisions of the test
procedure ATC-105 of CTI. The Performance Guarantee Test shall be conducted for 72
hours running.
ii) If the performance test shows a deficiency, the contractor shall rectify the defects without
any additional cost to the owner.
2.15 Technical Evaluation Criteria for Cooling Tower
COUNTER FLOW TOWERS
The offer of counter flow tower will be evaluated by Fulkerson's method using
Fulkerson's demand curve and fill characteristic curves applicable to the case.
CROSS FLOW TOWERS
The offer of cross flow tower will be evaluated by Kelly's method using Kelly's demand
curve and fill characteristic curves applicable to the case.
Note: The type of Cooling Tower shall be as per job requirement.
2.16 EXCLUSIONS
Following works are excluded from contractor’s scope, However, contactor shall be
responsible for coordination with Owner.
i) The cooling water recirculation pump house scope does not include pump house flooring,
cooling water pump foundations, cable trenches in pump house, steel platforms in pump
house.
ii) Supply and laying of incoming cables up to MCC in Owner’s substation. However,
termination at both ends is included in Contractors scope.
iii) Supply and laying of all outgoing cables from MCC in Owner’s substation to Cooling Tower
and Cooling Water Treatment Plant Area. However, termination of all the cables at both
ends is included in Contractors scope
iv) Supply and laying of incoming cables up to lighting/emergency lighting/power panels from
owner’s switchboard in sub station. However termination of incoming cable at both ends is
included in contractor’s scope.
v) Supply, testing and commissioning of the fire alarm system and plant communication
system (only installation of fire alarm equipment and plant communication equipment and

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 13 of 207

laying & termination of fire alarm/ plant communication cables & accessories is included in
contractor’s scope).
vi) Supply and Laying of all instrumentation (signal, alarm, control) multi cables from
contractor’s supplied Junction Boxes/ local control panels in field to Satellite Rack room /
control room. Supply and laying instrument power supply cables from power distribution
cabinet in Satellite Rack room / control room to one point up to the contractor’s supplied
power distribution panel at field.
vii) DSC/ PLC based system for the Cooling Tower package in Satellite Rack room / control
room (except for PLC of ClO2 generation system, which shall be supplied by contractor)
2.17 SCOPE OF SUPPLY
2.17.1 FREE ISSUE MATERIAL BY OWNER
The following equipment and devices shall be issued to the contractor as free issue.
Contractor shall install all the material as per the specifications of this tender and also meet the
requirements of OEM:
i) Fire detection and alarm system materials such as, manual call points, Fire Alarm cables for
buildings & plant area.
ii) Plant communication system materials such as field call stations, loud speakers, Plant
Communication cables.
iii) Corrosion Coupon and corrosion Probe.
iv) Flammable / toxic gas detectors and its beacons/ hooters.
2.17.2 CONTRACTOR’S SCOPE OF SUPPLY
Except as mentioned at S. no. 2.16.1 above, all other material, equipment, consumable, tools
& tackles, labour etc. required for completion of work shall be in contractor’s scope of supply.
All other works not exclusively mentioned in the tender document, but are necessary to
complete the system in all respects with respect to process requirements; P&ID, drawings and
data sheet etc. shall form a part of total scope of work.
2.18 SPARES
2.18.1 All mandatory, as listed elsewhere in the bid package and/or as listed on the equipment data
sheets / specifications shall be supplied to the Owner along with the equipment.
2.18.2 All the Commissioning spares as required shall be supplied by contractor. Contractor shall
procure the same from the equipment vendors and make it available well before
commissioning of Plant/Equipment. In case, any additional spares are consumed during
commissioning the same to be provided by the contractor. Any leftover spares shall be handed
over to owner.
2.18.3 Contractor shall furnish a list of spares recommended by the equipment vendor for two-year
normal operation and maintenance along with firm unit prices and shall be quoted separately.
2.19 STATUTORY APPROVALS
The package Contractor shall obtain all necessary approvals from statutory authorities such as
Factory Inspector, Local Municipal or Development Authorities, Town & Country Planning
Organisation, concerned electrical inspectorate (e.g. CEA etc.) etc. for the design and
construction. The package Contractor shall also prepare all drawings, documents as required
for obtaining such approvals. Any changes/ modifications etc. in design/construction required
for obtaining such approvals shall also be done by the package Contractor without any time &
cost implication to the Owner or PMC.
2.20 APPROVED VENDOR LIST

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 14 of 207

Vendor List for all items / equipment package/ tank/ vessel fabricator etc is provided in the
tender document. Contractor shall source the material from the vendors identified in the Vendor
List. Vendor list provided in the package is for the Make only, and not for any specific Model.
For any item, the offered model for the same must meet the specification and proven track
record (PTR) requirement. Item Sub-vendor shall meet the requirement conditions of EIL
approval for the Project Approved Vendor List. The EIL approval conditions are available with
the Sub-Vendors. Contractor shall follow the approval requirement.
For items not covered in the vendor list, contractor shall get approval for the vendors proposed,
prior to the placement of order

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 15 of 207

SECTION – B
(DESIGN BASIS & PHILOSOPHY)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 16 of 207

DESIGN BASIS / PHILOSOPHY

1.0 GENERAL CIVIL
1.1 STORM WATER DRAINS AND CULVERTS
Storm water drainage
Storm water drainage system within Cooling Tower battery limit area shall consist of RCC
drains covered with grating cover so that all the storm water is efficiently drained off without
any water logging. The storm water collected from the proposed facilities shall be conveyed to
the main plant drains.
All the storm water drains to be planned independently within scope limit and shall be
designed and connected finally to main drains available outside scope limit
Drains
Type Drains shall be RCC rectangular type
Culverts
Storm water drains shall cross the roads by pipe culverts or box culverts.
Material of construction of culverts shall be as below:
Pipe Culverts : RCC pipes (Class NP-3 as per IS: 458) as per
Standard No. 7-65-0103
Storm Water Box culverts : RCC Cast-in-situ Construction (RCC
M30) as per Standard Nos. 7-65-0104, 106)
1.2 RCC Pavements
RCC pavement of type-III shall be provided around Cooling Tower area as per scope of work.
The contractor shall provide the pavement as per std. no. 7-65-0404. Extent of heavy duty
Sub-grade shall be improved as per Geo-technical Recommendations.
1.3 DRINKING WATER / PLUMBING SYSTEM
Drinking water system is required to meet the requirements for drinking, sanitation, safety
shower & eyewash. The drinking water shall be tapped from the header available outside the
scope limit as shown in the scope drawing including hook-up and provide drinking water posts,
internal plumbing, piping, fittings, design, testing & commissioning as per relevant IS codes &
specifications. The drinking water lines in all buildings shall be concealed.
Individual buildings shall be provided with HDPE water storage tank on roof of the building as
per IS: 12701 of minimum capacity 500litrs.
Drinking water piping network shall be laid underground in paved area directly buried along
roadside or other locations and shall preferably be in closed loops. Min. clear cover of 600 mm
shall be provided in open areas except at road crossings and paved area, where it shall be
1200 mm. Isolation valve shall be provided at tapping points. Isolation valve and valve pit shall
be provided at junctions. Contractor to provide drinking water to DW posts, sanitary system in
building & safety shower & eye wash units.
Before entering the building, an isolation valve with RCC valve pit shall be provided on water
supply line.
The minimum size of tapping for any fixture shall be 15mm.
1.4 SANITARY SEWER SYSTEM
a. Drainage

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 17 of 207

 The system shall be designed as the principle of ‘Two pipe system’ i.e Soil Pipe (SP)
and Waste Pipe (WP)
 ‘WP’ shall receive water from wash basin, sink and cooler area etc.
 ‘SP’ shall receive waste from water closets & shall be directly connected to inspection
chamber/ manhole outside building.
 WP shall be connected to first manhole/ inspection chamber through gully trap.
 Floor traps shall be provided on WP, SP as required.
 All vertical stacks and ventilating pipe shall be carried to a height of at least 1.5 m
above parapet and shall be provided with cowl at top.
 RCC P1 class pipes shall be used inspection chamber onward and shall be hooked up
with main refinery sanitary network at scope limit.
The requirements of sanitary sewer shall be as follows.
b. Material
Manholes : RCC
Inspection chamber/ Gully trap : Brick Class-5
Piping from toilet block to : CI pipes as per IS: 3486
Inspection chamber
Vent pipe : CI pipes as per IS: 1729
Gravity mains & laterals : RCC pipe with socket/ spigot
Joints class P1 as per IS : 458
1.5 SAFETY SHOWER & EYE WASH
Contractor shall provide combined safety shower and eyewash units at various places as
required where acidic/ caustic or other chemicals are handled or toxic chemicals may be
present. Water shall be fed from drinking water line. The exact no. of safety shower and eye
wash shall be ascertained as per Process requirement by the Contractor. Safety Shower &
Eye wash units shall meet the requirements of IS: 10592.
1.6 APPROACH ROADS
Roads of adequate widths as per scope drawing (minimum 7.5m) shall be provided. Approach
roads shall be of RCC type-I pavement.
1.7 ELECTRICAL/ INSTRUMENTATION CABLES ROAD CROSSINGS
For all electrical/ instrument cables crossing the main/approach roads, suitable road crossings
by PVC pipes encased in concrete shall be provided as per standard drawing enclosed with
tender.
1.8 UNDERGROUND PIPING
All underground C.S pipes shall be provided with tape coating as per Specification for Corrosion
Protection Tape coating of underground steel pipelines No. 6-79-0011.
2.0 ARCHITECTURECODES & STANDARDS
2.1 All buildings’/ sheds’ design and engineering under the package shall fully comply to
applicable codes and standards such as National Building Code of India, State Govt. Factory
Acts, Local Municipality or any other Authority’s Bye-laws as applicable.
2.1 DESIGN REQUIREMENT

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 18 of 207

2.1.1 Spatial Requirement:

CWTP Building: Spatial requirements inside buildings shall be finalized based on activities to
be performed in the building and consequent occupancy pattern, equipment layout,
maintenance, HSE requirement etc. and shall be subjected to review/ approval of Owner/
PMC.
The drawing attached with the bid indicates the minimum functional spaces, which are not
exhaustive. Contractor shall finalize the requirements of functional spaces and accordingly the
building sizes during detail engineering and provide the same in accordance with requirements
indicated in the bid document and as approved by Owner/ PMC and provide the same and the
same shall be subjected to review/ approval by Owner/ PMC.
2.1.2 Space/ Building Arrangement:
2.1.2.1 Various spaces of buildings shall be integrated together by means of proper circulation spaces
considering functional requirement, inter-relationship between various spaces, Equipment lay-
outs, operation, maintenance and HSE requirements as reviewed/ approved by Owner/ PMC.
2.1.2.2 Package Contractor shall prepare equipment lay-out drawings and shall finalise the same
incorporating comments/ observations of Owner/PMC. Architectural design and drawings shall
be based on the approved equipment lay-outs.
2.1.2.3 Building arrangement shall also ensure optimum size/ shape, structural arrangement and
pleasing aesthetics as reviewed/ approved by Owner/ PMC.
2.1.2.4 Size of buildings if indicated in bid drawing/ document are indicative only. Package Contractor
shall finalize the building sizes during detail engineering and provide the same subjected to
review/ approval by Owner.
2.1.3 Structural System:
Structural/ Construction system of the buildings shall be as follows:

Serial Building Structural/ Construction system

No.

1 CWTP Building RCC frame structure with RCC roof & parapet
and brick masonry wall.

2 Cooling Water Pump RCC frame structure with RCC roof & parapet
House and brick masonry wall or Steel structure with
metal roofing, cladding and masonry walls as
specified in job specific requirements.

3 Industrial / Equipment Steel structure with metal roofing, cladding and

Shed masonry walls as specified in job specific
requirements.

2.1.4 Day Lighting and Natural Ventilation:

Day lighting and natural ventilation shall be provided in buildings in accordance with the
applicable codes and standards indicated in clause 1.1 above. Required level of illumination
shall be maintained for all parts of the buildings by means of windows, sky lights etc. Day
lighting shall be supplemented by electric lighting to obtain required illumination. Natural
ventilation shall also be supplemented by mechanical means of ventilation to obtain required
ventilation.
2.1.5 Safety Requirement:

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 19 of 207

Safety from fire and like emergencies shall be taken into account in building design and the
same shall be provided in in accordance with the applicable codes and standards indicated in
clause 1.1 above. Every building shall be provided with exits sufficient to permit safe escape of
occupants in case of emergency. The exits shall be in terms of doorway, corridors, and
passage ways to internal/ external staircase or to areas having access to the outside.
2.1.6 Building Services:
Following services shall be provided for buildings:
(a) Electrical Services: Electrical services for buildings shall consist of electrical power
supply and distributions, Electrical lighting installations, fans, exhaust fans, lightning
protection system etc. including all accessories, cabling etc.
(b) Plumbing/ Sanitary Services: This shall consist of Sanitary disposal/ supply services,
plumbing fittings and fixtures etc.
(c) Chlorine di-oxide generation and dosing system control room shall be provided with air
conditioning system.
2.1.7 Aesthetics:
Apart from the fulfilment of functional, maintenance & HSE requirement, aesthetic
requirement of the building shall be taken care of in the design. preliminary drawings
indicating Architectural treatment shall be submitted for Owner’s approval. Elements like
Canopies, overhangs & shading devices, gutters, door; Window/ Ventilator composition,
Colour Scheme etc. shall be considered as contributory elements to aesthetics and their
design etc. shall be subjected to the Owner’s approval.
2.1.8 Architectural Finishes:
2.1.8.1 Architectural finishes such as floor finishes, plastering & painting on walls & ceilings, doors/
windows/ ventilators, roofing treatment, plinth protection etc. shall be provided in buildings as
per following schedule.
2.1.8.2 Architectural finishes shall be in accordance with specifications and materials/ items shall be
procured from approved manufacturers.
2.1.8.3 External finishes:
CWTP Building: shall be as per attached drawing.
Cooling Water Pump House / Industrial Shed: Waterproof Cement paint for RCC frame,
masonry walls, precoated steel sheet for metal roofing and cladding.
2.1.8.4 Internal finishes:
CWTP Building: shall be as per attached drawing
Cooling Water Pump House / Industrial Shed:
 Heavy duty cement concrete flooring
 15/ 12mm thick plain cement plaster, Oil Bound Distemper for masonry work
 6mm thick plain cement plaster, Oil bound distemper for RCC work
 Skirting shall be of similar material as floor finish.
 Under deck insulation & false ceiling shall be provided in all AC areas.
 False ceiling shall also be provided in all habitable rooms, etc. whenever clear height
of roof is more than 4000mm

 False flooring shall be provided wherever required for under floor cable/conduit

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 20 of 207

connectivity irrespective of provisions in above table.

3.0 ELECTRICAL
The following shall form the basis for developing detailed design and engineering for electrical
facilities including electrical distribution system, electrical equipment and electrical installation
etc. The designed system shall comply with the requirement of relevant IS/IEC standards and
statutory regulations, Design, engineering, detailed engineering, preparation of drawings/
documents, supply, installation, testing and commissioning of the electrical system for the
plant shall be performed as per specifications, data sheets and drawings enclosed with tender.
3.1 SITE CONDITIONS
The equipment and the installation shall be suitable for continuous operation under the site
conditions as specified elsewhere in the Bid package. If not specifically mentioned, a design
ambient temperature of 40C and an altitude not exceeding 1000 meters above mean sea
level shall be taken into consideration for design purpose of Electrical equipment/system.
3.2 AREA CLASSIFICATION AND EQUIPMENT SELECTION
3.2.1 Area classification shall be carried out in line with IS-5572 and Petroleum rules. Area
Classification drawing prepared by the contractor shall indicate the zone of hazardous area
and the gas group. A hazard source list prepared by the contractor shall include the list of all
flammable materials handled along with their properties like flash point, ignition temperature,
explosive limits etc.
3.2.2 All the electrical equipment installed in hazardous areas shall be selected as per IS-5571
and as mentioned under clause 3.2.4 to 3.2.7 below, and shall meet the requirements of
relevant IS, IEC or NEC Standards.
3.2.3 Electrical equipment for hazardous areas shall have test certificates issued by recognized
independent test house (CIMFR/BASEEFA/LCIE/UL/FM OR equivalent).
3.2.4 Electrical equipment for hazardous areas shall generally be suitable for gas group II A, II B
and temp. class T3 as applicable to the selected type of explosion protection.
3.2.5 All electric motors for agitators/mixers and metering pumps handling flammable materials
and vertical oil sump pumps shall be flameproof type irrespective of the area being
classified as Zone-2 or Zone-1.
3.2.6 All emergency/critical lighting fixtures and associated control gear boxes & junction boxes in
hazardous areas (whether zone-1 & zone-2) shall be flameproof type.
3.2.7 Irrespective of area classification (i.e. whether zone-1 or zone-2), all power junction boxes
shall be flameproof type.
3.3 POWER SYSTEM DESIGN
The distribution system shall be designed in accordance with project specifications/data
sheets and shall ensure continuity /reliability of supply, flexibility of operation and safety. All
the components of electrical system must be sized to suit the maximum load, under the most
severe operating conditions.
3.3.1 Capacity of Electrical Plant
All components of the Electrical System shall be sized to suit the maximum load under the
most severe operating conditions. Accordingly, the maximum simultaneous consumption of
power, required by continuously operating loads shall be considered and additional margin
shall be taken into account for intermittent service loads, if any.
3.3.2 Voltage Drops
The maximum voltage drops in various sections of the electrical system under steady state

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 21 of 207

conditions at full load shall be within the limits stated in the following table:

Sl. MAXIMUM
PERMISSIBLE
No SYSTEM ELEMENT
VOLTAGE DROP
a) Cable between Motor control Centre and motors 3%
b) Circuit between lighting panels and lighting points 4%

3.4 Miscellaneous Requirements

3.4.1 All control cables shall be 2.5 sq mm copper conductor, PVC insulated, PVC inner
sheathed, armoured and overall PVC sheathed. Power cables upto 10 sq mm shall be with
copper conductor. However power cables having cross sectional area above 10 sq. mm
shall be with aluminum conductor.
3.4.2 All out door electrical equipment shall have IP-55 degree of enclosure protection.
3.4.3 Lighting design shall conform to relevant International codes, standards and IES hand book.
Maintenance factor of 0.8 shall be considered for illumination level calculations. Illumination
levels for specific areas shall not be less than the levels as mentioned below,
Control room: 500 Lux
Office area/operator room: 300 Lux
General process area: 60 Lux
Cooling Tower: 60 Lux
Pump house, sheds: 100 Lux
Loading area & stair case: 60 Lux
Roads & tanks: 10 Lux
4.0 INSTRUMENTATION
4.1 All instruments and equipment shall be suitable for use in specified site climatic conditions
and industrial environment in which corrosive gases and/or chemicals may be present. As a
minimum, all instruments and enclosures in field shall be dust proof and weather-proof to IP-
65 as per IS/IEC-60529 or equivalent NEMA enclosure rating or better and secure against
the ingress of fumes, dampness, insects and vermin. All external surfaces shall be suitably
treated to provide protection against corrosive plant atmosphere.
4.2 The design of electronic instruments shall be in compliance with the electromagnetic
compatibility requirements as per IEC 61000-4 'Electromagnetic compatibility for Industrial
Process measurement and Control equipment'.
4.3 Instruments used within the package battery limit shall generally be intrinsically safe and
shall be selected based on entity parameters. In case any instrument is not available in
intrinsically safe type, explosion proof instruments may also be supplied.
Instruments shall be certified by CCOE, India. Also indigenous flameproof equipment shall
comply with BIS requirement.
4.4 Material of construction and end connection rating shall be as per piping material
specification as a minimum except for control valves wherein the body & flange rating shall
be minimum 300#.
4.5 Smart transmitters when specified shall be used in analog mode with an accuracy of ±
0.075% of span with a rangeability of 10:1 unless specified otherwise.
4.6 Threaded end connections shall be to NPT as per ASME B 1.20.1. Flanged end

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 22 of 207

connections shall be as per ASME B 16.5. Orifice flanges shall be as per ANSI B 16.36
4.7 After first isolation gate valve (provided by piping) all the other isolation, vent & drain valves
in instrument installation are to be considered as Gate valves to facilitate rodding except
equalization valve which shall be Globe type.
4.8 All online process analysers shall be supplied complete with proper calibration apparatus /
calibration gas cylinders etc. In case of frequent sensor drift or requirement of frequent
calibration, built in auto calibration without operator interface to be provided.
4.9 Prefabricated FRP canopy shall be used for field electronic instruments, junction boxes and
analysers as applicable.
4.10 Vendor to carryout vibration analysis of TW wake frequency shall not exceed 80% of natural
frequency. TW shall be suitable for stresses due to stream velocity condition. Minimum ratio
of natural frequency to Von Karman trail shall be 1.5 in ambient water upto fluid velocity.
5.0 STATIC EQUIPMENT
5.1 General
This section covers design basis for material, design, fabrication, erection and testing of
pressure vessels and atmospheric storage tanks.
5.2 Design Basis
i) Vessels shall be designed, fabricated, inspected and tested as per ASME Code Sec. VIII
Div.1. (latest)
ii) Vessels full of liquid and/or with design pressure < 1.0 Kg/cm 2(g) shall be designed,
fabricated, inspected and tested as per ASME Code Sec. VIII Div.1 - Practice.
iii) Tanks shall be designed, fabricated, erected and tested in accordance with API 650. All
design calculations shall be carried out in corroded condition.
5.3 Minimum Wall Thickness
Vessel shell and heads shall have minimum wall thicknesses calculated with design pressure
and temperature, in accordance with codes, but in no case, shall the thickness be less than
that determined by following formulas :
a) For carbon steel vessels - 6mm (Including corrosion allowance not exceeding 3.0 mm), but
not less than that calculated as per the formula : Wall Thickness = ((dia./1000) + 1.5+
C.A.)- For vessel Diameter less than 2400 mm;-
For higher diameters, wall thickness = ((dia./1000) + 2.5+ C.A.)
All dimensions are in mm.
b) Min thicknesses of storage tank shells, bottom plate, roof plate etc., shall be as per API
650.
5.4 Design Pressure
Design pressure shall be calculated as per the following unless otherwise specified elsewhere
in the package:
a) Design pressure shall be equal to maximum operating pressure at top of vessel or
highest point in vessel plus 10% (minimum of 2.0 Kg/cm2) more than operating
pressure.
b) Design pressure at any lower point is to be determined by adding the maximum
operating liquid head and any gradient within the vessel.
c) Vessel operating under vacuum (or partial vacuum) shall be designed for differential
external pressure of 1.055 Kg/cm2.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 23 of 207

5.5 Design Temperature

Design temperature shall be calculated as per the following unless otherwise specified
elsewhere in the package:
a) For vessels operating at 0º C and over, the design temperature shall be operating
temperature plus 15º C. However, design temperature shall not be less than 65º C.
b) For vessel operating below 0º C, design temperature shall be lowest operating
temperature.
c) Minimum Design Metal Temperature (MDMT) shall be lower of minimum atmospheric
temperature and minimum temperature envisaged during operation.
5.6 Corrosion Allowance
Minimum corrosion allowance for carbon steel vessels shall be 3.0 mm unless otherwise
specified elsewhere in the package.
The corrosion allowance for each tank shall be as given in Tank data sheet attached with the
bid package. Otherwise it shall be determined by its intended service conditions and service
life.
Roof Supporting Structure if provided internally as per EIL standard, it shall be protected with
proper primer and painting as per the provisions of painting specification, as these structures
are designed without corrosion allowance.
Wherever corrosion allowance for roof is more than 1mm or the tank is rubber lined, roof
structure shall be provided externally. Central drum, curb angle shall be suitably modified etc.
EIL standards shall be used for guidance only. However, if any protective coating like epoxy
etc. is provided then roof structure may be provided inside the tank as per EIL standards.
External roof structure shall be attached to roof-plate with pad plate.
5.7 Allowable Stresses
Basic allowable stresses for shell, heads and other components etc. of vessels and shell, roof
etc. of tanks shall be the values specified in the design code.
5.8 Wind and Seismic Loads.
Wind and Seismic requirements are as follows For Vessels
a) Seismic analysis for all equipment shall be carried out as per seismic design basis, IS:
1893 – Latest and the following guidelines:-
 Seismic analysis for Design Basis Earthquake (DBE) shall be carried out
considering site spectra as per Seismic Spectra given in seismic design basis with
2% damping. In case of site spectra is available, the same shall be followed for
acceleration values.
 Value of factor ‘R’ shall be 2.0.and ‘I’ shall be as per IS 1893.
b) Design of equipment including anchor chair shall be carried out considering wind Load
as per IS 875 (Latest). Drag coefficient for cylindrical vessels shall be 0.7 minimum.
Earthquake and wind shall be considered not acting concurrently.
Wind and Seismic requirements are as follows For Tanks
a) Wind load shall be calculated as per Indian Standard IS 875 Part 3 or site specific wind
data if attached with the bid package. But uplift and anchorage requirements shall be
calculated as per API 650 for wind load.
b) Earthquake forces shall be calculated in accordance with Indian Standard IS: 1893 or it
shall be based on meteorological and seismic data of the site, if attached with the bid

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 24 of 207

package. For calculation of seismic loading, procedure given in Appendix E of API 650,
shall be followed.
5.9 General Requirements for Vessels
(i) All design calculations shall be made considering all loads for erection, operation and
hydro-test condition taking into account wind & seismic loads. The design cases and
the loading to be considered shall be as follows.
Erection Condition : Vessel (uncorroded) erected on foundation, without
platforms, etc. but with welded attachments plus full wind
on vessel.
Operating Condition : Vessel (in corroded condition) under design pressure,
including welded items, removable internals, piping,
platforms, ladder and operating liquid etc. plus full wind,
vessels with all other projections open to wind, or
earthquake forces.
Test Condition : Vessel (in corroded condition) under test pressure, filled
with water plus 33% of specified wind load on vessel
including all attachments shall be considered.
(ii) All internals shall be designed for full load condition. For welded internals, twice the
corrosion allowance shall be considered. Removable internal parts shall be designed
with single corrosion allowance. All bolted internals shall be provided with SS bolts and
two nuts.
(iii) Design of partition plates/Baffles/Grids/Flat ends:
 Pressure drop across the bed shall be added to the liquid head and dead weight
for the design of grid.
 Allowable stress in bending shall be 0.66 X yield stress at design temperature
 Beam seat shall be checked for bending stress and deflection of support plate
shall be limited to T/2 where T is corroded thickness of plate.
 Stiffeners if provided shall be designed such that deflection is limited to L/325
where L is span of the stiffener. Contribution of plate if considered shall be limited
to 16T on either side of stiffener.
 Allowable deflection of beams shall be 0.001 of corresponding beam length.
(iv) Anchor Bolts:
a) Tensile allowable stress for foundation anchor bolt: 1630 kg/cm2
b) Shear stress of bolts: 1120 kg/cm2.
The above values are maximum to be considered. No further increase on above on
account of wind or seismic loading is allowed. The values specified above are including
wind and seismic loading.
(v) Vessel weighing more than 5.0 MT shall be provided with lifting lugs. No nozzle or
other vital attachments on the equipment being lifted shall be used as supporting or
lifting points other than those which have been specifically designed and designated
for the purpose.
(vi) Fabrication tolerances indicated in EIL Standards shall be adhered to.
(vii) Nozzles upto 50 mm NB size shall be stiffened with 2 number of 40 mm wide x 6 mm
thick stiffeners welded at 90 apart.
(viii) Vessel diameter 300 mm NB and below shall be made from seamless pipe only.
(ix) Nozzle connections used for vessels shall not be less than 40 mm NB.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 25 of 207

(x) Rolling direction of plate for shell shall be lengthwise.

5.10 Materials
Materials of various pressure parts of equipment shall be selected as follows for general
industrial condition/services unless specified otherwise in respective Process data sheet.
Carbon Steel
Plates : SA 516 Gr. 60/70 (for vessels)/ IS 2062 (For tanks)/SA 516 Gr.60 for
Caustic/sour/ amine service tanks & vessels
Forgings : SA 105
Pipes : SA 106 Gr. B
External bolting : SA 193 Gr. B7/ SA 194 Gr. 2H
Gasket : As per PMS
MOC of internals shall be as per respective Process Data Sheet attached with the bid
package.
5.11 Sizing Requirements for Storage Tanks
i) For fixing the nominal capacity of the cone roof tank, allowance for free board (minimum
500 mm), vapour space and the dead liquid space at the bottom shall be taken into
account. Tank diameter and height shall be firmed up based on nominal capacity (cylinder
volume).
ii) Tanks shell shall be designed as per the code considering the liquid height up to curb
angle of the shell using one-foot method. However, for seismic load calculation, operating
liquid level may be considered.
5.12 Tank Foundation and Anchorage of the Tank
5.12.1 Anchor bolts shall be provided if required by calculation for uplift or stability for wind and
seismic load. Minimum anchor bolt size shall be M24 excluding any corrosion allowance on
bolt diameter. Tanks with diameter < = 10m shall be provided with anchor bolts at a spacing of
maximum 1800 mm. Heavy galvanized bolts and nut shall be used for anchor. If corrosion
allowance is specified on anchor bolt, it should be added to the bolt diameter.
5.12.2 Tanks having design temperature more than 100oC shall have thermal barrier (suitable fire
bricks) between tank bottom plate and foundation.
5.12.3 Under-tanks Leak Detection for Acid and Alkali Services:
5.12.3.1 Acid service tanks shall be supported on piers above grade. Details of foundation lined with
acid proof tiles, shall be as per EIL standard 7-67-0004 (Foundation for Acid Tanks).
5.12.3.2 Caustic/ Alkali service tanks shall rest on flat foundation. Foundation floor shall be lined with
alkali resistant bitumen mastic. Minimum 100 mm wide drainage channels (radial and circular,
depending on the size of tank ) shall be provided on the top of foundation.
5.12.4 Thickness of tank bottom shall be determined as per API 650 Appendix-I for tank bottom
supported by piers/grillage. Maximum deflection of corroded bottom plate shall not be more
than half of the thickness.
5.13 Tank Bottom Plate
5.13.1 Unless otherwise specified bottom plate slope shall be 1:100 from the centre of the tank
towards the shell.
5.13.2 Butt-welded annular ring below shell ( minimum 8 mm thick excluding corrosion allowance)
shall be provided for all tanks of diameter 12 m and above

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 26 of 207

5.14 Appurtenances and Accessories for Storage Tanks

5.14.1 Size of roof / shell manhole shall not be less than 600 mm NB. Minimum number of manholes
shall be as follows :

Tank Diameter Shell Flush Type* Roof*

Manhole Cleanout Doors Manholes

Diameter.  12 m 1 nil 1

12 m < Diameter  45 m 2 1 2

*Flush Type Cleanout door shall be provided where heavy sludge accumulation is there or
when it is specified in the process data sheet.
5.14.2 Platforms and Stairways
5.14.2.1 Tanks with instruments/accessories located on the roof shall be provided with platform
(Minimum size 1.2 m x 0.8 m) on roof. Platform shall be sized and located to permit easy
access to those items.
5.14.2.2 Primary access to roof shall be by means of cage ladders for tanks with height upto 6 m and
by spiral stairways for tanks with height more than 6 m. Intermediate landings shall be
provided for spiral stairways, preferably at every 5 m interval.
5.14.2.3 Hand railing shall be provided for stairways and all around the tank roof.
5.15 Other Accessories
5.15.1 All tanks shall be provided with venting device, level indicators and earthlings connections. A
gauge hatch with cover for gauging and sampling purpose is to be provided on the tank if
specified on tank data sheet.
5.15.2 Roof to shell joint shall be frangible type. Otherwise, suitable emergency venting devices shall
be provided as per API Standard 2000. Emergency Vent of Suitable size shall be provided for
fire exposure case as per API 2000 if needed.
5.16 General Requirements
 All tanks greater than 5.0 M dia. shall be erected using jacking up method.
 The roof plates shall be self supported or supported by structure. Column supported roof
shall be not acceptable. The roof and it’s supporting structure shall be designed to carry
the dead loads, internal and external pressure as specified in process data sheet and live
loads as per the design code. Roof plates shall not be attached to the supporting
members but will rest on it. Supporting Structure shall not be immersed in stored media.
The allowable stresses for structural members shall be as specified in applicable design
code.
 For tanks, Maximum height of unstiffened shell shall be calculated based on the corroded
thicknesses of shell courses. Section modulus of wind griders shall also based on
corroded thickness of shell courses.
 For all rubber lined tanks, bottom plates and roof plates shall be either in single piece or
butt-welded construction. All sharp edges and corners shall be grounded off and given
smooth radius.
 Inside/outside painting of tanks shall be carried out based on product stored and as per
process data sheet enclosed elsewhere in bid package.
6.0 PIPING

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 27 of 207

6.1 DESIGN BASIS

I. Preferred level of bottom of piping at grade shall be 500 mm.
II. Minimum level of overhead piping shall be such that clear 2.2 M headroom is available
below pipe/insulation/supports.
III. Minimum height of equipment foundations shall be 300 mm from finished grade level.
IV. All open vents to atmosphere shall be vented to safe location at least 3 M above nearest
operating floor or platform located within a radius of 6 M for steam and 8 M for
hydrocarbon/toxic discharge.
V. Hydrostatic test, Leak test, Non-destructive Examination shall be carried out as per
applicable piping design codes.
VI. Hydrostatic Vents and Drains shall be provided at High Point and Low points
respectively as per approved PMS and or good engineering practice.
VII. Piping systems shall be adequately flexible to cater for thermal expansion/contraction
under start-up, operating and shut down conditions. A comprehensive computerized
flexibility analysis should be carried out for lines of sizes 6” & above with design
temperature greater than 120ºC connected to rotating machines to ensure that the
stresses and loads do not exceed the values permitted in the applicable code or those
provided by equipment manufacturer. All hydrocarbon lines shall be designed
considering steam out temperature.
VIII. All instruments and valves requiring attention during normal operation shall be
conveniently operable.
IX. Adequate space shall be provided for removal of equipment components for routine
maintenance.
6.2 PIPE SUPPORT DESIGN BASIS
All piping shall be adequately supported, guided or anchored so as to prevent undue vibration,
deflection/expansion or loads on connected equipment and leakage at flanged joints. Piping
at valves and equipment such as heat exchangers and pumps, requiring periodic
maintenance, shall be supported in such a way so that the valves and Equipment can be
removed with a minimum necessity of installing temporary pipe supports. Pedestal height for
pipe supports on paved area shall be 150mm above HPP. In case of unpaved area, the
pedestal height shall be 300 mm.
6.3 PIPING MATERIAL & VALVE MATERIAL SPECIFICATION
The job piping material specification as applicable is provided as attachments. Vendor shall
follow these piping classes as shown in P&IDs. Basic details for valves are provided in the
Piping Material Specification. In case of variation in material/components from this
specification, vendor to ensure suitability and establish equivalence of proposed material.
6.4 PIPING BATTERY LIMIT & INTERFACE
I. All incoming and outgoing Piping shall be terminated at pipe rack/sleeper level by the
vendor at one location with isolation valves/spectacle blind/matching flange etc as per
the approved P&IDs. Access platform shall be provided at battery limit to access all
valves, spectacle blind, instrument etc.
II. Tie-in points/battery limit drawing shall be developed by vendor and indicate exact
location, levels and scope of unit package piping for all incoming and outgoing lines as
per P&ID. And platform shall have staircase access at both sides.
III. All incoming and outgoing piping at Battery Limit shall be anchored at B/L by contractor.
Location and detail of load due to thermal expansion shall be forwarded to other
contractor to design the piping accordingly and shall be co-ordinates through
owner/owner representative.
IV. Contractor shall provide suitable access to other contractor to enable them to execute
hydro-testing of their piping system up to the flange.
V. All the pipes shall be bevelled end at the B/L interface and shall be protected after

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 28 of 207

hydro-testing.
6.5 HOT INSULATION
I. Hot Insulation material shall be Rockwool. It shall be long fibred rock or glass material
processed from a molten state into fibrous form bonded with a binder and suitable for the
intended operational temperature range from ambient to 550OC.
II. All materials shall be of high quality and good appearance. Insulation materials shall be
of low chloride content, chemically inert, non-sulphurous , rot proof, vermin proof,
impervious to hot water and steam, non-injurious to health and non-corrosive to steel
and aluminum (even if soaked in water at ambient temperatures for extended periods).
III. Insulation thicknesses shall be as per the Process documents.
IV. Suitable protective system shall be provided to eliminate the corrosion under insulation.
V. Unless otherwise specified, all valves and flanged joints shall be completely insulated
only in steam, condensate service.
VI. Unless otherwise mentioned, aluminum jacketing shall be used as weather protection
over insulation. Aluminum jacketing shall be as per ASTM B209 Alloy 3003 H16 or IS:
737 designation 31000 conditions H3 for flat sheets and designation 31500/51300
condition H4 for corrugated sheets. Thickness of jacket shall be 0.71mm (22SWG) flat.
6.5.1 Insulation Material
Fibrous Materials (Rockwool & Glass Wool)
1 Shall be a preformed insulation and shall be of long fibred rock or glass material
processed from a molten state into fibrous form bonded with a binder and suitable for the
intended operational temperature range from ambient to 550OC and 350OC for rockwool
and glasswool respectively. Slagwool is not acceptable.
2 Unless otherwise specified, insulation material shall strictly conform to all the
requirements of quality standards listed below:

• Preformed pipe insulation IS:9842/ASTM C547 TYPE II or TYPE III

• Metal-mesh covered IS:8183 /ASTM C592 CLASSII for piping & equipt.
bonded mineral fibre Blankets shall be faced on one side with 20mm
blanket and blanket type galvanised 22SWG wire mesh stitched through with
pipe insulation 22 SWG galvanized lacing wire. For insulation over
‘Austenitic SS Piping & Equipment’ instead of
galvanized wiremesh & lacing wire SS304/316
wiremesh & lacing wire shall be applied.

• Bonded Mineral fibre slab IS:8183

insulation

• Mineral fibre block & board ASTM C612 TYPE IV/ TYPE V
thermal insulation

3 Insulation shall conform to the requirements of respective codes, unless otherwise

specified herein and shall be tested and test certificates on representative samples
furnished as per IS: 8183/IS: 9842/ASTM: C547/ ASTM: C592 /ASTM: C612.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 29 of 207

• Density(min) 140 & 128 kg/m3 for resin bonded pipe sections and
resin bonded LRB blankets respectively of Rockwool; 80
& 64 kg/m3 for resin bonded pipe sections and resin
bonded curved beveled segments or LRB slabs
respectively of glass wool. Max resin content at the
above mentioned densities shall be 2% and 5% for
Rockwool and glass wool respectively. 140 kg/m3 for
IS8183 bonded mineral fibre slabs and 240 kg/m 3 /320
kg/m3 for ASTM C612 TYPEIV /TYPE V respectively.

• Thermal **Mean Temperature Thermal Cond. (mW/cm OC)

O
Conductivity(max)* C
50 0.43
100 0.52
150 0.62
200 0.68
250 0.80
300 0.90

*The values mentioned are for insulation material as per IS code; For Apparent
thermal conductivity for material as per ASTM codes refer respective ASTM
code.

**Mean Temperature = (Hot Face Temperature + Cold Face Temperature) / 2

• Linear Shrinkage Not more than 2 percent when subjected to soaking heat
at the stated max. temperature of use (550 OC), for 24
hours.

• Compressive 250 kg/m2 for resin bonded pipe sections, curved

Strength (minimum) beveled segments and LRB slabs; 120 kg/m 2 for LRB
at 10% deformation blankets (mattresses) unless otherwise specified.

• Chloride Content For stainless steels, with inhibitors less than 10 PPM, for
other materials not to exceed 20 ppm.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 30 of 207

SECTION – C
(MANDATORY SPARE PARTS)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 31 of 207

MANDATORY SPARE PARTS

Contractor shall supply mandatory spares as listed below:

S. NO. PART DESCRIPTION QUANTITY REQUIRED

1.0 GENERAL CIVIL
1.1 ½” Mesh and 10 Mesh 2 nos. each 1 set

2.0 ELECTRICAL
MV induction motors 37 kW & above (one set of
2.1
spare for each rating & type)
2.1.1 Bearing set (DE & NDE)
2.1.2 Terminal/ bushing one set each

3.0 INSTRUMENTATION
3.1 Field Instruments
Pressure Gauges & Differential Pressure Gauges 10% subject to minimum
3.1.1
1 No. of each type
Temperature Gauges (with Thermowell), RTD/ 10% subject to minimum
3.1.2 Thermocouples (with Thermowell), Test 1 No. of each type
Thermowells
Remote output meters 10% subject to minimum
3.1.3
1 No. of each type
Transmitters for Pressure, Differential Pressure, 10% subject to minimum
3.1.4
Level (DP type), Flow (DP type), Temperature 1 No. of each type
Cables, cable trays, JBs, cable glands, instrument 10% subject to minimum
3.1.5
valves & manifolds, Tube, Tube fittings 1 No. of each type
3.2 Line Mounted Instruments
3.2.1 Control Valves and Shutdown Valves
i) Proximity type limit switches 10% subject to minimum
ii) Air filter Regulator 1 No. of each type
iii) Solenoid valve
iv) Smart Positioners/ I/P converters 1 set each for items v &
v) Packing & bonnet gasket for each valve vi
vi) Stem seal ‘O’ ring for actuators and piston ‘O’
ring for piston actuators
3.3 Local Control Panels
All items like push buttons, hand switches, lamps, Loose supply of 10%
holders, indicators, terminals, relays, lamps for subject to minimum two
3.3.1
annunciators & fuses/ MCBs etc. mounted in the numbers, whichever is
control station/ local panels. higher, of each type
10% subject to minimum
1 No. of each type of I/O
3.4 Contractor’s supplied PLC system module, communication
module, power supply
module.

4.0 ROTATING EQUIPMENT

4.1 CENTRIFUGAL PUMPS
Pumps - Horizontal/Vertical (General Purpose 1 set of mechanical seals
4.1.1
Process)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 32 of 207

5.0 STATIC EQUIPMENT

5.1 PRESSURE VESSELS & STORAGE TANKS
5.1.1 Bolting for internal flanges of each nozzle One set for each nozzle
5.1.2 Gasket for internal flanges of each nozzle 200%

6.0 PACKAGE EQUIPMENT

6.1 Air conditioning system
One full charge of refrigerant along with storage 1 Lot
6.1.1
cylinders for each air conditioning system

NOTES:-

1. The above no. of spares are minimum.

2. The word ‘TYPE’ means the Make, Model no., Type, Range, Size/ Length, Rating, Material as
applicable.
3. Wherever % age is identified, Contractor shall supply next rounded figure.
4. The terminology used under ‘Part Description’ is the commonly used name of the part and
may vary from manufacturer to manufacturer.
5. Mandatory spares shall be applicable for Electrical / Instrumentation items of sub-packages
also as per above mandatory spares philosophy.
6. Mandatory spares shall be procured along with the main equipment. These spares include
only those spares, which are critical for equipment and require longer delivery periods.
7. The word `Set' means the quantity required for full replacement of that part in one machine.
8. The Bidder shall quote for all the mandatory spares as defined above & as applicable to the
proposed design of the equipment. In case, any spare which is listed above but not applicable
due to specific construction/design of the equipment, the same shall be highlighted as `Not
Applicable' against that spare supported with proper technical explanation.
9. Spare parts shall be identical in all respects to the parts fitted on the main equipment,
including dimensions, material of construction, testing & heat treatment.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 33 of 207

SECTION – D
(DOCUMENTS/DRAWINGS FOR
OWNER’S / PMC’S REVIEW)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 34 of 207

DOCUMENTS/ DRAWINGS FOR OWNER’S/ PMC’S REVIEW

The following Data marked “” shall be furnished by Vendor

Sl. Documents With For For Remarks

No. Bid Review Record
1.0 Drawing & document schedule 
for Contractor generated
documents and Sub-Vendor
Documents for all disciplines
2.0 GENERAL CIVIL
2.1 Design calculations
Cooling Tower Technical data 
sheet
Cooling tower thermal design 
and Power consumption
calculations
Basin Holdup capacity 
calculation
The manufacturer's design  
performance curves as per
ATC 105 of CTI for 90%, 100%,
110% water flow rate and range
of 40OF, 36OF, 32O F
2.2 Basic drawings and design
data
GA drawing of cooling tower,  
basin, channel, access
stairway, escape ladder- plan
and section
GA of end wall and partition 
wall
GA drawing of sump and Pump 
House
GA of CWTP and Dosing area 
Fill support details 
Mechanical equipment removal 
details, motor removal details
Fan access door, installation & 
other details
Hot water manifold and 
distribution details
2.3 PR’s/ Data sheets
Sluice gate 
3.0 STRUCTURAL
Geotechnical Investigation
3.1 Details, Foundation Design

Basis/ Comprehensive Geo-
technical recommendations.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 35 of 207

Sl. Documents With For For Remarks

No. Bid Review Record
Detailed Structural Design
Calculation Documents for
foundation and superstructure
of all structures/ buildings/
sheds (including foundations for 
static & dynamic equipment & (one most 
storage tanks). The design critical (all other
shall be on the basis of structure/ structure/
3.2 specifications available in the building/ building/
bid package & PMC approved shed & eqpt shed &
Equipment Layout/ Equipment & tank fdn eqpt &
Datasheets/ Architectural of each tank fdn)
drawings. type)
Wherever computer software is
used for analysis & design, soft
copies of the input & output
files shall also be submitted.
Construction drawings (Civil-
Structural) of structures/
buildings (including equipment
foundations). Construction
Drawings for foundation and
superstructure shall contain the
following. These drawings shall
be based on the approved
Design.
i) Plans of all floors, levels
Elevations/ Sections and
Views as required for
3.3 ii) complete understanding
of the Design & (as per
(as per
Construction 3.2
3.2 above)
Complete Reinforcement above)
details of all RCC
iii) structural elements and
connection details for all
structural steel elements
Any other Drawing/
details as required for
iv) complete understanding 
of the Design &
Construction
Foundation and superstructure
design for Cable Rack, Pipe/
3.4 Cable Support, Supports for

Junction boxes, Structural
Crossover and Under-ground
Sump/ Pit/ Trench etc.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 36 of 207

Sl. Documents With For For Remarks

No. Bid Review Record
Fabrication and Erection
Drawings (including erection
scheme) for Steel Structures
3.5 with Complete Connection

details for all structural Steel
members with table showing
Design Moments and Forces of
members at each joint.
Monthly updated status of
3.6 BOQs of major items (i.e. 
Concrete & Structural Steel).
4.0 ARCHITECTURAL
GA & equipment lay-out of
4.1 buildings/ sheds indicating 
sizing of internal spaces
Construction drawings of all the
Buildings/ Sheds. Construction
Drawings shall contain the
followings. These drawings
shall be prepared incorporating
comments etc. on the
preliminary Drawings.
a. Plan of all levels, Terrace

Plan, Key Plan.
b. Sections as required for
complete understanding of 
4.2
the Design & Construction
c. Elevations of all sides. 
d. Door/Window details. 
e. False ceiling/ flooring

details & layouts
f. Schedule of Architectural

Finishes
g. Any other Drawing as
required for complete

understanding of the
Design & Construction.
4.3 Documents/ Drawings for
Statutory Approval in

accordance with the statutory
requirement
5.0 ELECTRICAL
5.1 Purchase Specification for 
Electrical Equipment
5.1 Single Line Diagrams 

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 37 of 207

Sl. Documents With For For Remarks

No. Bid Review Record
5.2 Sizing of Electrical Equipment / 
Design Calculations
- Load Analysis
- MV Switchboard sizing
- MV Cable Sizing
- Voltage drop during
motor start up
- Cable Trays / Trenches
- Earthing / Lightning
Protection area wise
- Illumination Level
calculation
5.3 Cable, Lighting, earthing and 
lightning protection layouts
5.4 Critical Vendor Drawings (e.g.)
- GA Drawings
- Block Logic diagrams
for control schemes.
- Data Sheets for all 
major equipment.
- Data Sheets for motors
- Type Test Certificates
for all major equipment
5.5 Area Classification drawings
along with hazardous source 
list
5.6 Bill of Material for cables, 
lighting, earthing & misc.
5.7 Cable schedules 
5.8 Interconnection Drawings 
5.9 Motor List 
5.10 Equipment List 
5.11 Lighting / Power Schedule 
6.0 INSTRUMENTATION
6.1 Estimated utility consumption
for Instrument Power Supply
(110V AC UPS, 110 V DC (for
solenoid valves & interlock  
interrogation voltage as per job
philosophy), 240V AC non
UPS), Instrument air
6.2 Estimated I/O counts for signals
connected to Purchaser’s DCS/  
PLC based control system
6.3 Instrument Index 
6.4 Instrument Sizing calculations  Note-5

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 38 of 207

Sl. Documents With For For Remarks

No. Bid Review Record
6.5 Nozzle elevation drawings 
(level sketches)
6.6 Purchase Requisition for all  Note 1
instruments (including catalog
with model decoding)
6.7 Functional loop schematics  Note-4

6.8 Logic diagrams  Note-4

6.9 Logic description/ write up 

6.10 System Configuration Diagram 
for contractor’s supplied PLC
system
6.11 Ladder diagrams (for
contractor’s supplied PLC
system) 
6.12 Instrument loop Diagram (for 
contractor’s supplied PLC
system)
6.13 
Control room equipment/ panel
foundation details (Channel
base drawings.) (for
contractor’s supplied PLC
system)
6.14 
I/O assignment (for contractor’s
supplied PLC system)
6.15 
Dynamic Graphic display
drawings.
6.16 Cable schedule/ Junction Box  Note-4
schedule, Wiring Diagram
6.17 Point data base for DCS/ PLC  Note-4
6.18 Instrumentation/ Electrical  Note-4
interface details
6.19 Instrument tray / trench layout 
6.20 Instrument location, JB/ local 
panel location, Air supply
distribution drawing
6.21 Local Control panels / PLC 
Cabinet GA drawing and
internal arrangement
6.22 Instrument installation drawings 

6.23 Instrument mounting details 

6.24 Instrument grounding details 
6.25 Bill of material for installation 
items

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 39 of 207

Sl. Documents With For For Remarks

No. Bid Review Record
6.26
Analyser cabinet layout
Note 1 (shall be
Analyser sample handling submitted part
system, calibration cylinder, of Analyser PR)
sample transportation time 
calculation
6.27 Loop Checking/Calibration 
Reports
6.28 
Factory testing and acceptance
procedures for systems
6.29 
Site testing and acceptance
procedure for systems
7.0 ROTATING EQUIPMENT
7.1 Filled in Equipment Data Sheet  All the
along with performance curves documents to
7.2 Equipment specific Deviation  be submitted
List together in one
7.3 Equipment Manufacturer’s  lot.
latest Catalogue
7.4 Filled in Experience Record  Copy of
Proforma & Equipment approved
Manufacturer’s general Process
reference list Datasheet must
7.5 General Arrangement Drawing, be attached for
Cross-sectional drawings with reference.
bill of materials & Schematic
drawing / P&ID Also refer Note-
1.
7.6 P & I Diagram with bill of 
material for process fluid, lube
oil system, seal oil system
nitrogen, instrument air, cooling
water, steam systems etc. for
the complete package
7.7 Utility consumption list (start up, 
normal operation &shutdown)
7.8 All Other drawings/data as 
specified elsewhere in the
tender document
7.9 PURCHASE REQUISITIONS
for Rotating Equipment

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 40 of 207

Sl. Documents With For For Remarks

No. Bid Review Record
7.9.1 Purchase Requisitions  All documents
containing: as mentioned in
a) Vendor’s scope of supply / S.No. b) to f)
work must be duly
b) Duly filled in equipment data approved from
sheets (approved copy) PMC and then
c) Performance curves shall be
(approved copy) attached to the
d) Completely filled in PR before
Experience record format submission for
(approved copy) PMC’s records.
e) List of Mandatory spares Incomplete PR
(approved copy) or PR
f) List of Agreed Deviations containing
(approved copy) unapproved
g) List of Commissioning documents
spares shall not be
h) List of Special tools / tackles entertained and
i) Detailed Vendor Data shall be
Requirement (i.e. GA drawing; returned.
C/S drawing; Layout drawing,
P&ID etc.)
8.0 STATIC EQUIPMENT
8.1 GA Drawings One storage
tank of max dia,
one caustic/
acid storage
tank, one
agitator and
 one no. of FRP
equipment shall
be in review
category,
balanced shall
be in record
category
8.2 Details of nozzles, manholes 
and other pressure parts
8.3 Details of internals 
8.4 Details of external clips 
8.5 Bill of materials with material

spec
8.6 Design calculations 
9.0 PACKAGED EQUIPMENT
9.1 Filled in equipment data sheets 
and other technical details.
9.2 Equipment list with basic 
parameters

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 41 of 207

Sl. Documents With For For Remarks

No. Bid Review Record
9.3 Capacity calculations (along 
with sizing calculation of all
critical items/equipment) /
Selection charts
9.4 Equipment GA and sectional
drawings/ Package layout 
drawing
9.5 Vendor 
catalogues/Charts/Characteristi
c Curves for equipment
selection.
Equipment load data and 
9.6
foundation details
Utility requirements including 
9.7
power consumption
9.8 PURCHASE REQUISITIONS
for Packaged Equipment
9.8.1 Purchase Requisitions for each 
package type containing:
* All
documents as
a) Vendor’s scope of supply /
mentioned in
work
S.No. b) to e)
b) Duly filled in equipment data
must be duly
sheets (approved copy)
approved from
c) Performance curves
PMC and then
(approved copy)
shall be
d) List of Mandatory spares
attached to the
(approved copy)
PR before
e) List of Agreed Deviations
submission for
(approved copy)
PMC’s records.
f) List of Commissioning
Incomplete PR
spares
or PR
g) List of Special tools / tackles
containing
h) Detailed Vendor Data
unapproved
Requirement (i.e. GA
documents
drawing; C/S drawing;
shall not be
Layout drawing, P&ID etc.)
entertained
and shall be
returned.
10 ENVIRONMENT
10.1 Chlorine dioxide generator system
10.1.1 Details of Chlorine dioxide
Generator including Model No. 
and Manufacturer’s Catalogue
10.1.2 P&ID for Chlorine dioxide

Generator System
10.1.3 Layout drawing 
10.1.4 Complete Filled in Process
datasheet with Material of 
Construction

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 42 of 207

Sl. Documents With For For Remarks

No. Bid Review Record
10.1.5 Complete Sizing and Capacity
Calculations of the ClO2
Generator system including 
Ejector and system Pressure
loss calculations
10.2 Side Stream Filtration System
10.2.1 P&ID for Side Stream Filtration
System 
10.2.2 GA drawing of the Side Stream
Filters 
10.2.3 Details of Filter and Supporting
Bed Media 
10.2.4 Pressure loss calculations

11 Process
11.1 Updated Process P&ID 
12 General (applicable to all
disciplines)
12.1 Sub vendor list for bought out 
items, equipment, instruments
and accessories (only for those
items not covered in
purchaser’s vendor list)
12.2 As-Built Drawings and 
documents
12.3 Manufacturer Catalogues, 
Brochures, Performance Data
of items etc.
12.4 Statutory approval certificates 
for all electrical and
instrumentation items
12.5 Battery Limit / Interface 
Drawing / Documents
12.6 Test, Calibration and Inspection 
reports and certificates for all
items / equipment
12.7 Detail of special test equipment 
/ tool requirement for
maintenance
12.8 List of Mandatory Spares 
12.9 Parts List 
12.10 Installation, operation and 
maintenance manuals
12.12 Recommended spares for two
years of normal operation and 
maintenance

NOTES:

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 43 of 207

A) GENERAL:
1) The categorization (Review / Records) is given as guidance only. The exact categorization shall be
decided during review of drawing / document schedule of the contractor / vendor.
2) The list given above is indicative only. Contractor shall generate all other drawings & documents
required for completion of the job as required by Owner / PMC.
3) Schedule of submission of drawings & documents shall be decided during detailed engineering
stage.
4) All vendor documents shall be reviewed & signed by the package contractor before forwarding the
same to Owner / PMC for review / Records.
5) All revisions of drawings/ documents shall have revisions clearly marked/ clouded. Further Bidder
shall submit a Revision Summary sheet listing the sheets where revision/ changes are made, type
of changes/ revision (e.g. ‘Model number changed’, ‘Body material changed’, ‘Size changed’,
‘Measuring range changed’, ‘Type of enclosure protection changed’, ‘Type of ingress protection
changed’, ‘Type of signal changed’, etc.), and reason for changes. In case bidder makes some
changes in the drawing/ document on his own (i.e. not as per EIL/ owner’s comment), bidder must
state those in revision summary sheet with reasons while submitting the revised drawing/ document.
6) It is mandatory for the bidder to furnish ‘AS BUILT’ revision of all drawings/ documents listed above.
7) CONTRACTOR shall note that all documents shall be submitted sequentially, viz. design
calculations followed by engineering drawings/fabrication drawings.
8) Design calculation shall be submitted in detail i.e. giving complete break- up of calculation/
indicating formula & reference etc. Contractor’s software shall be validated by any reputed third
party and validation report/ certificate & name of validation agency shall be furnished along with the
design calculations
B) STRUCTURAL:
1 For all other works/ building/ structures, design calculations and AFC drawings shall be sent to
PMC/ OWNER for record and to site for construction.
2 Submission of typical review category documents shall be taken up prior to record category
documents. In case PMC/ OWNER comments on review category documents require any
modifications on other drawings/ documents in record category, it will be Contractor’s
responsibility to incorporate the same before issuing drawings for construction.
3 Structural design and drawing for any structure/ building shall be submitted only after the
reference Equipment layouts/ Architectural drawings and GA drawings/ Equipment datasheets/
Vendor drawings have been reviewed (in at least Review Code 2) by concerned specialist of
PMC/ OWNER. Copies of these reviewed reference documents shall also be submitted along
with structural design and drawings while submitting them to PMC/ OWNER for review.
4 The design & drawing for each independent structure/ building/ foundation shall be submitted by
Contractor in one lot so as to facilitate an overall systematic review. This submission shall be
accompanied with soft copy of files created as input for computer analysis/ design and all the
necessary basis/ reference documents.
5 All re-submissions by Contractor (on account of incorporation of comments/ observations of
PMC/ OWNER) shall be accompanied with a confirmation statement (document stating point-
wise compliance to all PMC/ OWNER comments on previous submissions) until all such
comments/ observations are incorporated/ resolved.
C) INSTRUMENTATION:
1. Bidder shall furnish instrument data sheets (as per ISA format) for each tag incorporating
necessary sizing, range selection, material selection, make and model nos. Bidder can use in-

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 44 of 207

house datasheet formats, provided those contain all information as per ISA formats, as a
minimum.
2. All post-order instrument documents / drawings shall be submitted after issue of P&IDs. The
submission of document / drawing is sequenced in such a way that submitted document/ drawing
is neither dependent nor changed due to drawing / document yet to be submitted. Document/
drawing submission schedule shall be made accordingly.
3. Shall be submitted with respective PR (with first submission) & along with supply.
4. Bidder shall submit system engineering drawing/ documents in EIL formats only. Sample formats
will be given to successful bidder during detail engineering after order.
5. This can be submitted with respective PR (with first submission) and in subsequent submission if
calculations are revised.
6. All the above documents, as applicable, are also required for the sub-packages ordered by the
bidder. Sub-package drawings/ documents shall be first reviewed by bidder before submission to
EIL.
7. Bidder shall review free issue package supplier’s drawings/ documents for implementation and co-
ordination with free issue packager.
D) SED

1. Following documents (as applicable) shall be submitted to inspection agency for review/ approval
as per specifications:

i) Material test certificates

ii) Destructive test Reports for Weld Quality
iii) Radiographic test reports
iv) Time-temperature curves for PWHT
v) Certificate from Statutory authorities
vi) Fabrication Schedule
vii) WPS, PQR etc.
viii) Name Plate Rubbing
ix) Hydrotest and other test Reports
x) Heat treatment Procedures
xi) List & schedule of sub orders
xii) Welding Qualification Procedures in Form No. QW 482,483 ,484
xiii) Welding & testing Plan
xiv) Packing, Lifting and forwarding Instructions
xv) Quality Assurance Practice

2. The following documents after approval shall be submitted to the Inspection Agency for carrying
out inspection/ releasing despatch
- Approved fabrication drawing
- Approved list of spare parts.

3. Extent of Review:

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 45 of 207

For Review category equipment , the following shall be reviewed by Owner.

 Mechanical Design Calculations
 Design data including codes, NDT requirements, HT requirements, Lining details.
 GA drawings – Locations of process nozzles, supports
 Details of Internals
 Material of construction.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 46 of 207

SECTION – E
(SPECIFICATIONS)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 47 of 207

SPECIFICATIONS
1.0 GENERAL CIVIL
1.1 SCOPE
This specification deals with water packages, in which the various works covered are as
follows:
1.2 CODES & STANDARDS
IS: 458 Precast Concrete Pipes (with and without reinforcement)
IS: 554 Dimensions for pipe threads where pressure tight joints are
made on threads.
IS: 783 Code of practice for laying of RCC pipes.
IS: 1726 Cast iron manholes covers and frames
IS: 1729 Sand cast iron spigot and socket soil, waste and ventilating
pipes, fittings and accessories
IS : 1742 Code of practice for building drainage
IS : 2065 Code of practice for water supply in building
IS: 2720 Methods of Test of Soil
IS: 3486 Cast iron spigot and socket drain pipes
IS: 3764 Excavation work – code of safety.
IS: 4832 (Part-I) Chemical resistant mortar silicate type
IS: 4832 (Part-II) Chemical resistant mortar Resin type
IS: 4860 Acid resistant bricks
IS: 4985 Unplasticised PVC pipes for potable water supplies
IS: 10592 Specification for Industrial Emergency Shower, eye and face
fountain and combination units.
IRC: 19 Standard Specifications and Code of Practice for Water Bound
Macadam
IRC: 36 Recommended Practices for the Construction of Earth
Embankments for Road Works
NOTE: - Latest Edition of all Codes and Standards shall be followed.
1.3 MATERIAL
All workmanship and materials shall conform to the provisions of above referred BIS codes.
1.4 CONCRETE PAVEMENT
This section establishes the requirements of material, laying and finishing of concrete
pavements.
1.4.1 Preparation of Sub Grade
1.4.1.1 The area where concrete is to be placed must be cleared of all loose material and virgin soil
must be exposed. Such exposed surface must be consolidated properly to obtain 95% of
Maximum Laboratory Dry Density of the soil. All soft patches must be worked out to remove
the soft soil and selected approved earth must be filled back and compacted.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 48 of 207

1.4.1.2 For areas, where pavement is to be laid on cutting / natural grade level, Sub grade shall be
thoroughly compacted to 95% of laboratory dry density as per IS: 2720 Part VIII. For filled up
areas, top 450 mm of the soil shall be compacted to 95% of laboratory dry density below
pavement in layers of 150 mm.
1.4.1.3 The sub grade or sub base for laying of the concrete pavement shall comply with the following
requirements:
1.4.1.3.1 No soft spots shall be present in the sub grade.
1.4.1.3.2 The uniformly compacted sub grade or base course shall extend at least 300mm on either
side of the area to be concreted.
1.4.1.3.3 The sub grade shall be properly drained.
1.4.1.3.4 The minimum modules of sub grade in wet condition, reaction obtained with a Plate Bearing
Test as per IS: 9214, shall be 6.0 Kg/cm²/cm.
1.4.1.3.5 Sub grade shall be prepared to the lines and grades to match with the slope of pavement as
shown on the drawings.
1.4.2 Preparation of Sub Base
1.4.2.1 WBM under Type-1 Pavement (Ref. EIL Standard Drawing No. 7-65-0404)
WBM Base Coarse shall consist of 2 layers of WBM Gr.-II, each of 75mm compacted
thickness, as per IRC-19.

1.4.2.2 PCC 1:5:10 under Type-II and Type-III Pavement (Ref. EIL Standard Drg. No. 7-65-0404).

1.4.2.3 PCC 1:5:10 in sub base layer shall be as described in structural specifications.

1.4.2.4 Sub Base layer shall be prepared to the lines and grades to match with the slope of pavement
as shown on the drawings.
1.4.2.5 No concrete shall be placed around manholes or other structures until they have been brought
to required grade and alignment. All sides of manholes / pits etc. shall have same elevation.
1.4.2.6 The sub base layer shall be in moist condition at the time of concrete placement.
1.4.3 Reinforcement, Mixing & Placing of Concrete
1.4.3.1 Laying of Reinforcement
All reinforcement work shall confirm to IS: 456.
1.4.3.2 Placing
The place where concrete is to be poured should be clean and free from all loose dirt, wooden
pieces, dust, standing water etc.
1.4.3.2.1 Concrete shall be laid in panels as shown in the standard drawing.
1.4.4 Compaction & Finishing
1.4.4.1 Compaction
The surface of the pavement shall be compacted either by means of power driven finish
machine or a vibrating hand screed. For areas where width of the pavement is very small,
hand consolidation and finishing shall be done as follows:
1.4.4.1.1 Concrete as soon as placed, shall be struck off uniformly and screeded to the crown and
cross-section shown on the plans and to such level above the base that when compacted and
finished, the pavement shall conform to the grade and cross-section indicated by the plans.
The entire surface shall then be tamped until a close-knit dense surface is obtained.
1.4.4.1.2 The Tamper shall rest on the side forms and shall be drawn ahead with a swing motion in

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 49 of 207

combination with a series of lifts and drops alternating with lateral shifts. The aim of this
operation is compaction and screeding to the approximate level required. Subsequent
tamping should advance 75 mm at a time in the direction in which the work is proceeding and
in final stages, the tamping should be closer, about 12 mm at a time, until a level and dense
surface is obtained.
1.4.4.1.3 If so directed by Engineer-in-charge, hand operated vibrating tamper consisting of normal type
of hand tamper attached to a pneumatic or electric vibrating unit shall be used for compaction.
1.4.4.1.4 Segregated particles of coarse aggregate, which collect in front of the tamper, shall be thrown
outside the forms or thoroughly mixed by hand with a mass of concrete already on the base.
1.4.4.1.5 Compaction by tamping shall be carried on till the mortar in the mix just works up to the
surface. The surface shall be examined after compaction correction. If needed correction
shall be made by adding or removing concrete, followed by further compaction and finishing.
1.4.4.2 Floating
As soon as practicable, after concrete has been struck off and compacted, it shall be further
smoothened and compacted by means of a longitudinal float, 1200 mm long and 75 mm wide,
operated from a foot bridge.
1.4.4.3 Straight Edging
After floating is completed and excess water removed but while concrete is still plastic, the
slab surface shall be tested for trueness with a straight edge and rectified, if necessary.
1.4.4.4 Brooming
After belting and as soon as surplus water has risen to the surface, the pavement shall be
given a broom finish to produce corrugations of uniform appearance of not more than 1/16
inch in depth.
1.4.4.5 Edging
Before the concrete has its initial set, the edges shall be carefully finished with an edger of the
radius required and pavement edge shall be left smooth and true to line.
1.4.4.6 Curing
Curing of concrete shall be as described in structural specifications.
1.4.4.7 Joints
Wherever called for on the drawings, expansion joints, construction joints and sealing joints
shall be provided as per details indicated in the drawing and as directed by Engineer-in-
Charge.
1.4.5 Sealing of Joints
1.4.5.1 After the curing, the temporary seal or other intruded materials of all expansion and
contraction joints shall be removed completely and the slots filled with approved joint sealing
compound as conforming to IS: 1834, Type B. The filler material for Expansion and Sealing
joints shall be preformed fillers of Bitumen Impregnated Fiber, conforming to IS: 1838, Part-I.
1.4.5.2 The edges of the joints shall be thoroughly cleaned and primed with a thin bituminous paint,
which shall be allowed to dry before the sealing compound is applied.
1.4.5.3 The primer shall be applied with a brush. The composition of primer shall be as follows:
Name of Material Percent by weight
1. 200-Penetration Bitumen 66
Blended

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 50 of 207

2. Light creosote oil 14

Hot/Cold
3. Solvent Naphtha 20
The bitumen shall be melted and fluxed with oil. When cold, solvent Naphtha shall be added.
BITUMINOUS emulsion shall not be used as primers. Care shall be taken to ensure that the
sealing compound is not heated above 200oC and the temperature does not exceed 180oC for
long periods.
1.4.5.4 Sealing compound shall be poured into the joint opening in such a manner that the material
will not be spilled on the exposed surface of the concrete. When required to prevent pick up
under traffic, the exposed surface of the sealing compound shall be dusted with hydrated lime.
1.4.6 Opening To Traffic
1.4.6.1 Traffic shall not be allowed for a period of 28 days after laying of concrete in pavement.
1.4.6.2 Before opening the pavement to traffic, all joints shall be filled and trimmed or topped out as
required.
1.4.6.3 Sampling, testing and acceptance of concrete work shall be according to IS: 456-2000.

1.5 UNDERGROUND PIPING (WATER SERVICES)

1.5.1 Fabrication and Laying of Underground Piping
1.5.1.1 Fabrication
1.5.1.1.1 The contractor shall fabricate all the pipe work in conformity with the Standard Specification for
Erection of Piping, and requirements of relevant general arrangement drawings. Where
specific details of fabrication are not indicated on the drawings or not specified in the
specification, fabrication and erection shall be done in accordance with ANSI B 31.3.
1.5.1.2 Laying of Underground Piping
1.5.1.2.1 Laying
The Contractor shall lay the underground piping in accordance with the following clauses and
as per the piping arrangement drawings issued during the course of construction. Corrosion
protection tape coating of the underground lines shall be in accordance with Standard
Specification no. 6-79-0011.
The Contractor shall be responsible for correct layout and gradient of the line. Errors, if any,
shall be rectified by the Contractor at his own cost.
1.5.1.2.2 Trenching
1.5.1.2.2.1 The trench shall be cut according to the drawing, true to the line, levelled with the help of sight
rails provided at every 30 m, at change of direction / gradient and at any suitable distance, as
directed by Engineer-in-Charge.
1.5.1.2.2.2 If the trench is excavated below the required level as indicated in the drawing, the extra depth
shall be filled with concrete 1:5:10 or approved equivalent material, as directed by the
Engineer-in-Charge, at no extra cost to owner.
1.5.1.2.2.3 The trench shall be excavated to the required level as per drawing. The width of the trench
shall be sufficient to give free working space on each side of the pipe. It shall not be less than
150 mm on either side or 1/3 of dia of pipe, whichever is greater.
1.5.1.2.2.4 No excavated material shall be deposited within 1.5 meters from the excavated
trench.
1.5.1.2.2.5 In case of road cutting, all materials i.e. metal, etc., shall be taken out carefully and kept

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 51 of 207

separately for reuse. Road work shall be redone up to the original level and profile with the
excavated road materials, after laying and testing of the pipe line, within 10 days from the date
of starting the work, at the cost of the contractor. The contractor shall provide suitable slings
and barricades to prevent accidents. He shall also provide reasonable by-pass at his own cost
when a road is cut for laying pipeline.
1.5.1.2.2.6 The contractor shall do dewatering, shoring, strutting / timbering if required or do whatever
might be required to excavate the trench, install the pipe in it and backfill the trench, in
accordance with the specifications, at no extra cost to the Owner. Dewatering shall be done in
advance of the laying of the pipe, to allow adequate inspection of padding of the bottom, if
required. Dewatering shall be continued throughout during laying of the pipe and backfilling of
the trench.
1.5.1.2.2.7 In muddy / slushy ground, the bed shall be provided with a layer of sand or lean concrete.
1.5.1.2.2.8 The trench shall follow the gradient of pipeline as specified in the drawing. The contractor shall
keep the trench in good condition, until the pipe is laid and tested.. All materials to shore the
trench, in order to prevent caving, shall be furnished and removed by the Contractor.
1.5.1.2.2.9 In case pipe is lowered in caved trench and back filled before being inspected by the
Engineer-in-Charge, the Contractor shall re-excavate the trench for inspection and backfill it.
1.5.1.3 Lowering & Laying
The pipe shall be lowered by mechanical method when the trench is ready and bottom of the
trench is graded as per required pipe laying conditions and specifications.
1.5.1.4 By Machine
The shop coated pipe already transported to the pipe laying site in convenient length of pipe
assembly, near the trench after hydrostatic testing, shall be placed on clean square cut skids
suitably spaced, so as to keep the pipe away from touching the ground. The pipe may be
lowered down in the trench by the launcher cranes with sufficient care, to protect the coating
of the pipeline.
At tie in welds and other site fabrications, the contractor shall clean, prime, coat and wrap
manually.
Also short sections of pipelines, which are impracticable to shop-treat, may be hand treated,
but only after obtaining prior written approval of the Engineer-in-Charge.
1.5.1.5 By Hand
Only in unavoidable circumstances and after obtaining approval of Engineer-in-Charge, the
pipe may be lowered with the help of tripods and chain pulley blocks into the trench. However,
if in the opinion of the Engineer-in-Charge, the temperature condition does not allow direct
lowering, then the pipes shall be set down on clean square cut skids. The skids shall be so
spaced as to keep the pipe away from touching the ground.
1.5.1.6 Method & Time of Lowering Pipe
1.5.1.6.1 Under favorable temperature conditions and using methods, which will not damage the
coating, the pipe may be lowered into the trench.
1.5.1.6.2 Pipes previously set on skids, because of unfavorable temperature conditions, shall be
lowered into the trench normally in the cool of the morning and only when the temperature of
the pipes is below the softening point of the coating materials.
1.5.1.6.3 All skid marks and other places of damage shall be thoroughly examined to ensure proper
patching where necessary, before the pipe is finally lowered into the trench.
1.5.1.7 Handling Coated Pipe
1.5.1.7.1 Coated pipe shall not be placed in trench, until cave-in plugs, hard clods, stones, skids and

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 52 of 207

welding rods etc. have been removed from there. Where the trench has a hard or jagged
bottom, sufficient fine dirt or stand shall be placed therein, before the pipe is lowered.
1.5.1.7.2 Coated pipe shall not be handled or moved by means of cable or chains or by prying with
skids or bars. It shall be tied and lowered by using belts of a standard width and design, for the
size of pipe being handled.
1.5.1.7.3 Coated pipe shall not be dragged along the ground or otherwise handled in a manner that will
be detrimental to the coating.
1.5.1.7.4 Despite all precautions taken during handling of coated pipes, if the coating gets damaged,
same shall be recoated by Contractor at site, at his own cost, as per directions of Engineer-in-
Charge.
1.5.1.8 Lining Up & Welding
1.5.1.8.1 The ends of the pipeline shall be kept securely closed, to prevent entry of any foreign material/
moisture, after lowering into the trench.
1.5.1.8.2 Before making joints the pipe shall be laid carefully, so as to be perfectly aligned, in both plan
and profile and the end closures provided shall be removed.
1.5.1.8.3 Free access shall be provided for the welding of the circumferential joints by increasing the
width and depth of the trench at these points. There should be no obstruction to the welder
from any side, so that good welded joint is obtained.
1.5.2 Testing & Coating
The completed system shall then be tested as mentioned below and the field welded joints
coated as per specification 6-79-0011.
1.5.3 Back Filling
1.5.3.1 After testing and inspection of the pipeline to the entire satisfaction of the Engineer-in-Charge,
the trench shall be back filled with the excavated material. No trench shall be back filled
without the approval of the Engineer-in-Charge.
1.5.3.2 Backfilling with the excavated material shall be done in layers of 150 mm compacted
thickness, and should be well compacted with necessary watering, to obtain at least 90% of
maximum laboratory dry density.
1.5.3.3 The Contractor shall place soil over the trench to such a height as well as in opinion of the
Engineer-in-Charge, to provide adequately for future settlement of the trench backfill.
If due to exigencies of the work, some portion of the pipeline is backfilled without approval of
the Engineer-in-Charge, the Engineer-in-Charge shall have the right to order uncovering of the
pipe for examination and the cost of such uncovering shall be borne by the Contractor.
1.5.3.4 The backfill material shall be free from stone pieces.
1.5.3.5 When the trench has been dug through roads, all backfill shall be thoroughly compacted. In
certain cases, special compaction methods may be required by the Engineer-in-Charge. This
shall be done by the contractor at no extra cost to the Owner.
1.5.3.6 When the trench has been dug through unlined ditches, the backfill shall be thoroughly
compacted in 150 mm layers for a distance of 1.5m beyond the outside banks of the ditch on
either side. The banks of the ditch shall also be compacted in 150mm layers, at no extra cost
to the Owner.
1.5.4 Inspection
1.5.4.1 General
1.5.4.1.1 Owner's inspector shall have free access to all places where the work is being done or any
other thing and place concerned with the work.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 53 of 207

1.5.4.1.2 Owner is entitled to send his own inspector to field or shops, where prefabrication and erection
of pipe lines are being done, with the following functions but not limited to:
i) To check that the welding performance and welding equipment used on the job are suitable
and conform to relevant standards.
ii) To supervise welding procedure qualification.
iii) To supervise welder performance qualification.
iv) To check whether welding is conforming to relevant specification and the practice followed is
in accordance with good pipeline construction practice.
iv) To check any other performance to ensure quality of work.
1.5.4.1.3 Contractor shall notify sufficiently in advance the commencement of qualification tests, welding
work and acceptance tests, to enable the Owner's Inspector to supervise the same.
1.5.4.1.4 Contractor shall provide all the facilities to Owner's Inspector, necessary for carrying out his
work, at no extra cost to the Owner.
1.5.4.1.5 Approval from the Owner's Inspector shall not relieve the contractor partially or fully of his
responsibilities and guarantees under this contract.
1.5.5 Testing
1.5.5.1 General
1.5.5.1.1 The field test pressure shall not be less than the greatest of the following:
a) 1.5 times the maximum sustained operating pressure.
b) 1.5 times the maximum pipeline static pressure, and
c) Sum of the maximum sustained operating pressure or the maximum pipeline static
pressure and the maximum calculated surge pressure.
The field test pressure shall, wherever possible be not less than two thirds of the work test
pressure, and shall be applied and maintained for at least four hours.
Where the field test pressure is less than two-thirds the works test pressure, the period of test
shall be increased to at least 24 hours. The test pressure shall be gradually raised at the rate
of nearly 1.0 kg/cm2/minute.
1.5.5.1.2 The testing shall be carried out in convenient section as approved by the Engineer-in- charge.
The joints of the pipe, connecting the testing sections, shall be 100% radio graphed.
If some defect is noticed during the hydrostatic testing, the same shall be brought to the notice
of Engineer-in-Charge. Joints, if leaking, shall be rectified as per the welding specifications
and instructions of Engineer-in-Charge and tested to his satisfaction, at no extra cost to the
Owner.
1.5.5.1.3 The Engineer-in-Charge shall be notified in advance by contractor of all testing. The
hydrostatic testing / flushing of all the piping shall be carried out by the Contractor, at his own
cost.
1.5.5.1.4 Contractor shall make his own arrangements for flushing, at suitable points, as per the
instructions of the Engineer-in-Charge. Any extra work / modification on this account shall be
done by the Contractor at his own cost.
1.5.5.2 Test Medium
Construction water shall generally be used as the testing medium, for the hydrostatic testing of
piping system.
1.5.5.3 Cleaning

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 54 of 207

All systems shall be cleaned and flushed free of all dirt, debris or loose foreign material, after
testing.
1.5.5.4 Temporary Blinds
Open ends of piping systems, such as at pumps or wherever equipment has been removed or
disconnected prior to hydrostatic testing, or at termination point of piping branch connections,
shall be blinded off by temporary blind flange, made out of 10 mm thick CS plate.
1.5.5.5 Venting
All piping systems and equipment shall be properly vented, to remove air from system, during
filling.
1.5.5.6 Pressurizing
1.5.5.6.1 Pressure shall be applied by means of a suitable test pump, which shall not be connected to
the system until ready to test. A pressure gauge shall be provided at the pump discharge for
guidance in bringing the system to required pressure. The pump shall be attended to
constantly during the test, by an authorised operator. The pump shall be disconnected, after
the pressure test is completed.
1.5.5.6.2 The test pressure is to be maintained for sufficient time, to permit complete inspection of the
system under test, but in no case shall the time be less than ten minutes. Test shall be
considered complete only when approval is given by the Engineer-in-Charge.
1.5.5.7 Test Gauges
Contractor's own test gauge shall be installed as close as possible to the lowest point in the
system being tested. Prior to installation, the test gauge shall be checked against a standard
gauge or calibrated with the aid of a dead weight tester. Calibration of test gauges shall be the
responsibility of the contractor.
1.5.5.8 Draining
1.5.5.8.1 All lines and equipment shall be completely drained after the hydrostatic test of the system has
been completed. High point vents shall be open to prevent excessive vacuum and permit
complete draining.
1.5.5.8.2 If it becomes necessary to leave a system filled with the testing medium for any abnormal
length of time, suitable arrangement such as venting shall be made to provide for possible
liquid expansion with change in ambient temperatures.
1.6 SAFETY SHOWER AND EYE WASH
This specification covers the general requirements regarding material, design, fabrication and
acceptance tests for safety showers and Eye wash (combine unit).
1.6.1 Design Requirement
1.6.1.1 It shall be generally as per IS: 10592.
1.6.1.2 The twin fountain head shall give soft, controlled drenching of eye/face when the foot pedal is
pressed.
1.6.1.3 Shower head should give uniform shower of water as soon as the weight is applied on the foot
board.
1.6.1.4 Available inlet pressure shall be around 2.0 kg/cm²g.
1.6.1.5 All steel parts shall be properly painted with 3 coats of anticorrosive paints.
1.6.1.6 Water supply pipe size shall be 40mm at inlet of combined equipment.
1.6.1.7 Water flow shall be 110 lpm (minimum) for each combined unit.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 55 of 207

1.6.2 Material Of Construction

Pipe : GI heavy grade conforming to IS : 1239.
Self closing Valve : Gun Metal
Bowl for eyewash : Stainless steel
Eye wash nozzles : Copper
Shower head : C.P Brass or stainless steel
Foot Pedal : M.S. with aluminium top
Spring : M.S Galvanised
Pull chain : M.S Galvanised
1.7 ACID PROOF TILE LINING
This specification covers the requirement of material and laying of Acid Proof tile lining for
flooring on acid storage areas.
1.7.1 Material
1.7.1.1 Acid Proof Tiles
The Tiles shall conform to IS: 4860 – Class I quality. The size of the tiles shall normally be
230mm x 115mm or as per IS: 4860.
1.7.1.2 Acid Proof Mortar
1.7.1.2.1 Silicate Mortar
It shall consist of selected potassium silicate solution and inert filter powder. Both mixed well
to enable to set at ambient temperature. The mortar shall conform to IS: 4832 (Part – I). The
mixing proportion and other instructions for use shall be as specified standard manufacturers.
“Cement Proctor S.W.K” manufactured by Corromondal Prodorite or equivalent may be used.
This type of Mortar is resistant to most acids except hydro-fluoric acid and concentrated ortho-
phosphoric acid; they are not resistant to alkalies of any concentration or to boiling water or
stream.
1.7.1.2.2 Resin Mortar
The furane and phenolic mortar for jointing consist of inert powder synthetic resin syrup. No
water shall be used during mixing. This mortar shall conform to IS: 4832 (Part – II). The mixing
proportion and other instructions shall be as specified by standard manufacturers. “Furacin”
and “Phencil” manufactured by Corromondal Prodorite or equivalent may be used. This type of
Mortar has a good resistance to non-oxidising mineral acids, and poor resistance to oxidising
mineral acids. They are fairly resistant to inorganic alkalies and water.
1.7.1.3 Bitumen Primer
A bitumen primer is an asphalt based material thinned with petroleum solvent (conforming to
ASTM D-41) should be applied over the surface. Primers from standard manufacturers only
shall be used.
1.7.1.4 Bitumen Mastic
The bitumen mastic shall consist of a mixture of asphalt cement mineral filler, and mineral
aggregate, which are acid alkali proof. The composition, preparation and properties of the
bitumen mastic shall be as per IS: 9510 for resisting acid. The bitumen mastic shall be
insoluble in Benzol and the matter soluble in diluted hydrochloric acid should not be more than
five percent. “Prodorphalte” by Coromandal Prodorite or equivalent may be used.
1.7.2 Laying

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 56 of 207

1.7.2.1 Surface Preparation

a) All damaged or questionable areas should be chipped out and replaced.
b) Adequate floor slope for good drainage is important.
c) Low spot should be avoided because finished floor will follow contour or sub floor.
d) Concrete should be dry, clean and well cured before application of membrane is
started.
1.7.2.2 Primer Application
A bitumen primer should be applied over the prepared surface. It should be allowed to dry
before applying the membrane material.
1.7.2.3 Membrane Application
Bitumen mastic is used to build up the membrane. It is heated to 120-205º C and applied to
the primed surfaces. Multiple coat application should be made to thickness requirements. The
thickness of the mastic layer shall be to suit the acid concentration and expected load or as
specified by the Engineer-in-charge. Each coat should be inspected for blisters and pinholes.
If present, they should be broken and before applying subsequent coats. Bitumen mastic
should not be used as the membrane material where solvents are involved.
1.7.2.4 Reinforcement Application
Bitumen coated glass cloth can be used for membrane reinforcements at the corners, edges,
walls, etc. depending on the requirements.
1.7.2.5 Application of Mortar and Bricks
There are two ways of lining Acid resisting linings:
1.7.2.5.1 When Bedding and Jointing Material are the same
A thin layer of about 3mm suitable resinous mortar is spread on the back of the acid proof tiles
and the tiles are pressed down on the bed. Suitable joint thickness of about 3mm should be
maintained. Jointing is done with suitable resin mortar.
1.7.2.5.2 When Bedding and jointing material are different
A thin layer of about 6mm suitable silicate type mortar is spread on the back of the acid proof
tiles and the tiles are pressed down on the bed. Proper joint thickness of about 3mm should be
maintained and filled up with suitable resin type mortar. In case of pointing the joint thickness
should be 6mm and depth of the pointing should be 19mm.
In this case, joints with silicate mortar should be acid cured with 20 to 25 percent hydrochloric
acid or with 30 to 40 percent sulphuric acid before applying the resin type mortar. After acid
curing, the free acid in the joints shall be cleaned with water and sufficient time should be
allowed should be allowed for thorough drying. After curing resin mortar is used for filling up
the joints.

2.0 ENVIRONMENT
This part of specification covers the design requirements and specifications for the Side
Stream Filtration System and ClO 2 generation and dosing system in the Cooling Water
System.
2.1 Chlorine dioxide Generation and Dosing System Specifications
Chlorine dioxide shall be used for microbiological control in cooling tower circulating water.
Chlorine dioxide dosing shall be done continuously @ 2 mg/l (based on system holdup

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 57 of 207

volume) to maintain free residual chlorine dioxide of 0.2 - 0.4 ppm in the cooling tower return
header.
ClO2 shall be generated at site from the reaction of Hydrochloric acid and the Sodium Chlorite
solution.
The Capacity of the ClO2 Generators shall be provided accordingly.

The following shall comprise the Chlorine dioxide Generation system

I. Bulk Chemical Storage for Hydrochloric Acid with effective storage capacity of 15 Days
Total requirement. The Tank shall be provided with nozzle for vent, fume collection,
Density indicator and neutralization system, drain, overflow line. The tank shall be of
FRP (with UV protection) construction.
II. Bulk Chemical Storage for Sodium Chlorite with effective storage capacity of 15 Days
Total requirement. The Tank shall be provided with nozzles for vent, drain, and
overflow line. The tank shall be of FRP (with UV protection) construction.
III. Acid (HCl) and NaClO2 unloading pumps for unloading the Acid and Sodium Chlorite as
per Job Specifications.
IV. Acid (HCl) and NaClO2 dosing pumps for individual Chlorine dioxide Generators as per
Job Specifications.
V. Chlorine dioxide Generators for capacity as per Job Specifications for generation of
Chlorine dioxide solution.

The Minimum Conversion efficiency of the ClO 2 Generator unit shall be greater than
90% with respect to ClO2 yield.
The ClO2 Generator unit may be provided as a Skid mounted unit and can be
a. ClO2 Generator unit mounted on an enclosed Skid in a room.
b. Submerged Type Under Water ClO2 Generator unit.
The contractor shall submit all calculations / details / catalogue of the Chlorine dioxide
generator system to EIL/Owner for their review / approval during detail Engineering and shall
confirm to recommendations of the Chlorine Institute and relevant International/Indian
standards/ codes. The same shall be substantiated by relevant documents.
Air contact with chlorine dioxide solutions should be controlled to limit the potential for
explosive concentrations possibly building up within the generator. Vendor shall submit the
complete details and track record of the system for EIL approval before order/installation.
Service water shall be available at the battery limit. Pressure regulation if any as per ClO 2
generator system requirement shall be done by contractor. Booster pumps if required shall be
provided for the system.
Complete Chlorine dioxide generation and dosing system including sodium chlorite dosing
pumps, hydrochloric acid dosing pump, storage tanks of sodium chlorite, storage tanks of
hydrochloric acid, ejectors and dosing facilities shall be operated and controlled though a
dedicated PLC based control system.
The following Controls shall be provided with the following instruments and controls as a
minimum,
i. The Tanks shall be provided with Level Transmitters (Radar Type) and Level
Indicators.
ii. pH in Chlorine dioxide solution dosing line.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 58 of 207

iii. Residual Chlorine dioxide analyzer in the Cooling Water Return Header
iv. ClO2 Gas detector in the Chlorine dioxide generator room.
v. Flow meters on all chemical feed lines, dilution water lines, and chlorine dioxide
solution lines.
vi. Pressure indicator and Controller on the water inlet line to ClO2 generators, chlorine di-
oxide dosing controller, low vacuum switch, solenoid valves, etc. all complete and as
required shall be provided.
vii. The dosing in cooling tower sump shall be automatically controlled based on the signal
received from residual chlorine dioxide analyzer in the cooling water return header.
viii. All chemical storage tanks shall have automatic high level and low level cut off.
ix. In case of water supply to the generator stops, the chemical dosing pumps shall also
stop automatically.
x. Generators must be equipped with systems of dosing and/ or measurement for
reagents and diluting water. These systems must be able to shut down the operation of
the generator in case any of the supplies is cut off.
xi. ClO2 leak sensor with detector shall be installed at ClO 2 generator room. The least
count of sensor shall be 0.1 ppm and generator shall stop automatically on high alarm.
xii. Feed reagent filters shall be provided on the inlet lines to the chlorine dioxide generator
unit.

2.1.1 GENERAL SPECIFICATIONS

i. The Cooling Tower sump diffusers shall be of HDPE (A1Z) and shall span horizontally across
minimum 80% of the cooling water sump length.
ii. Material of construction of Chlorine-di-oxide solution line shall be of HDPE (A1Z).
iii. ClO2 generator equipment room in the CWTP Building for housing the Generator Units and
well as the Dosing Feed Pumps shall be provided. The CWTP building shall common for
Cooling Tower Treatment Chemicals Storage and dosing system, Chlorinators and Control
Room.
iv. The Material of Construction of the ClO2 generator units shall be fiberglass.
v. One Control Room shall be provided on the First floor of the CWTP building.
vi. The bulk storage Tanks shall be provided adjacent to the Chlorinator (Chlorine dioxide
generator room and shall be provided with dyke (minimum 1.0 m height). The dyke area shall
be provided with Acid/Alkali proof lining.
vii. The Unloading Pumps area shall be provided with a kerb wall and the kerbed area shall also
be provided Acid/Alkali proof lining.
viii. All Piping from the storage tanks to chlorine dioxide generators, up to the Cooling Tower sump
shall be properly supported and clamped. M.S. bolts clamps, etc. for all piping and SS holding
down bolts and clamps for diffuser.
ix. 1 (One) No. Safety shower and eye wash facility (located just outside the Chlorine-dioxide
generator room).
x. Safety Equipment: Chlorine institute approved shall have 2 (Two) nos. respiratory equipment
(pressure demand type air masks-full face for working in leak area), 2 (Two) nos. canister type
gas mask, 2 (Two) nos. of ammonia torches, 2 (Two) Nos. of emergency repair kit, One No.
Weather sock provided at a suitable location on the building, 2 (Two) each of Safety helmets,
goggles, rubber boots, gloves and coloured vests (aprons), Display charts of PFD, Safety
checks, maintenance procedure, Emergency Action Plan, etc.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 59 of 207

xi. Minimum clear distance between adjacent pumps foundations shall not be less than 900 mm.
adequate spaces shall be provided for approach to all valves and instrumentation.
xii. All pump pedestals shall have arrangement for collection of leakage and connection to the
nearest suitable drain.
xiii. Minimum width of R.C.C. stairs shall be 1.0 m except chemical house, which shall have a 1.2
m wide stair case. Minimum width of Steel stairs shall be 750 mm.
xiv. Minimum height of pedestal for Pumps shall be 150 mm above floor/ pavement level.
xv. Minimum clearance of 500 mm shall be provided around motors / equipment (pedestal) etc.
xvi. All outdoor motors of pumps shall be covered with canopy.
2.2 SIDE STREAM FILTRATION SYSTEM

SPECIFICATIONS FOR SIDE STREAM FILTRATION SYSTEM

SERVICE : COOLING TOWER SIDE STREAM FILTER
Maximum allowable hydraulic loading Per Filter, m3/ m2/ h 10
Backwash rate for each filter, m/ h 24-36
Duration of backwash, minutes 10-15
Backwashing frequency Not more than once in a
day
Rate of air scouring by plant air, m/ h 36-45
Air scouring pressure, Kg/ cm2. G 0.35
Air scouring duration, minutes 5
MEDIA DETAILS:
Minimum depth of sand bed, mm 600
Minimum depth of gravel bed, mm 450
Free board provided for bed expansion 50%
SPECIFICATIONS FOR SAND:
Effective size of sand, mm 0.45 To 0.70
Uniformity coefficient of sand 1.3 To 1.7
Ignition loss of sand by percentage weight <0.7
Soluble fraction In HCL by weight <5.0 %
Volume of impurities (clay, loam, silt, etc.,) <5.0 %
Silica Content >90%
Specific Gravity 2.5 to 2.65
Wearing Loss <3%
Size of Gravel 2 mm to 25 mm
SPECIFICATIONS FOR GRAVEL: (NOTE-7)
Average Specific gravity <2.5
Minimum number of grades of gravel to be provided based Four

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 60 of 207

on sieve sizes
Acid Solubility Note-8
TYPE OF INTERNALS:
Material of Construction of internals
Header-Lateral system SS 304
Strainers (with lock nuts) Poly Propylene
Strainer Plate SA 516 Gr. 60/70
Manholes/ Hand holes/ Sight Glasses/ Lifting Lugs, Etc., As Per EIL Standards
Ladder with platform on filter vessel Required as Per EIL
Standards
Type of dish Tori-spherical/ Semi
Ellipsoidal
Radiography – Shell Spot
Radiography – Dish Full
MOC Of Shell & Dish SA 516 Gr 60/70
Special surface on inside Epoxy Painted to EIL
Specifications/ Standards
Surface finish on external surface As per EIL painting
specifications
Type of filter operation Manual
UNDER DRAIN HEADER-LATERAL DETAILS:
Diameter of orifices (staggered) 5 to 12 mm
Spacing of orifices varies from:
for 5 mm DIA orifice 80mm
for 12 mm DIA orifice 200 mm
Ratio of total area of orifices to cross sectional area of >0.5 for 12 mm DIA orifice
laterals <0.25 for 5 mm DIA orifice
Ratio of total area of orifices to entire filter area > 60%
SPACING OF LATERALS ~ TO SPACING OF ORIFICE
Cross sectional area of manifold 1.5 to 2 times the total
area of laterals
INSTRUMENTS REQUIRED:
DPT with local and remote indication Across each filter
PI (diaphragm type) as per EIL standards At inlet and outlet of each
filter
PI on plant air inlet line Downstream of PCV/ PRV
FE-FT-FI At inlet of each filter
Any other instruments as indicated in EIL tender P&ID to be provided by the contractor.

NOTES:

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 61 of 207

1. For piping sizes and specifications refer to EIL P&ID and PMS attached with tender
document.
2. Concrete sub-fill to be provided as required in the vessel.
3. In case of horizontal filter exceeding 4.5 m length, filters to be split in to two
compartments or more as required.
4. A PVC/HDPE v-notch/ orifice board to be provided in the drain sump for backwash
flow measurement.
5. In case of pressure inadequate for backwashing purpose, contractor to provide
suitable booster pumps (1 working + 1 standby). In such a case, design pressure of
side stream filtration system and associated facilities shall be revised accordingly.
6. The orifices in laterals shall be located in downward portion of the pipe and will be
staggered at a slight angle of 30 degrees of the vertical axis of the pipe.
7. Filter Gravel shall be free from clay, sand, loam and organic impurities of any kind.
The gravel shall not contain more than 2% by mass of thin flat or elongated pieces
determined by hand picking.
8. Gravel should be free from excessive amount of limestone or shells and acid
solubility as per IS procedures should not exceed the following limits:
 For gravel size 10 mm or larger – 10% solubility
 For gravel size smaller than 10 mm – 5% solubility
Abbreviations:
mm : Millimeter
m : Meter
DPT : Differential Pressure Transmitter
PI : Pressure Indicator
PCV/PRV : Pressure Control Valve/ Pressure Reducing Valve
FE-FT-FI : Flow Element/ Transmitter/ Indicator

3.0 STRUCTURAL
3.1 CODES AND STANDARDS
SL.
TITLE NO.
NO.
1. Specification of Paving Bitumen IS:73
2. Specification for 33 Grade Ordinary Portland Cement IS:269
3. Specification for Coarse and Fine Aggregates From Natural Sources For IS:383
Concrete
4. Expanded Metal Steel Sheets for General purposes IS:412
5. Specification for mild steel and medium tensile steel bars and hard drawn IS:432
steel wire for concrete reinforcement
6. Specification for Portland Slag Cement IS:455
7. Code of practice for plain & reinforced concrete IS:456
8. General construction in steel - Code of practice IS:800
9. Code of Practice for use of Steel Tubes in General Building Construction IS:806
10. Dimensions for Hot Rolled Steel Beam, Column, Channel and Angle IS:808
Sections
11. Cold formed light gauge structural steel sections. IS:811
12. Code of practice for design loads IS:875
13. Common Burnt Clay Building Bricks - Specification IS:1077
14. Steel Tubes for Structural Purposes - Specification IS:1161
15. Bitumen-Mastic for Flooring -Specification IS:1195
16. Steel Tubes, Tubulars and Other Wrought Steel Fittings IS:1239
17. Specification for Bitumen Felts for Water Proofing and Damp-Proofing IS:1322
18. Hexagon Head Bolts, Screws and Nuts of Product Grade `C' - Part 1 : IS:1363
Hexagon Head Bolts
19. Technical Supply Conditions for Threaded Steel Fasteners IS:1367
20. Specification for Hard-Drawn Steel Wire Fabric for Concrete Reinforcement IS:1566

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 62 of 207

SL.
TITLE NO.
NO.
21. Code of practice for construction of stone masonry IS:1597
22. High Strength Deformed Steel Bars And Wires for Concrete Reinforcement- IS:1786
Specification
23. Specification for Hot Applied Sealing Compounds for Joints in Concrete IS:1834
24. Preformed Fillers for Expansion Joint in Concrete Pavement and IS:1838
Structures (non extruding and resilient type)
25. Criteria for earthquake resistant design of structures IS:1893
26. Code of practice for structural safety of buildings - Shallow foundations IS:1904
27. Code of practice for structural use of un-reinforced masonry IS:1905
28. Specification for Plain Washers IS:2016
29. Hot Rolled Low, Medium and High Tensile Structural Steel IS:2062
30. Specification for Sand for Masonry Mortars IS:2116
31. Code of Practice for Brickworks IS:2212
32. Steel wire ropes for general engineering purposes IS:2266
33. Thimbles for wire ropes. IS:2315
34. Bulldog grips. IS:2361
35. Drop forged sockets for wire ropes for general engineering purposes IS:2485
36. Recommended practice for hot dipped galvanising on iron and steel IS:2629
37. Integral Waterproofing Compounds for Cement Mortar and Concrete - IS:2645
Specification
38. Code of practice for design & construction of raft foundations IS:2950
39. Code of practice for design & construction of machine foundations IS:2974
40. Specification for Bitumen Mastic for use in Water-Proofing of Roofs IS:3037
41. Specification for Bitumen Primer for use in Waterproofing and Damp- IS:3384
Proofing
42. Code of practice for concrete structures for storage of liquids IS:3370
43. Methods of Tests of Burnt Clay Building Bricks IS:3495
44. Steel Chequered Plates - Specification IS:3502
45. Recommendations on Stacking and Storage of Construction Materials and IS:4082
Components at Site
46. Code of practice for earthquake resistant design and construction of IS:4326
buildings
47. Hollow Steel Sections for Structural Use IS:4923
48. Determination of dynamic properties of soil IS:5249
49. Cement paint IS:5410
50. Specification for Bitumen Mastic for Tanking and Damp-Proofing IS:5871
51. Code of practice for determination of bearing capacity of shallow IS:6403
foundations
52. Code of practice for anti-termite measures in buildings IS:6313
53. Code of Practice for Water-Proofing of Underground Water Reservoirs and IS6494
Swimming Pools
54. Specification for Glass fibre base coal tar pitch & bitumen felts IS:7193
55. Code of practice for damp-proofing using bitumen mastic IS:7198
56. Code of practice for calculation of settlements of foundations IS:8009
57. Specification for 43 grade Ordinary Portland Cement IS:8112
58. Specification for bitumen Mastic, Anti Static and electrically conducting IS:8374
grade.
59. Concrete Admixtures - Specification IS:9103
60. Two parts polysulphide based sealants IS:12118
61. Specification for sulphate resisting Portland cement IS:12330
62. Hot Rolled Parallel Flange Steel Sections for Beams, Columns and Bearing IS:12778
Piles - Dimensions and Section Properties
63. Code of practice for ductile detailing of reinforced concrete structures IS:13920
subjected to seismic forces

3.2 MATERIAL REQUIREMENTS

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 63 of 207

3.2.1 General
The minimum requirements of various materials to be used in Civil and Structural works are as
below:
3.2.2 Water
a) Water used in construction for all Civil & Structural works shall be clean and free from
injurious amounts of oil, acids, alkalies, organic matters and/ or other harmful substances
which may be deleterious to concrete, masonry or steel. The pH value of water sample
shall not be less than 6. Potable water will be considered satisfactory. All requirements of
IS: 456 have to be met.
b) Tests on water samples shall be carried out in accordance with IS:3025 and these shall
fulfill all the guidelines and requirements given in IS:456.
c) Water for curing shall be of the same quality as used for concreting and masonry works.
3.2.3 Aggregate (For Concrete)
3.2.3.1 General
a) Coarse and Fine aggregates for Civil and Structural Works shall conform in all respects to
IS: 383 (Specification for coarse and fine aggregates from natural sources for concrete).
Aggregates shall be obtained from an approved source known to produce the same
satisfactorily. Aggregates shall consist of naturally occurring (crushed or uncrushed)
stones, gravel and sand or a combination thereof. These shall be chemically inert, hard,
strong, dense, durable, clean and free from veins, adherent coatings, injurious amounts of
alkalies, vegetable matter and other deleterious substances such as iron pyrites, coal,
lignite, mica, shale, sea shells etc.
b) Aggregates which may chemically react with alkalies of cement or might cause corrosion
of the reinforcement shall not be used.
c) The maximum quantities of deleterious materials in the aggregates as determined in
accordance with IS:2386 Part II (Methods of test for aggregates for concrete), shall not
exceed the limits defined in IS:383.
3.2.3.2 Coarse Aggregates
a) Coarse aggregates are the aggregates, which are retained on 4.7 5mm IS Sieve. It shall
have a specific gravity not less than 2.6 (saturated surface dry basis).
b) These may be obtained from crushed or uncrushed gravel or stone and may be supplied
as single sized or graded. The grading of the aggregates shall be as per IS:383 or as
required by the mix design, to obtain densest possible concrete.
3.2.3.3 Fine Aggregates
a) Fine aggregates are the aggregates which pass through 4.75 mm IS sieve but not more
than ten percent (10%) pass through 150micron IS sieve. These shall comply with the
requirements of grading zones I, II and III of IS:383. Fine aggregates conforming to grade
zone IV shall not be used for reinforced concrete works.
b) Fine aggregates shall consist of material resulting from natural disintegration of rock and
which has been deposited by streams or glacial agencies, or crushed stone sand or gravel
sand. Sand from sea shores, creeks or river banks affected by tides, shall not be used for
filling or concrete works.
3.2.3.4 Sampling and Testing
The Contractor shall carry out all tests including mix designs of concrete, at the start of work
as well as during any stage of construction as per the requirement. Tests shall be carried out

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 64 of 207

in accordance with IS:516 (Methods of test for strength of concrete) and IS:2386 (Methods of
test for aggregates for concrete). The method of sampling shall be in accordance with the
requirements given in IS:2430.
3.2.3.5 Storage of Aggregates
a) Storage of all types of aggregates at the site of work shall be as specified in IS:4082.
Aggregates shall in no case be stored near excavated earth or directly over ground
surface.
b) Fine aggregates delivered at the site in wet condition or becoming wet due to rain or any
other means, shall not be used for at least 24 hours. For the use of such aggregates the
contractor shall adjust the water content in accordance with IS:2386 to achieve the
desired mix.
3.2.4 Sand (For Masonry & Filling)
3.2.4.1 Sand for Masonry Mortars
a) The sand shall consist of natural sand, crushed stone sand or crushed gravel sand or a
combination of any of these. The sand shall be hard, durable, clean and free from
adherent coatings and organic matter and shall not contain the amount of clay, silt and
fine dust more than specified in IS:2116.
b) The sand shall not contain any harmful impurities such as iron pyrites, alkalis, salts, coal
or other organic impurities, mica, shale or similar laminated materials, soft fragments, sea
shells in such form or in such quantities as to affect adversely the hardening, strength or
durability of the mortar.
c) The maximum quantities of clay, fine silt, fine dust and organic impurities in the sand,
when tested in accordance with IS:2386, shall not be more than 5% by mass in natural
sand, or crushed gravel sand or crushed stone sand. For organic impurities, when
determined in accordance with IS:2386, colour of the liquid shall be lighter than that
indicated by the standard solution specified in IS:2386.
3.2.4.2 Grading of Sand
a) The particle size grading of sand for use in mortars shall be within the limits as specified
below:
IS Sieve Percentage Reference to
Designation Passing method
(IS:460 Part-1) (by mass) (IS2386 Part-1)
b) 4.75 mm 100 In
2.36 mm 90 to 100 case of
1.18 mm 70 to 100 sand
600 micron 40 to 100 whose
300 micron 5 to 70 grading
150 micron 0 to 15 falls
outside the specified limits due to excess or deficiency of coarse or fine particles, this shall
be processed to comply with the standard by screening through a suitably sized sieve
and/ or blending with required quantities of suitable sizes of natural sand particles or
crushed stone screening which are by themselves unsuitable. The various sizes of
particles of which the sand is composed shall be uniformly distributed throughout the
mass.
3.2.4.3 Sampling and Testing
a) The method of sampling shall be in accordance with IS:2430. The amount of material
required for each test shall be as specified in relevant parts of IS:2386. All tests shall be
carried out in accordance with the relevant parts of IS:2386.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 65 of 207

b) If further confirmation as to the satisfactory nature of the material is required, compressive

test on cement mortar cubes (1:6) may be made in accordance with IS:2250 using the
supplied material in place of standard sand and the strength value so obtained shall be
compared with that of another mortar made with a sand of acceptable and comparable
quality.
3.2.4.4 Sand for Filling
Sand for filling shall meet the requirements of IS:383 and shall be natural sand, hard, strong,
free from any organic and deleterious materials. Sand obtained from sea shores, creeks or
river banks affected by tides, shall not be used for filling. Fine aggregates suitable for
concreting works shall be suitable for filling also. No sand below grading zone-III as per IS:383
shall be allowed for filling.
3.2.5 Cement
a) Unless otherwise specifically called for, cement for RCC and PCC/ lean concrete works
shall be one of the following:
i) 33 grade ordinary or low heat Portland cement conforming to IS:269
ii) 43 grade ordinary Portland cement conforming to IS:8112
iii) 53 grade ordinary Portland cement conforming to IS:8112
iv) Portland slag cement conforming to IS:455
v) Portland Pozzolana cement conforming to IS:1489
vi) Sulphate resisting Portland cement conforming to IS:12330
vii) High alumina cement conforming to IS:6452
b) The type of cement selected shall be appropriate for the intended use with respect to
durability and exposure conditions.
c) For masonry applications the use of Masonry cement (conforming to IS:3466) can be
made.
3.2.6 Steel
3.2.6.1 General
All steel bars, sections, plates, and other miscellaneous steel materials, etc. shall be free from
loose mill scales, rust as well as oil, mud, paint or other coatings. The materials, construction
specifications such as dimensions, shape, weight, tolerances, testing etc, for all materials
covered under this section, shall conform to respective BIS codes.
3.2.6.2 Reinforcement Bars
High strength deformed (HSD) steel bars of minimum grade Fe500 TMT (unless specified
otherwise in the Job Specifications), conforming to IS: 1786 and bearing standard mark of the
Bureau of Indian Standards, shall be used.
3.2.6.3 Structural Steel
Structural steel sections shall conform to BIS codes referred in Cl. no. 3.1:
3.2.6.4 Miscellaneous Steel Materials
Miscellaneous steel materials shall conform to the BIS codes referred in Cl. no. 3.1:
3.2.6.5 Anchor Bolts
Material for Anchor Bolts such as MS bars, washers, nuts, pipe sleeves and plates etc. shall
be as per relevant BIS codes mentioned above under Clauses 3.1.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 66 of 207

3.2.7 Brick
3.2.7.1 General
a) Bricks for masonry works shall conform to IS:1077 (Specification for common burnt clay
building bricks) and shall be of class and minimum compressive strength as specified in
the “Job Specifications” document. Physical requirements, quality, dimensions, tolerances
etc. of common burnt clay building bricks shall conform to the requirements of IS: 1077.
b) Bricks shall be hand-moulded or machine-moulded and shall be made from suitable soils.
The bricks shall have smooth rectangular faces with sharp corners and shall be well burnt,
sound, hard, tough and uniform in colour. These shall be free from cracks, chips, flaws,
stone or humps of any kind.
c) Testing of the bricks shall be done as per IS: 5454 and IS: 3495. Water absorption shall
not be more than 20% by its dry weight when soaked in cold water for 24 hours.
d) Locally available bricks of non-modular size (230x115x75mm) in place of bricks of
modular size (190x90x90mm) can be used in case the bricks satisfy the other
requirements of IS: 1077 (corresponding to class as defined above).
3.2.8 Admixtures
3.2.8.1 General Requirements
a) All concrete admixtures shall comply with the following Indian standards:
i) Specification for integral cement water proofing compounds IS:2645
ii) Specification for other admixtures for concrete IS:9103
In case of non-availability of any IS code for testing and acceptability criteria, relevant
American, British or German Code shall be applicable.
b) No admixture shall impair the durability of the concrete nor combine with the ingredients to
form harmful compounds, nor increase the risk of corrosion of reinforcement. Use of
admixtures shall not reduce the dry density of concrete. Once the proportion of admixtures
has been established, strict check shall be maintained not to alter the proportions of
ingredients and water-cement ratio of the Design Mix during execution.
c) The chloride contents in admixtures shall not exceed 2% by mass of the admixture or
0.03% by mass of the cement.
d) Admixtures which do not meet the requirements stipulated in this document shall not be
used.
3.2.8.2 Water Proofing Compounds
a) The permeability of the specimen with the admixture shall be less than half of the
permeability with a similar specimen without the use of these compounds. These
compounds shall be used in such proportion as recommended by manufacturer but in no
case it shall exceed 3% by weight of cement.
b) The initial setting time of the cement with the use of these compounds shall not be less
than 30 minutes and final setting time shall not be more than 10 hours. Tests shall be
carried out in accordance with IS:4031.
c) Compressive strength of the specimen at 3 days shall not be less than 160kg/cm 2 nor
80% of the 3 days compressive strength of mortar cubes prepared with same cement and
sand only, whichever is higher. Similarly compressive strength at 7 days shall not be less
than 220kg/cm2 nor less than 80% of the 7 days compressive strength prepared with the
same cement and sand only, whichever is higher. The test to determine the compressive
strength shall conform to IS:4031.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 67 of 207

3.2.9 Water Bars (Water Stops)

a) PVC water bars shall be used in reinforced concrete construction of liquid retaining
structures or any other structure to safeguard them from hydrostatic pressure and water
leakage and any relative movement between two parts of the structure due to thermal
loading shrinkage or differential movement of foundations.
b) Performance requirements of PVC water bars shall meet the requirements of IS:12200.
These shall be of an approved make and of ribbed/ serrated/ plane type with a bulb at the
Centre. The thickness and width of water bars shall in no case be less than 5mm and
150mm respectively. However, for concrete sections greater than 300mm thick, the width
of water bars shall not be less than 230mm.
3.2.10 Bitumen/ bituminous Materials
Bitumen to be used for various types of work shall meet all the requirements of relevant BIS
codes as referred in Cl. no. 3.1:
Tests and acceptable criteria shall be as per relevant BIS codes.
3.2.11 PVC Pipes
PVC Pipes shall conform to the requirements of IS:4985.
3.2.12 Anti-termite Compounds
Chloropyrifos emulsifiable concentrates (1%) conforming to IS:8944 shall be used for
treatment of soil for protection of buildings against attack by subterranean termites.
3.2.13 Poly-sulphide Sealants
All Poly-sulphide Sealants shall conform to IS:12118. Test conditions and requirements shall
be as given in the above referred BIS code.
3.3 CONSTRUCTION REQUIREMENTS
3.3.1 Construction
3.3.1.1 All concrete works shall be carried out as per the provisions of IS:456, IS:3370, IS:2974 and
other relevant BIS Codes. Concrete mix proportioning and design mix; sampling and strength
test of concrete, production and control of concrete, tolerances and placing of reinforcement
and for cover; transporting, placing, compacting and curing etc, inspection and testing of
structure (including requirement of non-destructive testing) shall be as specified in IS:456.
3.3.1.2 Continuous concreting shall be done for structures supporting dynamic equipment as per the
provisions of IS:2974.
3.3.1.3 The damp proof course shall be laid in two layers of equal thickness and each layer given two
coats of hot bitumen on top (grade A90/ S90 conforming to IS:73) at the rate of 1.7kg/m 2. Dry
sharp sand shall be sprinkled evenly over the top layer of bitumen before hardening.
3.3.1.4 Form work and stripping of form work shall be as per the provisions of IS:456.
3.3.1.5 Only steel shuttering shall be used for civil construction
3.3.1.6 Assembly of reinforcement in RCC structures shall conform to IS:456.
3.3.1.7 Fabrication of all structural steel works shall be carried out as per the provisions of IS:800/
IS:801/ IS:806 and other relevant BIS codes. Fabrication shall include cleaning, straightening,
cutting, bending, holding, bolting, welding, machining, painting, marking, assembling, erecting,
inspecting and testing etc. Welding procedure and welder qualification shall be as per IS:800
and/ or referenced BIS codes only.
3.3.1.8 Hand rails, shall be 1000 mm high provided to all walkways, platforms & staircases. Toe plate
(100 mm x 5 mm) shall be provided for all hand railing including stair landings (except for

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 68 of 207

inclined portion of staircases). Spacing of uprights shall be 1500 mm (maximum). Top rail,
mid-rail and upright shall be 32 mm diameter (NB) MS tubes.
3.3.1.9 Steel staircases shall have channels provided as stringers with minimum clear width of 750
mm and slope of 41 degree. The vertical height between successive landings shall not be less
than 2.6 m nor exceed 4.0 metres. Treads shall be minimum 230 mm wide made of grating
(with suitable nosing) spaced equally so as to restrict the rise to maximum 200 mm.
3.3.1.10 Erection of all structural steel works including supply of plant & equipment, storing and
handling, setting out, field connections, field welding and security during erection shall conform
to IS:800/ IS:801/ IS:806.
3.3.1.11 All masonry works shall be carried out as per the provisions of IS:1597/ IS:2212/ IS:4326 and
other relevant BIS codes.
3.3.1.12 Construction of all other items of works shall conform to relevant Indian Standards and sound
engineering practices.
3.3.1.13 The Contractor shall be responsible for the complete safety pertaining to all construction
works.
3.3.2 Tolerances
3.3.2.1 The limits of dimensional tolerances for Plain and Reinforced Cement Concrete Structures
shall be as per IS: 456/IS:14687 and National Building Code of India (SP7)
3.3.2.2 The limits of dimensional tolerances for fabrication of Steel Structures shall be as per IS: 7215
3.3.2.3 The limits of dimensional tolerances for erection of Steel Structures shall be as per IS:12843.
Tolerance limits as given for steel structures are applicable to concrete columns/ pedestals
also.

4.0 ARCHITECTURAL
4.1 GENERAL
4.1.1 All materials shall be of first quality conforming to the specifications & IS or equivalent with IS
marks and shall be obtained from the approved Manufacturer and shall submit necessary test
certificate.
4.1.2 Workmanship shall be to the satisfaction of the Engineer-In-Charge. The contractor shall
follow the specifications, relevant Codes & Manufacturer's guidelines for achieving desired
level of workmanship as per specification & good engineering practice.
4.1.3 All specialised items of work (e.g. Aluminium Doors and Windows, Waterproofing, Overdeck
Insulation, Precoated roof sheeting/ cladding, False ceiling, etc.) shall be got executed by the
Contractor only through authorised applicators/ sub contractors of approved manufacturer/
vendor.
4.2 FLOOR FINISHING
Reference shall be made to the following Indian Standards for any further information etc. not
covered in the specification. In case of any conflict/contradiction, provision of specification
shall override.
IS: 4971 Recommendations for selection of Industrial floor finishes.
IS: 777 Specification for glazed earthenware wall tiles.
IS: 2571 Code of practice for laying in situ cement concrete flooring.
IS: 4631 Code of practice for laying of epoxy resin floor toppings.
IS: 5491 Code of practice for laying in situ granolithic concrete floor topping.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 69 of 207

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 mortar.
4.2.1 Cement Concrete Flooring
4.2.1.1 Cement concrete flooring shall be laid in average 25mm thickness over sub base (as per
structural drawings/ specifications) and shall generally conform to IS: 2571. The flooring shall
be laid in panels and shall consist of:
4.2.1.2 25 mm thick base course of M-15 grade cement concrete (with 6mm and down size stone
aggregate) laid on the sub-base in panels (each panel not exceeding 1 Sq. Mtr. in area) in
desired shape and pattern. The panels shall be bound by 3x20mm PVC strips panel dividers;
fixed in position with their top at proper level maintaining the required levels, slopes, linearity
etc. as required. Base course shall be laid in alternate panels. Before laying the base course,
neat cement slurry @ 2.75Kg. of cement per Sq. Mtr. of area shall be applied (brushed) over
the prepared sub base surface. Cement concrete shall be placed in position and beaten with
trowel, including tamping and finishing smooth. Finishing of the surface shall follow
immediately after completion of laying of base. The bed for flooring shall be prepared either
level or sloped as per drawings and as instructed by Engineer-in-charge.
4.2.1.3 Neat cement @ 2.75Kg. per Sq. Mtr. mixed with water to form a thick slurry applied over the
base course (when the concrete is green), spread over the surface, pressed twice by means of
iron floats; once when the slurry is applied and second time when the cement starts setting.
The junction of floor with wall plaster, cladding, skirting shall be rounded off uniformly upto a
radius of 25mm unless otherwise mentioned.
4.2.1.4 Each finished portion of floor, on completion shall be kept wet with ponding for a minimum
period of 7 days.
4.2.2 Cement Concrete Granolithic Flooring
4.2.2.1 Cement concrete granolithic flooring shall be laid in overall 40mm thickness over sub base (as
per structural drawings/ specifications) and shall generally conforming to IS: 5491 in
workmanship. The flooring shall be laid in panels and shall consist of:-
4.2.2.2 25mm base Course (Under layer) of M-15 grade Concrete (shall generally conform to Civil
structural specifications) laid over sub base in panels (each panel not exceeding 1 Sq. Mtr. in
area) in desired shape and pattern. The panels shall be bound by 3x30 PVC strips panel
dividers; fixed in position with their top at proper level maintaining the required levels, slopes,
linearity etc. as required. Base course shall be laid in alternate panels. Before laying the base
course, neat cement slurry @ 2.75Kg. of cement per Sq. Mtr. of area shall be applied
(brushed) over the prepared sub base surface. The borders of the panels shall have mitred
joints at the corners of the room and intermediate joints shall be in straight line with panel
joints. Cement concrete shall be placed in position and beaten with trowel and finished
smooth. Beating shall cease as soon as surface is found covered with cream of mortar.
Necessary slope shall be provided.
4.2.2.3 15mm thick Wearing top layer of cement mortar 1:3 (1 cement: 3 course sand by volume)
which shall be laid within 15 minutes of laying the first layer. The cement and aggregates for
the top layer shall be mixed dry. After mixing, sufficient quantity of washed sand and water
shall be added to make the mix plastic but not flowing. The top and bottom layer shall firmly
grip together. The base course shall be free of excessive moisture before starting the floor
finishing. Use of dry cement, cement sand mixture sprinkled on the surface to stiffen the
concrete or absorb excessive moisture shall not be permitted.
4.2.2.4 While the concrete is still green, cement @ 2.75 kg per Sq.M of floor area shall be mixed with
water to form a thick slurry and spread over the surface. It shall be pressed twice by means of
iron floats, once when the slurry is applied and second time when the cement starts setting.
The junction of floor with wall plaster, cladding, skirting shall be rounded off uniformly upto a

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 70 of 207

radius of 25mm unless otherwise mentioned.

4.2.2.5 Each finished portion of floor, on completion shall be kept wet with ponding for a minimum
period of 7 days.
4.2.3 Heavy Duty Cement Concrete Flooring
4.2.3.1 Heavy duty Cement concrete flooring shall be laid in overall 50mm thickness over sub base
(as per structural drawings/ specifications); shall generally conform to IS: 5491 in
workmanship. The flooring shall be laid in panels and shall consist of:-
4.2.3.2 Base Course (Under layer) 35mm thick of cement concrete (1 cement: 1.5 coarse sand: 3.5
stone aggregates of 10mm to 6mm size by volume) laid over sub base in panels (each panel
not exceeding 1 Sq. Mtr. in area) in desired shape and pattern. The panels shall be bound by
3x40mm PVC strips panel dividers; fixed in position with their top at proper level maintaining
the required levels, slopes, linearity etc. as required. Base course shall be laid in alternate
panels. Before laying the base course, neat cement slurry @ 2.75Kg. of cement per Sq. Mtr. of
area shall be applied (brushed) over the prepared sub base surface. The borders of the panels
shall have mitred joints at the corners of the room and intermediate joints shall be in straight
line with panel joints. Cement concrete shall be placed in position and beaten with trowel and
finished smooth. Beating shall cease as soon as surface is found covered with cream of
mortar. Necessary slope shall be provided.
4.2.3.3 Wearing Top layer/ Finishing layer shall be of cement, hardener and stone aggregate mix of
15mm thickness laid over the base course. Unless otherwise mentioned, one part of approved
quality hardener and four parts of cement by weight shall be mixed dry. This dry mixture shall
be mixed with stone grit of 6mm and down size in the ratio of 1 hardener and cement mixture :
2 stone grit by volume. Just enough water shall then be added to the mix.
4.2.3.4 The mixture so obtained shall then be laid on the base course within 2 to 4 hours of latter's
laying. It shall be firmly pressed into bottom concrete so as to have a good bond with it. After
the starting of initial setting, the surface shall be finished smooth and true with steel floats.
4.2.3.5 Each finished portion of floor, on completion shall be kept wet with ponding for a minimum
period of 7 days.
4.2.4 Cement Plaster Skirting
4.2.4.1 Cement plaster skirting shall be laid with cement mortar (1 cement:3 coarse sand by volume)
shall be of 18mm thickness. The surface on which the skirting is to be applied shall be
prepared and skirting shall be laid. The junction between flooring and wall shall be rounded off
to a radius of 25mm if not otherwise mentioned.
4.2.4.2 While the mortar is still green, cement @ 2.75Kg per square metre shall be mixed with water
to form a thick slurry and applied over the mortar. It shall be pressed twice by means of iron
floats, once when the slurry is applied and second time when the cement starts setting. The
flooring shall be cured for 7 days.
4.2.5 Tile Work (Glazed/ Ceramic/Vitrified Porcelain)
4.2.5.1 Glazed ceramic tiles shall conform to IS: 13753. Ceramic tiles for flooring shall be matt
finished and non slip type. All tiles shall be decorative type of approved shade, pattern, texture
and design and of approved manufacturer. The sizes of the ceramic tiles shall generally be
300x300x8mm for flooring and 100x200x6mm or 300x200x6mm for walls (dado). Vitrified tiles
shall conform to EN 176. The sizes of Vitrified Porceilin tiles shall be as per approved
manufacturer’s standards/ as approved by owner. Pigments to be admixed with mortar for
grouting the joints shall conform to Table -1 of IS: 2114. The tiles shall be laid over a coating of
approved neoprene based adhesive (as per manufacturers specification) laid on base floor/
wall plaster. The joints of the tiles shall be flush pointed with cement paste (white cement and
pigment conforming to IS:2114, Table-l) matching the shade of colours. The tile work shall be

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 71 of 207

suitably cured.
4.2.6 Kota Stone Flooring/ skirting/ dado
4.2.6.1 Kota Stone Flooring shall be laid in minimum 40mm overall thickness over sub base (as per
structural drawings/ specifications). The Kota Stone slabs shall be of selected quality and
shade, hard, sound, dense, homogenous in texture, free from cracks, decay, weathering and
flakes. These shall be machine cut to the requisite size and thickness and chisel dressed. For
flooring and skirting/ dado/ riser the thickness of the stone slabs shall be 25mm and 18mm
respectively. Skirting shall normally be 125mm high unless specified otherwise.
4.2.6.2 The slabs shall have smooth top (exposed) face before being laid. Before starting the work,
the contractor shall get the samples of slabs approved by Engineer-in-charge. Each slab shall
be machine cut to the required size and shape and fine chisel dressed at all edges to full depth
and machine rubbed to a smooth surface finish. All angles and edges of the slabs shall be true
square and free from chippings giving a plane and smooth surface.
4.2.6.3 For steps, joints in Kota stone shall be permitted only when width/ length is more than 0.6/ 2
metre. For flooring minimum size of Kota stone slab shall be 450mm x 450mm and shall be of
uniform size.
4.2.6.4 Preparation of base shall include making it rough, cleaning thoroughly and applying neat
cement slurry @ 2.75 kg of cement per Sq.M. of area to receive the mortar. Cement mortar
shall be 15mm thick 1:6 (1 cement: 6 Coarse sand by volume) for flooring and 12mm thick 1:3
(1 cement: 6 Coarse sand by volume) for skirting. The mortar shall be laid for fixing one slab at
a time. The slab shall be washed clean before laying. It shall be laid over cement mortar
bedding on top, pressed, tapped gently to bring it in level. It shall be then lifted and laid aside.
Top surface of the mortar then shall be corrected by adding fresh mortar at hollows and
depressions. The mortar then shall be allowed to harden and cement slurry of honey like
consistency @ 4.4.kg of cement per Sq. M shall be spread over the mortar. The edges of the
slabs shall be buttered with white cement (with necessary pigment) grout to match the shade
of the slabs. The slabs shall then be gently placed in position and tapped with wooden mallets
till it is properly bedded in level. The joints shall be as fine as possible. Surplus cement on the
surface of the slab shall be removed. The slabs in flooring shall continue for not less than 10
mm under the plaster/skirting. The finished surface shall be true to levels and slopes as
instructed by the Engineer-in-Charge. Cut size may be used along periphery as required.
Curing, as required shall be done.
4.2.6.5 Grinding shall be commenced when the joints are properly set. Unevenness at the meeting
edges of slabs shall be removed by fine chiselling. Grinding shall be done by machines except
for skirting and small areas. First grinding shall be done with Carborundum stones of 48 to 60
grade grit fitted in the machine. Water shall be properly used during grinding. When the floor
has been uniformly rubbed, it shall be cleaned with water baring all pin holes. It shall then be
covered with a thin coat of cement mixed with pigments to match with colour of the Kota stone.
This grout shall be kept moist for a week. Thereafter the second grinding shall be started with
Carborundum stone of 120 grit. Grinding and curing shall follow again.
4.2.6.6 Final grinding shall be with Carborundum of grade 220 to 350 grit using water in abundance.
The floor shall be washed clean with water, oxalic acid powder shall then be dusted at 35
gms/sq. m. on the surface rubbed with machine fitted hessian bobs or rubbed hard with
woollen rags. The floor shall then be washed clean and dried with a soft cloth or linen. If any
stone slab is disturbed or damaged, it shall be refitted or replaced and properly jointed and
polished.
4.2.7 Epoxy Coating
4.2.7.1 Epoxy floor coating shall be pigmented (approved shade) made of a solvent based, two pack
system with epoxy resins and amine curing agents, chosen to withstand high degrees of
chemical and abrasive action as per approved manufacturer’s specification and shall consist

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 72 of 207

of:-
4.2.7.2 Screed:
The screed shall be provided in flooring and shall consist of a solvent free combination of epoxy
resin, modified amine hardeners filled with specially graded and selected chemically inert
aggregates of high strength. The system shall include an epoxy resin primer and screed which
are both supplied in pre-weighed units ready for on-site mixing and application. The thickness
of screed shall be minimum 3mm thick. The primer shall be applied by brush and shall be
allowed to become tacky. The screed shall be prepared as per manufacturers specification and
laid evenly over the base floor by trowel. In case of flooring, the finished, cured screed shall
have a slightly granular texture.
4.2.7.3 Finishing Coat:
An epoxy resin sealing coat in two coats @ 125 gms./sq.m. (minimum) per coat shall form the
topping coat over the screed in case of flooring and over plastering in case of vertical surfaces.
The epoxy resin topping shall be applied at least 24 hours after the laying of the screed. This
topping shall be applied by brush or sprayed to a specified thickness in two coats with 3-5 hours
interval between them. Care shall be taken to finish the topping perfectly smooth and devoid of
any bubbles and unevenness. The newly laid floor shall be protected from dust or moisture and
allowed to be used only after a minimum lapse of 48 hours.
4.2.7.4 The surface on which the epoxy coating is to be done shall be sound, clean and dry in order to
achieve maximum adhesion with the primer coating of epoxy resin as per approved
manufacturer’s specification.
4.3 DOORS AND WINDOWS
4.3.1 Aluminium Glazed Doors, Windows and Ventilators
4.3.1.1 Aluminium glazed doors/ windows/ ventilators shall be made of extruded tubular
electrostatically powder coated (min. 30 microns) Aluminium sections conforming to IS : 733
and IS : 1285 of ‘INDAL” or approved equivalent manufacturer with 6.3mm laminated safety
glass conforming to I.S.: 2553 fixed with rubber lining or EPDM gasket and extruded anodised
aluminium beading.
4.3.1.2 Extruded aluminium sections used for various application shall have minimum weights as
under.
A. Doors
1. For fixed frames
i) Sides & Top members : 1.975 Kg/RM
ii) Lock rail : 1.594 Kg/RM
iii) Bottom rail : 3.495 Kg/RM
2. For shutter frame : 1.202 Kg/RM
3. Glazing clips (beading) : 0.182 Kg/RM
B. Window/Ventilator
1. For fixed frames : 0.639 Kg/RM
2. For shutter frame : 0.636 Kg/RM
3. Glazing clips (beading) : 0.165 Kg/RM
4. Coupling bars : 0.933 Kg/RM
5. Member for fixing the frame : 0.463 Kg/RM
4.3.1.3 The frames shall be fixed to masonry by means of Aluminium lugs fixed to the frame by
counter sunk brass machine screws and grouted with M-15 grade concrete in minimum 150 x
150 x 50 mm sized hole in the masonry. In case of RCC, the frames shall be fixed with 12mm

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 73 of 207

dia dash fasteners in case of concrete. Any steel item coming in contact with Aluminium shall
be galvanised.
4.3.1.4 Aluminium glazed doors shall be provided with cup pivots (of aluminium alloy conforming to IS
designation NS-4 of IS 737 and IS designation of A-5-M of IS : 617) riveted to outer and inner
frames to permit to swing through an angle of 85 degree.
4.3.1.5 Following hardware shall be provided for the doors.
1. Heavy duty & hydraulically operated double or single action adjustable door closer
conforming to IS: 6315
2. 250mm and 150mm long, 10mm dia Aluminium tower bolts as per IS: 204
one each for each shutter.
3. Brass body 6 lever mortise lock as per IS: 2209
4. Aluminium door handle for each shutter for each side.
(Note: All Aluminium fittings/ fixtures shall be of same finish as that of doorframe & shutter)
4.3.1.6 Side hung window shutters shall be fixed to the frame with Aluminium alloy friction hinges and
shall be complete in all respects including accessories, fittings fixtures of same finish as that of
window frame & shutter, handles of cast aluminium conforming to IS designation A-5-M of IS :
617 mounted on a handle plate riveted to opening frames, Aluminium Tower bolts, peg stays
for ventilators etc. Wherever specified, decorative aluminium safety grills of approved design
shall be provided which shall be screwed to the main frame.
4.3.2 Steel Doors
Steel doors shall consist of:
4.3.2.1 Pressed steel door frame of overall 125x 65mm size conforming to IS : 4351 and made of 16
SWG pressed steel sheet bent to required shape using bending machine to form solid/ true
mitred edges/ corners, stiffened with 50 x 5mm thick MS flat spacers welded to the frame
facing the wall/ column @ 600mm c/c maximum vertical spacing. The frame shall be fixed to
the masonry by means of 300 x 25 x 6 mm thick MS hold fast welded to the spacer and
grouted with M-15 concrete in minimum 350 x 100 x 100 mm sized hole in the masonry. In
case of concrete, the frames shall be fixed by 96mm long, 12 mm dia metallic counter sunk
type dash fasteners through the frame & spacers. Provision for hinges, locking arrangement
and other hardware shall be provided in the frame by machine cutting of required size cutouts
in the frame and welding/ screwing to 3 mm thick MS pad plates already welded over the
cutout from behind. The frame shall be thoroughly cleaned of rust, mill scale, dirt, oil etc. and
then finished with 2 or more coats of approved quality synthetic enamel paint of approved
shade over a priming coat of approved red oxide zinc chromate primer. The hollow frame shall
be packed with PCC to fill the cavity without gap.
4.3.2.2 Pressed steel door shutter shall be made with 18 gauge steel sheets formed by machine
bending in the form of hollow box (overall 40mm thick) welded at meeting of the sheets with
pad plate of 3mm thick MS flat all along the perimeter. The shutter shall be braced with
channel shaped 35mm wide horizontal stiffeners by folding 16 gauge MS sheets @ 500mm c/c
fixed by flush riveting. 3mm thick MS pad plates shall be welded inside at required locations
for fixing of hardware. The cavity inside shall be packed with rigid PU foam/ phenolic foam or
glass wool insulation to fill into the box cavity without gap.
4.3.2.3 For double shutters, an MS angle (25x 45x 3mm thick) shall be welded to one of the shutter
providing a minimum 25mm wide rebate for the other shutter at the meeting point.
4.3.2.4 The shutters shall be fixed to the door frame by means of heavy duty MS butt hinges of
150mm size conforming to IS : 1341 @ 500mm c/c maximum.
4.3.2.5 Each door shutter shall have following accessories.
1. Spring loaded pressure die cast zinc alloy door stopper.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 74 of 207

2. Heavy duty, MS aldrop 400mm long for double shutter & 300mm long for single
shutter.
3. 12mm dia, 300mm long pressure die cast zinc alloy handles on both sides.
4. 12mm dia, 250mm long MS tower bolt at top and 12 mm dia 150mm long at bottom.
5. 3- way spring loaded locking & latching system.
6. 150mm x 300mm Vision panel with 16 gauge MS beading bent to ‘Z’ shape & 4mm
thick plain glass conforming to IS: 2853.
4.3.2.6 The entire shutter including all accessories, fittings & fixtures etc. shall be painted with 2 or
more coats of approved quality synthetic enamel paint of approved shade over a coat of
approved quality red oxide zinc chromate primer.
4.3.3 Wooden Flush Doors
Flush doors shall consist of:-
4.3.3.1 Frame: Pressed steel door frame of overall 125x 65mm size conforming to IS : 435 and made
of 16 SWG pressed steel sheet bent to required shape using bending machine to form solid/
true mitred edges/ corners, stiffened with 50 x 5mm thick MS flat spacers welded to the frame
facing the wall/column @ 600mm c/c maximum vertical spacing. The frame shall be fixed to
the masonry by means of 300 x 25 x 6 mm thick MS hold fast welded to the spacer and
grouted with M-15 concrete in minimum 350 x 100 x 100 mm sized hole in the masonry. In
case of concrete, the frames shall be fixed by 96mm long, 12 mm dia metallic counter sunk
type dash fasteners through the frame & spacers. Provision for hinges, locking arrangement
and other hardware shall be provided in the frame by machine cutting of required size cut outs
in the frame and welding/ screwing to 3 mm thick MS pad plates already welded over the cut
out from behind. The frame shall be thoroughly cleaned of rust, mill scale, dirt, oil etc. and then
finished with 2 or more coats of approved quality synthetic enamel paint of approved shade
over a priming coat of approved red oxide zinc chromate primer). The hollow frame shall be
packed with PCC to fill the cavity without gap.
4.3.3.2 Shutter: Flush door shutters shall be factory made and overall 35mm thick consisting of solid
core block board bonded with phenol formaldehyde synthetic resin conforming to IS : 848. The
shutters shall be faced on both sides with 3 mm thick Teakwood veneering conforming to IS:
303, BS: 476 part-7. 1 mm thick approved quality melamine faced lamination shall be
provided on both sides in case of toilet doors. 35 x 20mm second class Teakwood lipping shall
be provided all around the shutter by means of approved quality neoprene based adhesive
and nailing @ 300mm (maximum). Teakwood veneering along with lipping shall be french
polished (lacquer finish) as per specifications. The shutters shall be fixed to the frame by
means of 125mm long MS butt hinges conforming to IS: 1341 @ 600mm c/c maximum.
4.3.3.3 Teakwood used for lipping, beading etc. shall be second class Indian teakwood (conforming to
IS: 4021) of good quality, well seasoned and free from defects such as cracks, dead knots,
sapwood etc. and shall be with no individual hard & sound knots more than 15 Sq.CM in area
and the aggregate area of such knots not exceeding 2% of area of the piece. The wood shall
be fairly closed grains having not less than 2 growth rings per Cm. Width in cross section.
4.3.3.4 Following hardware of approved quality and shade shall be provided in each shutter:-
1. Heavy duty, overhead hydraulically operated door closer conforming to IS: 3564.
2. Anodised aluminium tower bolts as per IS : 204, 10mm dia 250mm long (at top) and
150mm long (at bottom), one each for each shutter on either side.
3. Brass body 6 lever mortise lock as per IS : 2209 including pair of handles of
pressure die cast zinc alloy (satin finished )
4. 3mm thick plastic kick/push plate (150mm high at bottom for entire width &
200mm x 100mm at handle location).
5. Zinc alloy pressure die cast chromium plated spring loaded door stopper with heavy
duty rubber shoes.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 75 of 207

6. 150mm x 300mm Vision panel with of 4mm thick plain glass conforming to IS: 2853
fixed with second class Teakwood beading (not for toilet doors).
4.3.4 Steel Rolling Shutter
4.3.4.1 MS rolling shutters shall conform to IS: 6248 and shall be constructed with interlocking lath
sections formed out of cold rolled 0.9mm thick, 80mm wide steel strips for shutter width upto
3.5 M, or 1.25mm thick, 80mm wide steel strips for shutter width beyond 3.5 M, jointless MS
channel section of 3.15mm thickness for guide, MS girders & bottom rail, shutter suspension
stud with pully & cage, top rolling springs, locking arrangement etc. all complete as per
manufacturers approved drawings. The entire shutter including all accessories shall be painted
with 2 or more coats of approved quality & shade synthetic enamel paint over a coat of
approved quality red oxide zinc chromate primer. All the damaged surfaces of wall, columns,
plastering etc. shall be made good.
4.3.4.2 Rolling shutters shall be mechanically operated type, when the size of the shutter exceeds 9
Sq.M and shall be complete with all accessories for mechanical operation as per approved
manufacturers design & drawings.
4.3.4.3 Wherever specified the Rolling shutters shall be electrically operated; complete with all
accessories, electrical motor, cabling etc. as per approved manufacturers design and drawings
4.3.4.4 Wherever specified the Rolling shutters shall be grill type or partly grill & partly solid type or
fully solid type depending on ventilation requirement.
4.4 PLASTERING & WALL FINISHING
4.4.1 Plain Cement Plaster
Plain Cement plaster shall be provided in following thickness:
4.4.1.1 12mm thick in 1:6 cement mortar for all plumb of the internal masonry walls & RCC Columns
coming in line (flush) with this side of wall.
4.4.1.2 15mm thick in 1:6 cement mortar for rough side of internal masonry walls RCC Columns
coming in line (flush) with this side of wall.
4.4.1.3 The external plastering shall be with waterproof compound (cement mortar mixed with
approved acrylic waterproof compound @ 1 Kg. per 50 Kg. of cement) 18mm thick cement
plaster in 1:6 cement mortar for all external surfaces as indicated.
4.4.1.4 6mm thick in 1:4 cement mortar for all RCC ceiling, beam etc. However if the undulation in
ceiling is beyond 6mm thick plaster, extra thickness of plaster shall be applied without any
extra cost to give a smooth and fair surface to the satisfaction of Engineer-In-Charge.
4.4.1.5 Sand face plaster wherever require as per architectural treatment.
4.4.1.6 The plastering work shall include preparation of background surface which shall consist of
cleaning of all dust, loose mortar droppings, traces of algae, efflorescence or any other foreign
matter by water or by brushing, roughening up of smooth surfaces by wire brushing or
hacking, trimming of projections whenever necessary. The surface shall be washed off and
well wetted before applying the plaster.
4.4.1.7 For external plaster, the plastering shall be started from top floor and carried downwards.
Internal plastering shall start with ceiling. Plastering shall be applied evenly in specified
thickness. The entire surface shall be finished smooth by means of trowel or wooden float.
4.4.1.8 All the brick/stone masonry and RCC joints shall be provided with 20 gauge chicken wire mesh
stretched tight and fixed with G.I. type nails before plastering.
4.4.1.9 20mm x 10mm grooves (horizontal and vertical) shall be provided in perfect straight line &
plumb in plastering as per drawings and instructions of Engineer- In - Charge.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 76 of 207

4.4.1.10 Curing shall be started 24 hours after finishing the plaster. The plaster shall be kept wet for a
period of 7 days. During this period the plaster shall be suitably protected from all damages at
the contractor's expense by such means as approved by the Engineer-in-charge. The date of
execution of plastering shall be marked on the plastering to ensure the proper duration of
curing.
4.4.1.11 The plastering shall include all scaffolding, damage rectification etc. complete.
4.5 ROOF TREATMENT/ WATERPROOF COATING
4.5.1 APP Bituminous membrane Water proofing
Material:
The water proofing membrane shall have a non-woven polyester membrane coated on both
side with APP (Atactic polypropylene) modified bitumen. It shall have a Black finish with a very
thin polyethylene foil on both sides It shall be in rolls of 1x10m for continuous laying on large
lengths. When installed, it shall form an impervious, flexible blanket, which accepts normal
structural movement without breaking or cracking.
Workmanship:
a) Preparation of surface:
The roof surface (or screed) shall be thoroughly cleaned with a wire brush and all foreign
matter etc. shall be removed. Well-defined cracks on the surfaces shall be cut to a ‘V’
section, cleaned and filled up flush with a paste of filling compound and cement in the
ratio of 1:2. The finished surface shall be perfectly dry and any dampness should be
allowed to evaporate.
b) Laying:
The membrane shall be laid on the perfectly dry prepared surface by torching-on method
with a gas torch. All joints shall have an overlap of 75mm which shall be torch sealed. The
overlap shall be done in a manner, which does not hinder water flow along the roof slope.
The membrane shall be finished with bituminous base aluminium paint.
The waterproofing shall be continued up to the parapet/wall for a minimum of 600mm over
the finished roof surface. It shall be continued into rain water pipes by at least 100mm.
c) Cement Screed:
Plain cement concrete (1:2:4) of 25mm min. thickness with 24 SWG chicken wire mesh
shall be laid to slope in panels not exceeding 6 m.sq. area per panel over the roof slab.
The joints between panels shall be raked out neatly (after stipulated curing period) to a
min. 6mm x 6mm V-groove and filled up with an approved quality sealant compound.
Drain outlet shall be provided for all spouts/ rain water pipes by suitable rounding, filling
and sloping of PCC. At the junction of the roof and parapet or any other vertical surface, a
fillet of 75mm radius shall be formed in cement mortar (1 cement: 4 coarse sand).
The finished work shall be measured in M.Sq of area for the purpose of payment.
A guarantee of 10 years shall be provided by the manufacturer against the performance of the
finished waterproof coating.
4.6 PAINTING & POLISHING
4.6.1 Reference shall be made to the following Indian Standards for further information etc. not
covered in the specification. In case of conflict/ contradictions provisions of the specification
shall override.
IS : 2395 : Code of practice for painting concrete, masonry and plaster surfaces.
IS : 63 : Specification for whiting for paint and putty.
IS : 5411 : Specification for plastic Emulsion paint for interior use.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 77 of 207

IS : 2338 : Code of practice for finishing of wood, and wood based materials.
IS : 5410 : Cement paint, colour as required.
IS 110 : Ready mixed paint, brushing, grey filler enamels for use over primers.
IS 426 : Paste filler for colour coats.
IS 3585 : Ready mixed paint, alum. brushing priming water resistant for
woodwork.
IS 426 : Paste filler for colour coats.
IS 106 : Ready mixed paint, brushing, priming for enamels, for use on metals.
4.6.2 All materials required for the execution of painting work shall be obtained direct from approved
manufacturers and shall be brought to the site in makers drums, bags etc. with seals
unbroken.
4.6.3 In case of ready mixed paints, thinning if necessary, the brand of thinner shall be as per
recommendations of the manufacturer.
4.6.4 Paint shall be applied by brushing or spraying. Spray machine used may be of high pressure
type or low pressure depending on the nature and location of work. The paint containers, when
not used shall be kept close and free from air.
4.6.5 After the finishing of work, the adjacent surfaces not intended to be washed/
distempered/painted/polished, shall be thoroughly cleaned of all paint patches and shall be
finished in accordance with surface finishing of such surfaces.
4.6.6 Oil Bound Distempering
The oil bound distempering work shall consist of:
4.6.6.1 Preparation of surface
The surface shall be thoroughly brushed free from dust, dirt, grease, mortar droppings, other
foreign matter and shall be made smooth by sand papering. In case of distempering over
existing distempered surface, the existing distempering shall be scrapped by steel scrappers
leaving a clean surface. All nails shall be removed. Pitting in plaster shall be made good with
plaster of paris mixed with distemper of colour to be used. The surface then shall be rubbed
down again with a fine grade sand paper and made smooth. A coat of distemper shall be
applied over the patches. The surface shall be allowed to dry thoroughly. The surface affected
by moss, fungus, algae, efflorescense shall be treated in accordance with IS: 2395. Any
unevenness shall be made good by applying putty made of plaster of paris mixed with water
including filling up the undulation and then sand papering the same after it is dry. Scaffolding
wherever required shall be erected in such a way that no part of the scaffolding shall rest
against the surface to be painted.
4.6.6.2 The primer coat
The primer coat shall be alkali resistant primer or distemper primer and shall be of the same
manufacture as oil bound distemper.
4.6.6.3 Base preparation
After the Primer coat, the base preparation shall include applying two or more coatings of oil
based putty in paste form made from chalk powder mixed with linseed oil, white zinc, varnish
etc. as per manufacturers recommendations. After each coat of putty, sandpapering of the
surfaces shall be done.
4.6.6.4 Application of Distemper
4.6.6.4.1 After the base preparation coats have dried, the surface shall be lightly sand papered and
dusted off avoiding rubbing off of the primer coat. The distemper shall conform to IS: 428 and
shall be diluted with water or any other prescribed thinner recommended by the manufacturer.
Minimum two coats of distemper shall be applied with brushes in horizontal strokes followed
by immediate vertical strokes, which together shall constitute one coat. The subsequent coats
shall be applied after at least 24 hours between consecutive coats to permit proper drying of

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 78 of 207

the preceding coat. The finished surface shall be even and uniform without patches, brush
marks drops etc. Application of a coat in each room shall be finished in one operation.14 cm
double bristled distemper brushes shall be used. After each day’s work brushes shall be
thoroughly washed in hot water with soap solution and hung down to dry.
4.6.6.4.2 Surfaces of doors, windows, floors etc. shall be protected from being splashed upon. Such
surfaces shall be cleaned of distemper splashes.
4.6.7 Plastic Emulsion Paint
The Plastic Emulsion paint work shall consist of
4.6.7.1 Preparation of surface
The surface shall be thoroughly brushed free from dust, dirt, grease, mortar droppings, other
foreign matter and shall be made smooth by sand papering. In case of plastic emulsion paint
work over existing distempered/ emulsioned surface, the existing distempering/ emulsion shall
be scrapped by steel scrappers leaving a clean surface. All nails shall be removed. Pitting in
plaster shall be made good with plaster of paris mixed with plastic emulsion of colour to be
used. The surface then shall be rubbed down again with a fine grade sand paper and made
smooth. A coat of plastic emulsion shall be applied over the patches. The surface shall be
allowed to dry thoroughly. The surface affected by moss, fungus, algae, efforescense shall be
treated in accordance with IS: 2395. Any unevenness shall be made good by applying putty
made of plaster of paris mixed with water including filling up the undulation and then sand
papering the same after it is dry. Scaffolding wherever required shall be erected in such a way
that no part of the scaffolding shall rest against the surface to be painted.
4.6.7.2 The primer coat
The primer coat shall be alkali resistant primer or emulsion primer and shall be of the same
manufacture as plastic emulsion paint.
4.6.7.3 Base preparation
After the Primer coat, the base preparation shall include applying two or more coatings of oil
based putty in paste form made from chalk powder mixed with linseed oil, white zinc, varnish
etc. as per manufacturers recommendations. After each coat of putty, sandpapering of the
surfaces shall be done.
4.6.7.4 Application of Plastic Emulsion Paint
4.6.7.4.1 After the base preparation coats have dried, the surface shall be lightly sand papered and
dusted off avoiding rubbing off of the primer coat. The plastic emulsion paint shall conform to
IS: 5411 (Part- I) and shall be diluted prescribed thinner recommended by the manufacturer.
Minimum two coats of plastic emulsion paint shall be applied with brushes in horizontal strokes
followed by immediate vertical strokes, which together shall constitute one coat. The
subsequent coats shall be applied after at least 24 hours between consecutive coats to permit
proper drying of the preceding coat. The finished surface shall be even and uniform without
patches, brush marks drops etc. Application of a coat in each room shall be finished in one
operation.14 cm double bristled distemper brushes shall be used. After each days work
brushes shall be thoroughly washed in hot water with soap solution and hung down to dry.
4.6.7.4.2 Surfaces of doors, windows, floors etc. shall be protected from being splashed upon. Such
surfaces shall be cleaned of splashes.
4.6.8 Plaster of Paris Punning
Plaster of Paris punning shall be applied over roughened plastered surfaces. Superior quality
Plaster of Paris of approved make shall be mixed with water to obtain paste like consistency
and shall be applied on walls, ceiling etc. in sufficient thickness to give an absolutely smooth,
plumb and straight surfaces.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 79 of 207

4.6.9 Exterior Acrylic Paint

Exterior Acrylic Paint shall be Premium Acrylic smooth exterior paint with silicon additives
(Snowcryl-XT of 'Snowcem India Ltd. Or approved equivalent) of required shades on new
work applied in two or more coats at the rate of 1.43 lts/10 Sq.M. over and including base
coat of waterproof cement paint ( of Snowcem Plus or approved equivalent ) including
cleaning, preparation of surfaces, curing etc.
4.7 ROOFING
4.7.1 The roof slope shall be as specified and in general not pitched flatter then 1:5. The normal
pitch if not specified shall be 1:2. Materials shall be supplied by approved manufacturer. The
items supplied shall be free from cracks, chipped edges or corners or other damages. Storage
and safety precautions shall be taken to avoid damage to the accessories.
4.7.2 P.V.C. Rain Water Pipes
PVC rain water pipes shall be 110mm dia (O.D.) or 160mm dia (O.D.) as specified/ indicated
in drawings; of 6 Kg./ sq. cm. pressure rating. The pipes shall be provided complete with
necessary clamps, connections, bends, Tees, other accessories (as per approved
manufacturer’s specifications) and shall be jointed with approved quality bonding solution.
Embedded rain water pipes shall be suitably embedded/ encased in masonry/ cement
concrete (M-15) with nominal reinforcement.
4.7.3 Precoated Galvanised Steel Sheet Roofing/ Cladding
4.7.3.1 The base metal of the roofing shall be Cold rolled in high tensile Galvalume Steel of 550 MPA
yield stress conforming to IS:513, IS:14246 and ASTM A446 Grade E. The substrate shall
have hot dip metallic coating of aluminium- zinc alloy (150 grams per sq. mtr. total on both
sides, coating class AZ150 as per per ASTM A792). The bottom unexposed surface shall then
be coated with alkyd backer of minimum 7 microns. Top exposed surface shall have SMP
(Silicon Modified Polyester) paint system Minimum 20 microns top coat applied over 5 microns
primer with additional coating of Fluropolymer (PVF2) paint system (for coastal areas only)
over and above the top coating. The top coat shall be in specified colour.
4.7.3.2 The precoated galvalume steel sheets shall meet the following performance standards
Pencil Hardness : F minimum
Formability : 2-3 t
Specular Glass (60 deg) : 20- 35%
(ASTM D523)
Impact Resistance : Greater than 10J
Salt spray test : 750 hours
QUV-Wealterometer Test : 1000 light hours
Humidity Test : 1000 hours
Temperature Resistance : 100C
Fire performance : Class I
4.7.3.3 The SMP coated steel sheet in standard colour under normal well washed conditions of
exposure shall not show any cracking, flaking or peeling of paint film for at least 10 years.
Colour change during service, determined according to ASTM D2244 should not exceed 5E
hunter lab units on light colours.
4.7.3.4 The profiles shall have a depth of not less than 28mm and pitch of 190mm. Overall sheet
thickness shall be minimum 0.50mm. Minimum weight of the sheet shall be 5.2 kg/ Sq.M
4.7.3.5 All roofing accessories like ridge, gutters, north light curves etc. shall be fabricated out of
precoated sheet of same thickness (as for roof sheeting) and as per manufacturer’s
specifications. Metallic Fasteners and Fixing accessories shall be corrosion proof (polyester
polymer coated). Self drilling screws/ fasteners with integral washers and EPDM seals, and

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 80 of 207

nylon colour caps and joint sealants shall be provided for fixing of sheets as per approved
manufacturer’s specifications. Non metallic fasteners shall be of neoprene. Sealants shall be
natural cure type and of cold setting variety.
4.7.3.6 Wind ties shall be of 40 mm x 6 mm flat iron section and other size as specified. These shall
be fixed at the two eaves end of the sheet. Fixing shall be done with the same loose bolts
which secure sheets to the purlins. Slot holes shall be cut in the wind ties to allow for
temperature variations. The wind ties shall be painted with two or more coats of synthetic
enamel paint of same shade as that of sheeting over a coat of approved primer.
4.8 SANITARY FITTINGS AND FIXTURES
4.8.1 Reference shall be made to the following Indian Standards for any further information etc. not
covered in the specification. In case of any conflict/ contradiction provisions of specification
shall override.
IS-2556 : Specification for Vitreous Sanitary appliances (Vitreous- China, Part 1- 15).
IS-774 : Specification for Flushing Cistern for Water Closets and Urinals.
IS-781 : Specification for Cast copper alloy screw down bib taps and stop
valves for water services.
IS-2064 : Code of Practice for Selection, Installation and Maintenance of
Sanitary appliances.
All glazed earthen ware shall be of approved make, colour and of one piece construction. All
metallic fixtures like taps, stop cocks, soap holders etc. shall be CP brass and approved make.
All wall fittings shall be fixed with nylon sleeve and CP brass screws and washers.
4.8.2 Wash Down (European) Type Water Closet
4.8.2.1 Wash down water closet shall conform to IS:2556 Part-II. Water Closet shall be of one piece
construction, double trap syphonic type. This shall be fixed with plastic seat and cover as per
IS:2548 of approved make and colour, fixed with CP brass hinges and rubber buffers and an
integral 100 mm dia 'S' or 'P' trap with antisyphonage vent horn.
4.8.2.2 A low level earthenware cistern conforming to IS:774 of about 10 litres capacity, with 15mm
dia PVC inlet pipe (with 15mm dia CP Brass stop cock) and brass union with wiped solder
joint, internal overflow arrangement, 40 mm dia CP brass flushing pipe. CI or MS supporting
brackets shall be fixed with the water closet. All exposed metallic surfaces shall be painted
with two coats of synthetic enamel paint of approved quality over a coat of red oxide zinc
chromate primer. The clearance between top of pan and bottom of cistern shall not exceed
300 mm.
4.8.2.3 One number heavy grade approved quality CP Brass bib cock conforming to IS: 781 (with
necessary connections); one number approved quality CP Brass Toilet paper holder (fixed to
wall with wooden cleats, CP Brass screws) shall be provided with each WC.
4.8.2.4 The work shall include providing and fixing of all fittings, breaking floors and wall, making good
the same, making inlet and outlet connection to the cistern and the closet, testing of joints,
painting the exposed metallic surface with two coats of synthetic enamel paint over a coat of
primer etc. complete.
4.8.3 Urinals
4.8.3.1 Urinals shall be integrated photocell operated flushing system type ( Integrated EFS of “
Parryware” or approved equivalent) conforming to IS:2556 Part VI. Urinals shall be of single
piece construction with integral flushing box rim. These shall be mounted on walls. The
flushing inlet pipe shall be of CP brass 15 mm dia and waste pipe 32 mm dia GI, 750 mm long
shall be embedded in wall. Necessary unions and CP bottle trap shall be provided in the waste
line.
4.8.3.2 Rawl plugs with CP brass screws shall be used for fixing the urinal. Fixing shall ensure that no

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 81 of 207

liquid is left over in the pan after flushing. Unless otherwise indicated height above finished
floors shall be 600 mm.
4.8.3.3 The work shall include urinals inlet and outlet pipes, flushing cistern, breaking and making
good the walls and flooring, making inlet and outlet connections including all related G.I. piping
work (embedded in wall), painting exposed brackets and exposed metallic parts with two coats
of synthetic enamel paint of approved quality over a coat of red oxide zinc chromate primer
etc. all complete.
4.8.3.4 All the Urinals shall be separated by Marble partitions (of minimum 19mm thick White Makrana
marble/ granite slab each partition in one piece) of minimum size 1000mm x 600mm. These
partitions shall be inserted up to 100mm depth in the wall and fixed with cement mortar 1:3 (1
cement: 3 coarse sand by volume) and suitable sized M.S. Channel (embedded in wall with
grouting) at bottom. The M.S. Channel at bottom shall be finished with two coats of synthetic
enamel paint of approved quality over a coat of red oxide zinc chromate primer.
4.8.4 Wash Basins
4.8.4.1 Wash basins shall be counter top type and shall be provided with granite counter top with
require number of tap holes and conforming to IS: 2556 Part-IV. of size 550mm x 480mm size.
Each wash basin shall be provided with 15mm dia pillar cock of approved make, rubber plug
with CP brass chain, 32mm CP Waste fitting of standard pattern with 32mm dia G.I. pipe, CP
Brass bottle trap, CP Brass 15mm dia stop cock etc. complete with all related accessories,
fittings and fixtures. The top of rim of the wash basin shall be fixed at 800 mm above finished
floor level, unless otherwise specified.
4.8.4.2 The work shall include provision and fixing of wash basin with all accessories, providing stop
cocks and pillar cocks, breaking and making good walls, fixing and making inlet and outlet
connections for stop cock, pillar cock and waste pipe, providing & fixing MS brackets painted
with two coats of synthetic enamel paint of approved quality over a coat of red oxide zinc
chromate primer etc. complete.
4.8.4.3 Following fixtures of approved quality shall be provided for each Wash Basin.

1. Mirror Full length Bevelled edged Mirror of 5.5mm thick float glass
with 6mm thick plywood backing
2. Glass Shelf 600mm x 120mm x 4mm thick Glass shelf with CP brass
bracket & guard rails fixed on wall.
3. Towel Rail Chromium plated brass towel rail of 20 mm dia, 600mm
length & 1.25mm thickness.
4. Liquid Soap Container Chromium plated Liquid soap container
5. Hand drier Fully automatic “no touch” (“KOPAL” or approved equivalent)

4.8.4.4 All the fixtures shall be fixed to the wall at identified locations with wooden cleats and CP
Brass screws including cutting walls, making good the same etc. complete.
4.9 False ceiling, Partitioning, Underdeck insulation
4.9.1 Gypsum Board False Ceiling
Gypsum Board false ceiling work shall consist of:-
4.9.1.1 GI Grid System made of:
4.9.1.1.1 GI intermediate channels (main runners) shall be 0.9 mm thick, of size 45 mm and with two
flanges of 15 mm each. The intermediate channels shall be suspended from the ceiling @

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 82 of 207

1200 mm with 25 mm x 0.5 mm GI hanger bolted to the channel and fixed to the ceiling (by
means of bolting to GI cleat fixed to the ceiling with dash fasteners).
4.9.1.1.2 GI channel shaped ceiling sections (cross runners) shall be 0.5 mm thick having a knurled
Web of 51.1 mm and two flanges of 26 mm each with lips of 10.5 mm. The ceiling sections
shall be fixed to the intermediate channels in perpendicular direction at 450 mm C/C with the
help of connecting clips
4.9.1.1.3 Wall channels shall be made of 0.5 mm thick GI of size 27 mm, one flange 20mm and the
other 30 mm. Wall channels shall be fixed to peripheral walls by rawl plugs/ dash fasteners @
450 mm c/c.
4.9.1.1.4 GI grid system for supporting gypsum board false ceiling tiles shall be perfectly leveled,
aligned at desired height in accordance with false ceiling pattern.
4.9.1.2 Gypsum board Tiles:
4.9.1.2.1 Gypsum board tiles shall be 12mm thick. The gypsum board used for tiles shall conform to
IS: 2095 and shall have following properties:-

i) Thermal Conductivity : 0.16 W/mk

i) Thermal Resistance : 0.08 Sq.M K/W
iii) Fire Propagation
a) Index of performance : Not exceeding 12 and a sub index not
exceeding 6 (when each side is tested separately
to BS 476, Part -6)
b) Surface spread of flame : Class 1 (both sides) as per test
to BS 476 (Part -7).
4.9.1.2.2 The Gypsum board shall be screw fixed to the under side of false ceiling grid system with
12.5mm dia dry wall screw @ 230 mm C/C by drilling machine. Joints in the board shall be
finished flush with fillers, finisher and primer as per manufacturer's recommendation to give a
seamless finish and shall be finished with two or more coats of plastic emulsion paint of
approved make and shade.
4.9.2 Polyisocyanurate Foam Under deck Insulation
4.9.2.1 Polyisocyanurate foam (PIR) shall be rigid slabs of size 1000 x 1500mm and
thickness of 30mm conforming to IS:12436 having density not less than 32kg/Cu.M,thermal
conductivity(K-value) not more than 0.023 w/mk measured at 10 deg.C. The slabs shall be
covered on one side with glass fibre tissue/Aluminium foil having 50mm overlap. The
insulation shall be classified as Non-Combustible as per BS 476,part 5 and Class 1 for surface
spread of flame as per BS 476,part 7.
4.9.2.2 First, holes in RCC slab/beam shall be drilled and nylon rawl plugs of size 8 x 25mm shall be
inserted( 5nos. for each slab-One each at 4 corners and one at centre. Entire RCC surface
shall be thoroughly cleaned of all dust, dirt and loose particles by wire brushing. Then a coat of
bituminous primer @ 0.5 Litres/Sq. M shall be applied to bare RCC surface and allowed it to
dry. After the primer has dried, hot blow grade bitumen of 85/25 grade or cold adhesive CPRX
shall be applied on RCC surface and to the two surface of each PIR panel and shall be
pressed in position while the bitumen is still tacky. The PIR panels shall be secured in position
with the help of GI screws( no. 8 x 75mm long) fixed into rawl plugs and GI washers 25mm
dia. Facing side of the panels shall be the one covered with fibre tissue/ Aluminium foil. The
overlaps shall be covered with appd. Quality sealing compound (MAS-94 or equivalent).
Chiken wire mesh 24G X 19mm shall then be fixed to GI screws & tightened with lacing wire.
4.9.2.3 The underdeck Insulation shall be fixed only after all fixtures like hooks, clamps, cleats etc, for
light fixtures, ducts etc., have been fixed in the ceiling.
4.10 MISCLLENEOUS ITEMS

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 83 of 207

4.10.1 M.S. Pipe Handrail

The M.S. Pipe handrail shall consist of 25mm M.S. square balusters (one on each step; similar
spacing for horizontal portions) with 40mm x 40mm x 6mm M.S flat shoe welded at bottom of
baluster; embedded into floor/ steps and grouted with M-15 grade concrete in a cut out of
100mm x 100mm x 150mm size block. 32mm dia N.B. (Medium) M.S. pipe handrail shall be
welded to balusters at top. The entire railing and balusters shall be painted with two or more
coats of synthetic enamel paint over a coat of approved quality red oxide zinc chromate
primer. All embedded metallic portions shall be provided with primer.
4.10.2 Plinth Protection
The plinth protection shall consist of a layer (150mm thick) of compacted sand and over that
100mm thick M-15 grade concrete top layer laid to slope. The top concrete layer shall be
trowel finished, cured etc. complete. The work also includes carrying out the necessary
excavation, disposal of surplus earthwork etc.
4.10.3 Cinder Filling
All the sunk R.C.C slabs shall be provided with cinder filling comprising of:-
(a) Plastering the R.C.C. slab top, sides etc. with 18mm thick cement plaster 1:6 (1 cement: 6
sand by volume) mixed with approved waterproof compound @3% of cement by weight and
finishing with a floating coat of neat cement slurry @ 2.75 kg. per sq. Mtr, finishing, curing etc.
The work includes preparation of base surface as described in Plastering item.
(b) Filling with Cinder concrete 1:10 (1 cement : 10 cinder of 12mm and down grade) including
consolidating, finishing, curing etc. complete.
4.10.4 Anti Termite Coating
All woodwork (frames, panels etc. including hidden/ embedded portions of wooden members
shall be provided with anti- termite coatings of approved quality aldrine- chlornated phenol
compound conforming to IS: 401. Three or more coats as required @ 3 Sq. Mtr. per coat per
Kg. covering capacity shall be applied before applying the finishing (painting, polishing,
lamination etc. as specified) coats.
4.10.5 G.I. Spout
50mm dia GI pipe spouts shall be fixed to slope for drainage of canopy, sunshade etc.,
including puncturing the masonry/ RCC and grouting with M-15 grade concrete, finishing etc.
all complete.
5.0 ELECTRICAL
5.1 Scope
5.1.1 This specification along with specific job requirements (if any) defines the requirements for
design, engineering, procurement, installation, testing and commissioning of the electrical
facilities for the package unit.
5.1.2 It is not intended to cover all aspect of system design but to indicate the basic requirements
only. Contractor shall ensure that detailed design and installation is carried out as per good
engineering practices and shall meet the requirements of safety, reliability, ease of
maintenance and operation, aesthetics, scope for future expansion and maximum
interchangeability of the equipment. Contractor shall acquaint himself with EIL standards and
specifications as deemed necessary for proper execution of the work.
5.1.3 Compliance with this specification and /or review of any of the contractor documents shall not
relieve the contractor of his responsibility towards his contractual obligation with regard to the
completeness and satisfactory operation of the plant.
5.2 Codes and Standards

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 84 of 207

All electrical equipment and complete installation shall meet the requirement of this
specification in addition to the relevant Indian Standards / code of practices, Statutory
regulations and sound engineering practices. Complete system shall also conform to the latest
revisions of following:
a) Indian Electricity Act and CEA Regulations 2010
b) Fire insurance Regulations.
c) Indian Petroleum rules and any other regulations laid down by chief Controller of
Explosives.
d) The factory Act and any other regulations laid down by Factory inspectorate.
e) Regulations laid down by local statutory authorities and CEA/ Electrical Inspectorate.
5.2.1 Obtaining approvals from statutory authorities for materials, plant design/ drawings and
complete installation shall be the responsibility of the contractor.
5.2.2 Where Indian Standards do not exist, the relevant IEC, British or German (VDE)/ IEEE/NEMA
standards shall apply. Any other standard may also be followed provided it is equivalent to or
more stringent than the applicable Indian standards.
5.2.3 In case of any contradiction between various referred documents the most stringent one shall
govern. Owner's concurrence shall, however be obtained before taking a decision in this
matter.
5.3 General Requirements
5.3.1 The offered equipment shall be brand new with state of art technology and proven field track
record. No prototype equipment shall be offered.
5.3.2 Contractor shall ensure availability of spare parts and maintenance support services for the
offered equipment at least for 10 years from the date of supply.
5.3.3 Contractor shall give a notice of at least one year to the end user of equipment and EIL before
phasing out the product/ spares to enable the end user for placement of order for spares and
services.
5.4 Equipment Specifications
All equipment shall be supplied by approved reputed manufacturers. Equipment requiring
specialized maintenance or operation shall be avoided as far as possible. All equipment shall
be complete with all necessary weather and anticorrosion protection including tropicalization to
prevent damage due to climate, saline atmosphere, dust and corrosive vapours.
Certain minimum requirements for the major equipment shall be as follows.
5.5 Medium Voltage Switchboards (Motor Control Centre)
5.5.1 Main bus bars shall have rating at least equal to the maximum demand under any circuit
configuration plus a provision for 10% future load growth. Incomers of these switchboards
shall be designed to cater to the complete load including 10% margin for future load growth.
5.5.2 Spare outgoing feeders shall be provided in all switchboards. At least one number of each
rating and type or 10% whichever is more shall be provided as spare.
5.5.3 Separate feeders shall be provided in the switchboard for each load/motor. However, as an
exception maximum two numbers welding receptacles may be connected to one power feeder.
5.5.4 For motor above 5.5 KW, CTs shall be provided in the switchgear for ammeter on the local
control stations.
5.5.5 The Motor Control Centre (MCC) shall generally include motor feeders of rating upto and
including 55 KW. The maximum rating of busbar shall be limited to 800 Amps. MCC shall be

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 85 of 207

provided with two incomers and tie switch for bus sectionalising. Each incomer shall be
provided with three numbers of indicating lamps, ammeter and voltmeter with selector
switches. Heavy duty type load break switches/ACB shall be used for incoming and tie
feeders and these shall have suitable interlocks and shall be designed to withstand the
specified shorts circuit level for minimum 1 sec. All motor starters shall be DOL type unless
otherwise specified.
5.5.6 Design and Fabrication Requirements
5.5.6.1 Medium voltage switchboard shall be metal enclosed fixed type free standing, floor mounting,
compartmentalized, modular type suitable for indoor installation.
5.5.6.2 The switchboard enclosure shall be dust and vermin proof and shall provide a degree of
protection not less than IP-41.
5.5.6.3 The switchboard shall be assembled out of vertical panels of uniform height, not exceeding
2450mm in a single line up.
5.5.6.4 All identical equipment and corresponding parts shall be fully interchangeable.
5.5.6.5 The frame, of individual vertical panels shall be fabricated using pressed and cold rolled sheet
steel. The sheet steel used for panel shall be of minimum 2mm (14SWG) CRCA except the
doors and covers that may be made of 1.6mm (16SWG) CRCA. Wherever required, stiffeners
shall be provided to increase stiffness of large size doors and covers.
5.5.6.6 The switchboard shall be provided with integral base frame for each vertical panel. The
switchboard integral base frame shall be suitable for tack welding.
5.5.6.7 All openings, covers and doors shall be provided with gaskets around the perimeter to make
the switchboard dust and vermin proof.
5.5.6.8 Metal sheets shall be provided between two adjacent vertical panels running upto the full
useful height of the switchboard.
5.5.6.9 All 415V switchboards shall be in single front execution.
5.5.6.10 Switch fuse /contactor feeder modules shall be of following types and internal control wiring of
all modules of each type shall be identical for all ratings.
SFU Switch Fuse Unit modules with no control terminals.
SFC Switch Fuse Contactor modules with 18 control terminals.
5.5.6.11 Separate control transformer shall be provided for each motor starter module.
5.5.6.12 To facilitate site modification due to changes in motor KW ratings and to minimise spares
inventory, overload relays and power fuse links shall meet the following requirements.
5.5.6.13 All bimetal overload relays shall be separately mounted type with connecting links rated for the
maximum rating of the contactor in a starter module.
5.5.6.14 Bimetal overload relays of various current ranges required for motors likely to be connected to
a contactor must be identical in dimension for inter-changeability. In case offered relays are
with different dimension for any particular starter module, special mounting plate suitable for
mounting different relays shall be provided in all the modules of that size.
5.5.6.15 Heavy duty starters shall be provided with saturable type, current transformer operated
overload relays only, which shall be suitable for motor starting time of 15-60 seconds.
5.5.6.16 All contactor controlled starter feeders shall meet the requirements of type-2 co-ordination as
per IS/IEC: 60947.
5.5.6.17 Clustered LED type indicating light with minimum 8mm diameter size shall be provided for
ON/OFF/Trip indications.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 86 of 207

5.5.6.18 Rating of Switch, & contactor for DOL motor starter feeders shall be standardised for below
mentioned range/block of KW ratings of motors.
Motor feeders having rating up to 5.5KW, Motors feeders having rating above 5.5KW and
up to 11KW, Motor feeders having rating above 11KW & up to 22KW, Motor feeders having
rating above 22KW & up to 45KW, Motor feeder of rating 55KW,
5.5.6.19 Motors rated above 55KW will be fed from Owner’s sub-station. Required feeders in Owner’s
sub-station/switchboard shall be provided by owner along with associated power and control
cabling.
5.5.7 Switches
Rating of switches for starter module shall meet the requirements of AC-23 duty as per IS/
IEC 60947 and minimum rating shall be 16A.
5.5.8 Fuses
5.5.8.1 Fuses shall be non-deteriorating HRC cartridge link type.
5.5.8.2 Power fuses shall be pressure fitted type and shall preferably have ribs on the contact blades
to ensure good line contact.
5.5.8.3 It shall be possible to handle fuses during off load conditions with full voltage available on the
terminals. Wherever required fuse pullers shall be provided. The fuse base shall be so located
in the modules to permit insertion of fuse pullers and removal of fuse links without any
problem.
5.5.9 Contactors
5.5.9.1 The contactors shall be air break type, equipped with three main contacts and minimum
1NO+1NC auxiliary contacts.
5.5.9.2 The coil of the contactor shall be suitable for operation on 240 V, 1 Phase, AC supply.
5.5.10 Thermal overload relay
5.5.10.1 Bimetal relays shall be provided for protecting the motor from thermal overload.
5.5.10.2 Bimetal relays shall be manually reset type with the reset push button brought out on the front
of the panel. The reset push button shall be capable of being operated without opening the
compartment door.
5.5.10.3 Bimetal relays shall be positive acting ambient temperature compensated type with adjustable
setting range.
5.5.10.4 Bimetal relays shall have built-in single phasing prevention feature, which operates even with
50% rated current at the time of single phasing.
5.5.11 Instrument transformers (CTs/PTs)
5.5.11.1 Current transformers for instruments shall have an accuracy class 1.0 and accuracy limit factor
less than 5.0. However accuracy class of 3.0 is acceptable for CT meant for remote ammeters.
5.5.12 Measuring instruments
5.5.12.1 All measuring instruments shall be of 96 x 96 mm and 72 x 72 mm square pattern, flush
mounting type for incomer and outgoing feeders respectively in the switchboard.
5.5.12.2 All AC ammeters and voltmeters shall be of moving iron type with accuracy class of 1.5 or
better as per IS: 1248. Ammeters for motor feeders shall have a non-linear compressed scale
at the end to indicate motor starting current and red mark for the full load current.
5.5.13 Space Heaters
The switchboard panels shall be provided with space heaters with switch, fuse or double

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 87 of 207

pole MCB and thermostat to prevent moisture condensation. The space heater shall be
located in the bottom part of each panel.
5.5.14 Earthing
5.5.14.1 All panels shall be connected to a tinned copper earth bus bar running throughout the length of
the switchboard.
5.5.14.2 The minimum earth bus size shall be 30x6 mm 2 copper for fault level up to 31.5kA and 50x6
mm2 copper for fault level above 31.5kA.
5.6 Medium Voltage Motors
5.6.1 Starting
a) Motors shall be designed for direct-on-line starting.
b) Motors shall be designed for re-acceleration under full load after a momentary loss of
voltage with the residual voltage being 100% and in phase opposition to the applied
voltage.
c) Minimum locked rotor thermal withstand time at rated voltage shall be 10 seconds
under cold conditions and 8 seconds under hot conditions
d) All motors shall be suitable for starting under specified load conditions with 75 % of the
rated voltage at the motor terminals.
e) Motors shall be designed to allow the minimum number of consecutive starts indicated
in Table below:
Min. no. of
Starts
consecutive starts
No. of consecutive start-ups with initial temp. of
3
the motor at ambient level (cold)
No. of consecutive start-ups with initial temp. of
2
the motor at full load operating level (hot).

5.6.2 Performance
5.6.2.1 Motors shall be rated for continuous duty (S1).
5.6.2.2 The starting current (as % of rated current) shall not exceed 700% (subject to IS tolerance) for
motors up to 22 kW. For motors more than 22 kW, starting current (as % of rated current) shall
not exceed 600 % (subject to IS tolerance).
5.6.2.3 The minimum values for performance characteristics of motors rated up to and including 37
kW shall be as per IS-8789 TABLE-1 to TABLE-8.
The minimum value for product of efficiency and power factors of 2 pole, 4-pole, and 6-pole
motors rated above 37 kW shall be as given in Table below.

Rated Product of efficiency & power factor at rated load

output (minimum)
2-Pole 4- Pole 6-Pole
45 kW 0.82 0.80 0.79
55 kW 0.82 0.80 0.79
75 kW 0.82 0.80 0.80

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 88 of 207

90 kW 0.82 0.80 0.80

110 kW 0.86 0.80 0.80
125 kW 0.86 0.80 0.80
132 kW 0.86 0.80 0.80
160 kW 0.86 0.81 0.80
180 kW 0.86 0.83 0.80
200 kW 0.86 0.83 0.80

5.6.3 Construction Details

5.6.3.1 Windings
Motors shall be provided with class `B' insulation as a minimum. In case of motors with class
‘F’ insulation, the permissible temperature rise above the specified ambient temperature shall
be limited to those specified in the applicable Indian standards for class `B' insulation.
5.6.3.2 Terminal Box and Cable Entries
The terminal box shall be located on the right hand side as viewed from the driving (coupling)
end. The terminal box shall have side cable entry from non-driving end. However, as a special
case, terminal box located on top may also be accepted, particularly for hazardous area
motors, in case manufacturer has only TOP mounted terminal box design which is duly
tested/certified by CIMFR and approved by PESO/CCOE for installation in hazardous area.
The terminal box design shall allow rotation in steps of 90 degree to facilitate cable entry from
any direction.
5.6.3.3 Cooling System
All motors shall be self-ventilated, fan cooled. TEFC, IP-55.
5.6.3.4 Miscellaneous Accessories
All motors rated 30 kW and above shall be provided with 240 V anti-condensation heaters
sized and located so as to prevent condensation of moisture during shutdown periods.
The heater leads shall be brought out, preferably, to a separate terminal box which shall be of
the same specification and grade of protection as the main terminal box.
A warning label with indelible red inscription shall be provided on the motor to indicate that the
heater supply shall be isolated before carrying out any work on the motor.
5.7 Medium Voltage Cables
5.7.1 Outer sheath of all cables shall be black in colour and the minimum value of oxygen index
shall be 29 at 27 + 2 º C. In addition suitable chemicals shall be added into the PVC
compound of the outer sheath to protect the cable against rodent and termite attack.
5.7.2 All cables shall be flame retardant (FR). The outer sheath of cables shall possess flame
propagation properties meeting requirements as per IS-10810 (Part-62) category AF.
5.7.3 All power/control cables for use on medium voltage systems shall be heavy-duty type,
650/1100V grade with aluminium/ copper conductor, PVC insulated, inner-sheathed,
armoured/ unarmoured and overall PVC sheathed.
5.7.4 The conductors shall be solid for conductor of nominal area up to and including 6mm² and
stranded beyond 6mm². Conductors of nominal area less than 16 mm2 shall be circular only.
5.7.5 The core insulation shall be with PVC compound applied over the conductor by extrusion and
shall conform to the requirements of type 'A' compound as per IS: 5831. The thickness of

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 89 of 207

insulation and the tolerance on thickness of insulation shall be as per Table 2 of IS: 1554
(Part-1). Control cables having 6 cores and above shall be identified with prominent and
indelible Arabic numerals on the outer surface of the insulation. Colour of the numbers shall
contrast with the colour of insulation with a spacing of maximum 50 mm between two
consecutive numbers. Colour coding for cables up to 5 cores shall be as per Indian standard.
5.7.6 The inner sheath shall be applied over the laid-up cores by extrusion and shall be of PVC
conforming to the requirements of Type ST-1 PVC compound as per IS: 5831. The minimum
thickness of inner sheath shall be as per IS: 1554 (Part-1). Single core cables shall have no
inner sheath.
5.7.7 All cables shall be provided with armour except those specifically specified as unarmoured.
For single core cables, the armour shall be with H4 grade hard drawn aluminium round wire of
2.5 mm diameter.
5.7.8 The outer sheath for the cables shall be applied by extrusion and shall be of PVC compound
conforming to the requirements of type ST-1 compound as per IS: 5831. The minimum and
average thickness of outer sheath for unarmoured cables and minimum thickness of outer
sheath for armoured cables shall be as per IS: 1554 (Part -1).
5.8 Local Control Stations
Each motor shall be provided with a local control station in the field near the motor. The
local control station shall have die-cast aluminium / sheet steel enclosure with IP - 55
protection for safe area and shall be flameproof type with cast light metal alloy enclosure for
installation in hazardous area. The control station shall include START /STOP push buttons,
ammeter for motors rated 5.5KW and above, local/remote selector switch, cable glands,
Auto/Manual selector switches etc, as required. STOP push button shall have stay put
feature except in the case of critical drives such as lube oil pump etc. Each push button shall
have one normally open & one normally close contact and shall be complete with necessary
inscription plates. Outdoor control stations shall have necessary canopies. Motors installed
at elevated platforms (such as cooling tower fan, air fan cooler etc.) shall be provided with a
stop push button at ground level in addition to Local Control station near motor.
5.9 Hazardous area Equipment
5.9.1 All equipment, viz. control stations, lighting and power panels, plugs, socket outlets, hand
lamps, lighting fixtures and junction boxes, for use in hazardous area shall have test
certificates issued by recognized independent test house (CIMFR/ CPRI/ ERTL/ Baseefa/
LCIE/ UL/ FM or equivalent). All equipment (indigenous & imported) shall also have valid
statutory approvals as applicable for the specified location. All indigenous flameproof
equipment shall have valid BIS license and marking as required by statutory authorities.
5.9.2 The enclosures of hazardous area equipment shall be made of cast light metal alloy and
provided with gaskets made of non-inflammable and self- extinguishing material.
5.9.3 Equipment shall be suitable for use in outdoor open locations and shall have IP-55 degree of
protection. Equipment like control stations, lighting and power panels and socket outlets shall
preferably be provided with integral canopy. However, where the enclosure has been certified
without integral canopy, a separate canopy can be accepted. The canopy shall be suitable for
providing protection against rain from top and two sides.
5.9.4 A warning inscription “Isolate power supply elsewhere before opening” shall be provided on
each enclosure. The warning inscription shall be embossed on the enclosure or a separate
warning plate with above inscription shall be fixed to the enclosure with screws. The warning
plate shall be of nickel plated brass or stainless steel.
5.9.5 For flameproof equipment, terminal box can be provided in ‘Exe’ execution.
5.9.6 Flameproof Lighting and Power Panels

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 90 of 207

5.9.6.1 All the non-current carrying metallic parts of the panel shall be inherently bonded together.
Each lighting and power panel shall be provided with two earthing studs with lugs on the
exterior of the panel enclosure suitable for termination of 10 mm dia GI wire rope.
5.9.6.2 Each outgoing feeder shall be provided with distinct terminals for phase, neutral and earth.
The terminal block enclosures shall be adequately sized to properly terminate the cables by
taking into account the required bending radii of cable cores and shall have the following
minimum gland to terminal distances:

Up to 2.5 Above 2.5 mm2 Above 10 mm2 Above 35 mm2

Conductor Size
mm2 & Up to 10 mm2 & Up to 35 mm2 & Up to 70 mm2
Gland to
terminal 40 mm 60 mm 100 mm 150 mm
distance
5.9.6.3 The panels shall be provided with suitably sized cable entries at the bottom/ sides, for
incoming and outgoing cables. Panels shall be complete with double compression type nickel
plated brass flameproof cable glands. Flameproof nickel plated brass sealing plugs shall be
supplied, for plugging the unused cable entries.
5.9.6.4 Bus bars in the lighting and power panels shall be made of high conductivity copper, and shall
be supported by non-hygroscopic insulators. Bus bars shall be colour coded for identification
of phases and neutral.
5.9.6.5 The incomer shall have one no. 4 pole MCB isolator (without overload and short-circuit
release) and one no. 4 pole ELCB. ELCBs shall have a maximum sensitivity of 30mA.
5.9.6.6 The outgoing feeders shall be provided with double pole MCBs having overload and short-
circuit releases.
5.9.6.7 Minimum conductor sizes shall be as below:
Incomer : 16 mm²
Outgoing : 2.5 mm²
5.9.7 Hazardous Area Lighting Fixtures
5.9.7.1 All well glass fixtures shall be provided with either galvanized steel or epoxy powder coated
mild steel protective wire cage using minimum 5mm welded steel construction and having
mesh dimension not exceeding 50mm x 70mm.
5.9.7.2 The fixing parts of the enclosure, which are to be opened for replacement of bulb, shall be so
fastened that they can be unfastened only with special tools.
5.9.7.3 The lighting fixtures in Zone-2 area shall be Ex nR type. Lamp holder shall be Edison screw
type.
5.9.7.4 The lighting fixtures having integral control gear box or to be used with incandescent lamps
shall be provided with 2 nos. threaded entries and 2 nos. double compression nickel plated
brass cable glands. All other lighting fixtures shall be provided with 1 no. threaded entry and 1
no. double compression nickel plated brass cable gland. The glands shall be suitable for the
specified cable size. Unused entries shall be sealed using nickel plated brass plugs.
5.9.7.5 The top of all well glass lighting fixtures shall be identically drilled/ threaded to facilitate
installation on pole/ column or ceiling.
5.9.7.6 The flood lighting fixtures shall be supplied with adjustable mounting arrangement both in
horizontal and vertical plane.
5.9.7.7 The lighting fixtures for aviation purpose, if any, shall have cluster LED lamps of medium

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 91 of 207

intensity (as per ICAO regulations) and of red colour, with toughened glass.
5.9.7.8 All lighting fixtures shall be provided with suitable mirror-polished aluminium internal reflector
of suitable thickness to ensure adequate mechanical strength. Additionally, all well glass
fixtures shall be provided with an anodized mirror-polished aluminium external reflector of
minimum thickness 1.2mm and parabolic in design.
5.9.7.9 External reflectors, for use with well glass fixtures with lamps rated up to 150W, shall have a
height not less than 60% of the length of the well glass in use. Height of the external reflectors,
for use with well glass fixtures with lamps rated above 150W, shall extend at least 10mm
below the full length of the well glass in use.
5.9.7.10 Lighting fixtures suitable for discharge lamps shall be provided with power factor correction
capacitor, choke starter etc., housed in separate control gear box. The choke shall be copper
wound. The complete control gear shall have power factor not less than 0.9.
5.9.7.11 The control gear boxes shall be provided with 3 nos. entries and 3 nos. double compression
nickel plated brass cable glands. The glands shall be suitable for the specified cable size.
Unused entries shall be sealed using nickel plated brass plugs.
Control gear box for flame proof fixtures shall be flameproof type and for Ex nR type fixtures
shall be increased safety type, except that the control gear boxes having a fuse inside the
enclosure shall be necessarily of flameproof type. The fuses shall be HRC type.
5.10 Welding Receptacles
The welding receptacles shall be industrial heavy duty type rated for 415 V, 60 Amp, three
phase system, complete with scraping earthing facilities, necessary interlocks and associated
plugs. The receptacles shall be weatherproof type and additionally flameproof type for
hazardous areas. Adequate number of welding receptacles shall be provided at suitable
locations to ensure accessibility with a 50 meters length of trailing cable to any point within
battery limits of the package unit.

5.11 Cabling System

5.11.1 Cables shall be laid above or below grade to be decided by contractor.
Above ground cables shall be well supported on GI cable trays and suitably protected against
mechanical damage. Routing shall be decided to avoid interference with hot surfaces or
places subject to undue fire risk. Above ground cables shall preferably be laid in overhead
cable trays along the pipe rack/pipe sleepers wherever available. Wherever pipe rack/pipe
sleepers are not available, cables shall be laid in above ground cable trays on separate
sleepers/rack.
Below grade cables in paved areas shall be in concrete lined trenches with concrete covers
having proper slope and suitable drainage arrangement to avoid water collection. In unpaved
areas cables shall be directly buried in ground. In hazardous areas trenches shall be
completely filled up with sand. Concrete lined cable trenches shall be sealed against ingress of
liquid and gases wherever the trenches leave a hazardous area or enter MCC room. The
cable trenches shall be sized depending upon the number and voltage grade of cables.
Where underground cables cross roadways, pipe sleepers at grade etc., they shall be
protected by being drawn through PVC sleeves/ducts to provide a permanent crossing. Pipes
laid for mechanical protection shall be sealed at both ends.
5.11.2 Medium voltage, control and signal (FA/PA/Telephone) cables shall be separated from each
other by adequate spacing or running through independent pipes, trenches or cable trays as
applicable. Cable trays, racks and trenches shall be sized to allow for 20% future cables.
Cable installation shall provide minimum cable bending radii as recommended by cable
manufacturer.
Cable route markers shall be installed at every 30m interval all along the routes of directly

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 92 of 207

buried cable trench and also at locations where the direction of cable trench changes.
5.11.3 All cable trays and accessories shall be prefabricated and hot dip galvanized as per
manufacturer standard.
Cable trays shall be prefabricated ladder type made of hot dip galvanised sheet steel.
Vertical supports for prefabricated trays shall be fabricated out of ISMC 100 and horizontal
supports shall be with 65 x 65 x 6 mm angle iron sections. Cable trays shall be covered with
removable top covers on upper most tiers allowing adequate ventilation. Where Oil or
spillage of chemicals can be expected or process pipelines are passing from close
proximity, the bottom most tray shall be provided with GI cover.GI cover sheet shall allow
adequate ventilation to the cables and shall be in standard length of 3000 mm, flanged on
both sides for fixing on cable tray
5.11.4 All power and control cables shall be of continuous lengths without intermediate joints. Where
joints are unavoidable, these shall be provided with the permission of Engineer-in-charge. In
any case joints shall not be located in classified areas All cables shall carry tag number for
easy identification. In case of control cables all cores shall be identified at both ends by their
terminal numbers using PVC ferrules as per interconnection diagrams.
Cable glands shall be of nickel plated brass unless otherwise specified. The single
compression type cable glands shall be used for indoor panels/equipment . The cable glands
for outdoor terminations shall be weather protected, double compression type. Cable glands
forming a part of relevant FLP enclosure shall be FLP type, tested by CIMFR or any other
recognized independent testing laboratory and approved by CCoE or any other statutory
authority as applicable. Indigenous FLP glands shall have valid BIS license as per the
requirements of statutory authorities.
The size of cable glands shall be appropriate to the size of cable. Entry thread of cable gland
shall be compatible to the entry thread provided in the equipment (BS, ET, NPT, PG as
applicable). If required, suitable reducers/adopters shall be used.
5.12 Lighting System
5.12.1 Lighting system shall consist of lighting panels/power panels, fixtures, junction boxes, 3 pin 5
A / 15A convenience socket outlets, cable glands etc. all conforming to the required area
classification and environmental conditions.
5.12.2 It shall be Contractor’s responsibility to demonstrate the illumination levels as specified using
luxmeter. If the illumination levels are found to be below the specified values, the Contractor’s
shall provide additional lighting fixtures and install them in uniformity to achieve the illumination
level. Dark patches and uneven illumination shall be avoided.
5.12.3 HPMV lamps shall generally be used for outdoor plant & pump house/lighting. Keeping in view
the restrike time lag, necessary incandescent lamps shall be judiciously distributed throughout
the plant area to avoid complete darkness in case of voltage dip/black out condition.
Fluorescent lamps shall be used for indoor lighting for non-process buildings and control room.
Safe area street lighting shall employ sodium vapour lamps. All chemical handling facilities
shall be provided with chemical resistant fixtures. Low pressure sodium vapour lamps shall not
be installed in hazardous areas. All ballasts shall be with copper winding and capacitor for
power factor improvement (to 0.95) shall be provided with fixtures as applicable. Tall
structures shall have aviation obstruction lighting as per statutory requirements. All lighting
fixtures shall be supplied complete with control gear and lamps.
5.12.4 Lighting wiring between panels and lighting fixtures shall be done by PVC insulated, 3 core
(phase, neutral and earth) armoured cables except for non-plant buildings which shall be
through concealed conduit. All lighting cables shall be 3x2.5 mm², 660 / 1100 V grade, copper
conductor, PVC insulated, armoured type. Conduit wiring shall be done in 25 mm dia minimum
16 gauge black enamelled steel surface conduit or PVC concealed conduit, with 660 V grade
PVC insulated copper wire of min, size 2.5 mm² for fixtures / 5A receptacles and 4 mm² for

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 93 of 207

power sockets. Not more than seven wires shall be accommodated in each conduit. All lighting
fittings/ convenience outlets shall be earthed through the third wire / separate core in
conduit /cable. All cable / wire shall be BIS approved.
5.12.5 On walkway, platforms and other outdoor areas, lighting fixtures shall be nearer to landing of
stairs or ladders, gauges, flow meters, panel boards and other equipment requiring good
illumination. In pump areas and other locations at ground level, lighting fixtures shall be
mounted preferably 4 meters above floor level. Where this is impracticable, the minimum
height of any lighting fixture shall not be less than 2.5 meters. Socket outlets in process plant
areas shall be approximately 1200 mm above grade and 300 mm above grade in office area.
Lighting /power panels shall be mounted such that the top of the panel is 1800 mm above
finished grade. Control gears of light fixtures with separate control gear shall be mounted at
suitable height from ground/platform for easy access / maintenance.
5.12.6 Emergency lighting shall be provided for escape routes and strategic locations, where specific
safety/shutdown operation are to be carried out, emergency lighting units shall be fed by a
self-contained battery and charger operating on 240V AC supply.
5.12.7 Lighting and power panels shall be provided with MCB and ELCB as incomer and Miniature
Circuit Breakers (MCBs) for outgoing feeder to control and protection of lighting circuits. MCBs
shall not be loaded beyond 80% of rated capacity. A minimum of 25% MCB in each panel shall
be kept as spares. Two pole MCBs shall be used for controlling lighting circuits in hazardous
areas. Power and lighting panels for safe area shall be of 14 gauge sheet steel construction
and shall be suitable for surface or flush mounting. A hinged door to cover the operations
knobs shall be provided. These panels shall be flush mounting in the buildings with operating
Knobs projecting out. Outdoor panels shall be housed in outdoor weather protected KIOSK
with IP55 protection.
5.12.8 Sufficient number of 5A and 15 A receptacles shall be provided within the offices and other
rooms /buildings as required. 24V, 5A Flameproof sockets with built in 240V/24V transformers
shall be provided near the manholes of vessels inside the process units. Adequate no. (at
least 20% of the sockets provided) of 24V, 5A Flameproof sockets connected with extension
cord & a 60w hand lamp shall be supplied loose.
5.12.9 Adequate number of ceiling fans shall be provided in offices and rooms allocated for operating
and maintenance personnel etc. In places where ceiling fans are provided, lighting fixtures
shall be suspended below fan level with the help of conduits/chains to avoid shadows on the
floor.
5.13 Earthing System
5.13.1 Earthing system design and installation shall generally be as per IS: 3043. All metallic non
current carrying parts of electrical apparatus, current and potential transformer secondaries,
columns, vessels, towers, stacks, storage tanks, loading racks etc. shall be earthed at least by
two distinct separate earth conductors from the earth plate connected to the main earthing
loop.
5.13.2 The main grid conductor shall be hot dip galvanized MS flat unless otherwise specified. The
amount of galvanising shall be min.610 g/m². The main earth loop shall be laid at a depth of
500 mm below grade level.
Earthing conductor shall be laid around the package unit area. Horizontal conductors shall
be laid in both longitudinal and transverse direction to facilitate the earthing of various
equipment in most economical and reliable manner.
The cable trays in offsite/utility/process areas shall be earthed at an interval of approx. 30 m
with the help of risers emerging from main earthing conductors laid below/adjacent to
structures carrying cable trays.
Joints and tappings in the main loop shall be made in such a way that reliable and good

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 94 of 207

electrical connections are permanently ensured. All joints below grade shall be welded and
suitably protected by giving two coats of bitumen and covered with hessian tape.
5.13.3 Adequate number of 65 mm dia. 3 m long GI pipe earth electrodes with earth pit shall be
provided. All earth electrodes shall preferably be driven to a sufficient depth to reach
permanently moist soil. Package unit earth grid shall have provisions for interconnection to
owner's main plant earth grid.
5.13.4 Multiple earth connection shall be taken from suitably located earth plates connected to earth
loop. All hardware used for earthing installation shall be hot dip galvanized or zinc passivated.
Spring washers shall be used for all earthing connections of equipment. Unless otherwise
specified, earth connections to individual equipment shall be done in accordance with standard
equipment earthing schedule. Earthing connections to equipment shall be made by means of
specially provided bolts and lugs.
5.13.5 Lightning protection shall be provided for Equipment, structures & buildings as per IS-2309.
Self conducting structures may not be provided with aerial rod and down conductors but shall
be connected to the earthing grid at minimum two points of the base. An independent earthing
network shall be provided for lightning protection and this shall be bonded with the main
earthing network minimum at two points at the buried electrodes.
5.13.6 All utility, process pipelines shall be bonded and earthed on entering/leaving any hazardous
area. In addition, steel pipe racks shall be earthed at every 24 meters.
5.13.7 The resistance value of an earthing system to the general mass of earth shall be as follows:
a) For the electrical system and equipment a value that ensure the operation of the protective
device in the electrical circuit but not in excess of 5 ohms. However for Generating stations
& large sub-stations this value shall not be more than 1 ohm. The main earthing network
shall be connected to the plant-earthing network at minimum two points.

b) For lightning protection, the value of 5 ohms as earth resistance shall be desirable, but in no
case it shall be more than 10 ohms.

5.14 Inspection and Testing

5.14.1 All the equipment shall be tested and inspected at vendor works before dispatch to ensure
compliance applicable codes and standard and agreed quality assurance/testing plan.

5.14.2 The owner or his authorised representative may visit the works during manufacture of various
electrical equipment/materials to assess the progress of work as well as to ascertain that only
quality raw materials are used for the same. He shall be given full assistance to carry out
inspection. Owner's representative shall be given minimum two weeks advance notice for
witnessing the final testing.

5.14.3 Field tests as per the approved procedures/procedures available with engineer-in-charge or
his authorised representative shall be performed on the electrical system/ equipment before its
being put into service. All test equipment shall be arranged by the vendor. Test reports shall
be approved by the Engineer-in-charge before acceptance of the complete plant and
equipment.

5.15 Painting

5.15.1 All metal surfaces shall undergo manufacturer’s standard cleaning/painting cycle. After
preparation of under surface, the equipment shall be painted with two coats of epoxy based
final paint. Colour shade of final paint shall be 632 of IS-5/RAL 7035 for outdoor mounted
equipment and shall be 631 of IS-5/RAL 7032 for indoor located equipment. All unpainted

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 95 of 207

steel parts shall be suitably treated to prevent rust formation. If these parts are moving, these
shall be suitably greased.

6.0 INSTRUMENTATION
6.1 General:
6.1.1 This Specification with all other documents attached with the tender defines the minimum
requirements of Cooling tower and cooling water treatment plant package for Instrumentation.
All the instrumentation shall be provided as per the approved P&IDs and other requirement
specified in the tender.
6.1.2 Design and terminology shall comply, as a minimum, with the latest edition prior to the date of
purchaser's enquiry with following codes, standard practices and publications:-
ANSI/FCI American National Standards Institute/Fluid Control Institute
70.2 Control valve Seat Leakage
API American Petroleum Institute
520 Sizing, selection and installation of pressure relieving devices in refineries.
Part-I - Sizing and selection
Part-II - Installation
RP 521 Guide for pressure relieving and depressurising systems.
RP 526 Flanged steel Pressure Relief Valves.
RP 527 Seat tightness of Pressure Relief Valves.
RP 551 Process Measurement Instrumentation
Part I - Process Control and Instrumentation
S 2000 Venting Atmospheric and low-pressure storage tank
BS British Standards
5308 Part-II: Specification for PVC insulated cables.
7244 Specification for Flame Arrestors for General Use.
IS/IEC Indian Standards / International Electrotechnical Commission
IS/IEC 60079 Electrical Apparatus for Explosive Gas atmosphere
IEC 60332 Test on bunched wires or cables.
IS/ IEC 60529 Degree of protection provided by enclosures (IP code)
IEC 60534-2 Industrial Process Control Valves-Flow capacity.
IEC 60584-2 Thermocouple Tolerances
IEC 60751 Industrial Platinum Resistance Thermometer Sensors
IEC 61000-4 Electromagnetic compatibility for Industrial Process measurement and control
equipment.
IS Indian Standard
IS-1554 PVC insulated (heavy duty) electric cables working
Part I -voltage up to and including 1100V
IS-3624 Specification for pressure and vacuum gauges

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 96 of 207

IS-5831 PVC insulation and sheath of electric cables.

IS-7358 Specifications for Thermocouples
IS-8784 Thermocouple compensating cables.
ISA International Society of Automation
S-5.2 Binary logic diagrams for process operations.
S-75.xx Standards related to control valves.
ISO 5167 Measurement of fluid flow by means of orifice plates, nozzles and venturi
tubes inserted in circular cross-section conduits running full.
NEMA National Electrical Manufacturer's Association
ICS-6 Enclosures for Industrial control and systems.
OSHA Occupational Safety and Health Authority.
SAMA Scientific Apparatus Maker’s Association
6.2 Specification for Instrumentation and Control
i. All electronic instruments shall be SMART type with HART protocol in general. Location of
field instruments/ equipment shall be considered as hazardous for this package and shall be
suitable for IEC Zone-2, Gr IIA, IIB, Temp. Class T3.
ii. Control and monitoring for this package shall be from DCS located in Satellite Rack Room/
Control Room. Interlock & shutdowns shall be executed in PLC located in Satellite Rack
Room/ Control Room. DCS & PLC shall be in the scope of purchaser except for the PLC
required for Chlorine dioxide Generation and Dosing System which shall be supplied by
Contractor.
iii. Process instrument type for alarm and shutdown shall be transmitters only with switch
action generated in control system. No field process switches shall be provided. This
shall override any requirement specified elsewhere including process package
iv. Junction boxes for flameproof instruments shall be flameproof. Junction boxes for intrinsically
safe instruments shall be weather proof. Increased safety/ non incendive concept for
instruments including junction boxes & cable glands is not acceptable.
v. Certification for use in hazardous area shall be as follows:
a) Certificates from statutory authorities like BASEEFA, FM, PTB, UL, and CENELEC etc.
for items of foreign origin, and from CMRI etc. for items of Indian origin.
b) Approval certificate from CCE (Chief Controller of Explosives) for items to be installed in
India, irrespective of country of origin and the same is mandatory. In case CCE certificate
is not available at the time of quotation, bidder shall confirm that the certificate shall be
furnished before shipment.
c) Approval certificate from BIS (Bureau of Indian Standards) for all flameproof instruments
of Indian origin
vi. Start / Stop, Auto / Manual, Local / Remote commands for all electrical drives from Local
Control Station in field (A/M switch shall be in the control room) shall be directly wired to MCC.
Status signals of drives from MCC shall be wired to marshalling cabinet in control room and
shall be repeated to desired destinations.
vii. Transmitters:
a. All transmitters shall be smart type with HART protocol (latest version) and Output signal
shall be 4-20mA DC (2 wire system).The transmitter shall be microprocessor based and it

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 97 of 207

shall incorporate a non-volatile memory which shall store complete configuration data of
transmitter and sensor characterization. All necessary signal conversions, including
conversion to produce output with the required protocol shall be carried out in the
transmitter electronics. Transmitter shall also run complete diagnostic subroutines and
shall provide diagnostic alarm messages for sensor as well as transmitter healthiness. In
the event of detection failure, the output shall be driven to a predefined value, which shall
be field configurable.
b. All field transmitters for flow, pressure, level, differential pressure and temperature. Shall
be supplied with accessories for 2” yoke mounting and shall be provided with universal
mounting bracket for mounting in both horizontal as well as vertical pipe.
c. All transmitters shall be provided with integral LCD type output meter.
d. Temperature Transmitter shall be able to accept both grounded and ungrounded sensors
and shall have provision for cold junction compensation of T/C or RTD input.
e. Universal Type Hand held calibrator shall be suitable for all makes/ model nos. of
transmitters and positioners. Otherwise, 1 no. hand held configurators shall be supplied
for each differing type.
f. Remote indicator/ indicator in local panel shall be microprocessor based, intrinsically safe,
Loop powered type.
g. Over range /static pressure (PT, PDT, FT, DP LT) rating shall be as follows:

Range of Transmitter Over range/ static pressure (Note)

Pressure Transmitter Differential Pressure

(kg/cm²) Transmitter (kg/cm²)

0 < ® < 250 mm WC 20 20

250 < ® < 1000 mm WC 45 52

1000 < ® < 5000 mm WC 45 70

5000 < ® < 10000 mm WC 45 160

1 < ® < 10 kg/cm² 52 160

10 < ® < 100 kg/cm² 160 210

> 100 kg/cm² 210 210

Note : However if the Over range/ static pressure value specified above is less than
the maximum/ design pressure of service conditions, offered instrument shall be
suitable for the maximum/ design pressure.

h. Transmitter accuracy shall be mentioned below:

Transmitter accuracy (PT, PDT, FT, DP LT)

For ranges of >=760 mm WC ±0.075% of full scale

For ranges < 760 mm WC ±0.15% of full scale

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 98 of 207

Temp. Transmitter accuracy (with cold junction compensation with

thermocouple element)

For temperature between 150 °C to 350 °C ± 0.5% of range

For temperature < 150 °C ± 0.75% of range

Temp. Transmitter accuracy (with RTD element)

For temperature range between 150 °C to 350 °C ± 0.15% of full scale

For temperature range < 150 °C ± 0.2% of full scale

viii. Temperature Element / Gauges :

a. Thermowell & flange material shall be minimum SS316. Thermowell shall be fabricated
out of bar stock material. Built-up thermowells shall be considered for immersion lengths
greater than 500mm. In case of underground vessels, the thermowell length shall be
calculated based on the location of the measurement point inside the vessel as
specified in process data sheets In general, the immersion lengths shall be as follows:

Line Size Immersion length

From 4" to 6" 280 mm

From 8" onwards 320 mm

Vessels / columns 400 mm

Immersion length is based on 200 mm length between flange face and outer
wall of pipe. Any pipe line less than 4" nominal bore shall be blown to 4" size
to install thermowell.

b. Temperature Gauges shall be bimetallic type in general. Dial size shall be 150mm.
Casing material shall be SS as a minimum. Accuracy shall be ±1.0% URV.
c. The temperature bulb shall be of stainless steel construction. The gauge connection
shall be all angles adjustable. Gas filled type shall be used when measuring range is
beyond the limits of Bimetallic gauge or thermowell length exceeds 550 mm or in
applications involving excessive vibrations. Mercury filled type temperature gauge shall
not be used.
d. For filled type with capillary extension, capillary tubing shall be a minimum of 304 SS
with stainless steel flexible armouring, and PVC covering over armour. Filled type
gauges shall be manufactured as per relevant SAMA class.
e. Thermometer stem adjustable gland with union connection and bushing shall be
suitable for 1/2" NPTF connection.
f. Temperature Elements shall be Duplex type and in general it shall be RTD type for
temperature upto 400 deg. C and above 400 deg C, it shall be thermocouples of K type,
grounded type. Element shall be 20AWG for duplex type. Insulation shall be with
magnesium oxide. Remote mounted Temperature transmitters shall be provided for all
temperature inputs, but not head mounted and shall have a built-in linearising function

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 99 of 207

to produce an output linear to temperature range. Burn out protection must be provided
with temperature transmitters and trip amplifiers. Upscale or downscale protection shall
be decided based on its application to ensure fail-safe operation
ix. Pressure Gauges
a. Case material shall be SS304 with dial size of 150mm. Accuracy of the gauge shall be
±1.0 % URV. Differential pressures gauges may have an accuracy of 2% of URV Over
range protection shall be provided (at least 130% of maximum operating pressure) with
blow out discs. Process connection shall be ½” NPTM (bottom entry). Pointers shall have
micrometer adjustment.
b. Sensing element shall be bourdon tube/ diaphragm (for low pressures). Material shall be
SS316.
c. Glass shall be shatter proof. Solid front case shall be provided for gauge range of 60
kg/cm2g and above.
d. Over range protector and pulsation dampener, whenever used, shall be of SS 304, as a
minimum. Pulsation dampener shall be used for all pulsating services. It shall be floating
pin type, externally mounted and externally adjustable.
e. Ranges shall be so specified that the gauge normally operates in the middle third of the
scale and shall conform to IS-3624 standard dials.
x. Flow Element :
a. Flow elements shall be in general Orifice plates. Dimensions shall be as per EIL standard
7-52-0041. Minimum material shall be SS316 with minimum flange rating of 300# and
material being as per PMS. Flange tapping shall be provided for line size less than or
equal to 14”.
b. Averaging Pitot Tube shall be provided with insert- retract mechanism (hand crank type)
with isolation ball valve of 3” size. Nozzles shall be provided with weldolet. Suitable
straight lengths shall be provided based on manufacturer’s recommendation
xi. Level Instruments:
a. Level gauges shall be generally steel armoured reflex type or transparent type with body
& cover material of forged carbon steel as a minimum. Gauge glass shall be tempered
borosilicate glass with suitable gasket. All gauge glasses must have a rating equal to or
more than vessel design pressure & temperature. Transparent type of gauges shall be
provided with integral illuminators operating at 240 V 50 H z supply.
b. Reflex type will be used for clean and colourless liquids, except liquids level interface.
For low temperature, low boiling point service, large chamber type will be used.
Transparent type will be used on acid, caustic, dirty or viscous, colored liquids and liquid
interface. Transparent type with Mica or Kel-F shields shall be used for treated water,
condensate services and for corrosive liquids, which will attack glass.
c. All gauges shall have top and bottom chamber connections, unless otherwise specified.
However side-side chamber connection is acceptable where nozzle installation is a
constraint. In addition each gauge shall be provided with ball check valves and pipe
union.
d. The visible range of level gauge shall be selected to cover the complete operating level
as well as measuring range of the other level instruments provided for the same purpose.
Maximum visible length for single level gauge is 1490mm. above this range, multiple
gauges shall be used.
e. The gauge glass shall meet the following Test Pressure as a minimum:

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 100 of 207

Type of chamber Type Test pressure (Kg/Cm2G)

Standard Reflex up to 300# Flange 165

Transparent up to 300# Flange 84

Large Reflex up to 300# Flange 50

Transparent up to 150# Flange 40

f. Level instruments shall be provided as per the approved P&IDs. In general, Guided Wave
Radar or displacer type instruments (only in interface applications) shall be used up to
ranges of 1219mm. Standard lengths for GWR or displacers shall be 356 mm, 813 mm
and 1219 mm. Above 1219mm, differential type of level transmitters shall be used. Level
transmitters shall meet all requirements specified in transmitter section above.
g. Generally Guided Wave Radar type level; instrument shall be provided with external cage
and side-side connections. The instrument shall work on TDR principle. The type of wave
guide shall be selected based on specified application. The external chamber/cage shall
be with 2" flanged end connections. The chamber/cage shall also have 3/4" NPT vent and
drain connection. Accuracy shall be ±3.0mm. Internal type top mounted Guided wave
radar shall be used only upto a maximum length of 4500mm.
h. Displacer type instrument shall be torque tube type with torque tube material of inconel,
as a minimum. Internal displacer type level instrument shall be avoided unless application
necessitates its use.
i. Differential Pressure transmitters for use on corrosive or fouling service shall generally be
diaphragm wafer with extended filled capillary type. Diaphragm material shall normally be
stainless steel or any other special alloy.
j. For Non-contact type radar instruments, contractor shall select suitable type of antenna
with still well (wherever required) considering the process conditions including dielectric
constant, viscosity and performance requirements. Accuracy shall be ±3.0mm.
k. For Ultrasonic type level instruments, Probe shall be selected to ensure that distance
between the probe and the maximum level to be measured is more than the blocking
distance of the probe. Accuracy for ultrasonic type level transmitter shall be Better than +
0.25%.
xii. Control Valves:
a. Control Valves shall be normally globe type, single seated or double seated with a
minimum leakage class of IV.. Sizing shall be carried out as per ISA S75-01. The valve
shall permit up to 150% of normal flow or 110% of maximum flow, whichever is higher.
Minimum control valve body size shall be 1" in general for line size 1” and above.
Reduced trims can also be considered where flow values are less. Trim characteristic
shall be considered as equal percentage type in general.
b. Body material, of Control Valve shall be as per piping specifications as a minimum. body
rating and flange rating shall be 300# as a minimum. Material used for trim shall be
minimum SS 316. Stellited trim shall be used wherever required as per PMS and/ or
pressure drop higher than 10 Kg/cm².
c. Valve actuator shall be pneumatic spring opposed diaphragm type, in general. Actuator
shall be able to withstand maximum shut-off pressure with the minimum instrument air
pressure specified elsewhere in the tender.
d. Maximum allowable noise for control valves is 85 dBA SPL (Sound Pressure Level).

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 101 of 207

Source treatment for noise shall be performed by using special trims like anti-noise trims.
e. Control valve positioner shall be Smart type with HART protocol. The smart positioners
shall be provided with necessary hardware/ software for maintenance, diagnostics,
programming etc. One license shall be provided for each Make/ Model number of
positioner. The smart positioner shall have HART protocol of latest version and shall be
suitable to operate with Instrument Asset maintenance system (IAMS) of various makes
of DCS. Positioner shall be universal in nature capable of implementing universal
commands to facilitate use with any type of pneumatic actuator like single acting and
double acting for both sliding stem and rotary shaft valves. Valve signature data with seat
load, bench set and valve friction, dynamic error and dynamic linearity of control valve,
diagnostic graphics with adequate resolution shall be provided for the positioner. When
mounted on control valve, the factory valve signature test report shall be provided
f. Positioner enclosure shall be metallic.
g. Any on-off valves required for the package shall be full bore ball type with soft seated
having leakage class VI up to a design temperature of 200 deg. C and metal seated with
leakage class V for design temperature above 200 deg. C.
h. Control valve limit switches, when provided shall be proximity type. Each limit switch shall
have 2 separate cable entries for open and close positions.
i. Instrument air filter regulator of suitable size, range and capacity shall be supplied for
each pneumatic instrument. The body of the filter shall be anodised aluminium. The filter
shall have 5 micron sintered bronze/ceramic filter element and shall be provided with
manual drain and 2" nominal size pressure gauge.
j. Solenoid valves, wherever used, shall be universal and continuous rated type with class F
coil insulation. Body material shall be SS as a minimum. . Surge suppression diodes shall
be integral part of solenoid valves.
k. The type (with internal or external sensing and upstream/ downstream regulation) of self
actuated control valves shall be selected as per approved P&IDs and process conditions.
The body material and trim material of the self-actuated control valves shall be .as per
PMS The drop of the valve shall be less than 10% of the set pressure. Actuator casing
and diaphragm shall be suitable to withstand shut-off pressure.
xiii. Pressure Relief Valves:
a. All pressure relieving devices shall be designed in accordance with ASME code for
'Boilers and Pressure Vessels' and API-521.
b. Pressure relief valves shall be full nozzle full lift type except for thermal relief valves
wherein semi-nozzle/ modified nozzle design can be used.
c. Conventional valves shall be provided for constant back pressure while bellows seal type
valves shall be provided for variable back pressure more than 10% of set pressure. Pilot
operated pressure relief valves shall be used for special services and where set pressure
is closer than 10% of the operating pressure or back pressure is more than 50% of set
pressure or as per Process requirements..Bellow shall be used to isolate the spring and
guiding surface from the corrosive and dirty fluids. Test gag shall be provided for all
pressure relief valves. Lifting lever shall be provided for air or water above 65 degree
service.
d. The body material of PSV shall, as a minimum, be as per piping specifications. Nozzle
and disc material shall be SS 316 as a minimum with machined stainless steel guide and
spindle. Whenever semi nozzle designs are unavoidable, body material shall be at least
same as nozzle material for pilot operated valves.
e. Spring material shall be normally Carbon steel with weather protective coating up to

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 102 of 207

230°C relieving temperature and Tungsten alloy steel above 230°C.

f. Orifice size/designation shall be selected as per API RP-526 based on the required
relieving capacity. However, 3/4" x 1" threaded (NPT) modified nozzle type valves with
typically 0.38 cm2 orifice size shall be provided for thermal relief.
xiv. Analysers
a. Contractor shall supply TOC/ Water quality analyzer, pH Analyzer, Conductivity Analyzer,
and any other Analyzers wherever required as per the approved P&IDs. Analyzer type,
make, model number shall be proven for similar application. Necessary sample handling
system shall be provided by contractor.
b. The design of sample system shall ensure a clean representative and measurable sample
for the selected analysers. System shall include sample probe/ sensor, pressure reducing
station, filters, regulators, safety valves etc and calibration arrangement. The design
must include a sample flow switch, which will provide alarm and inhibit analysis whenever
a low flow is sensed. Contractor shall consider provision of fast loops and sample return
to process as necessary to meet performance requirements. The sample return shall not
be vented or routed to drain unless the return is a waste product and non-hazardous.
c. Analyser shall be microprocessor based with state-of-the-art technology, which shall be
capable of being configured from analyser front panel locally using analyser keyboard.
The configuration related data of the analyser including set range shall be stored in a non-
volatile memory such that this remains unaffected by power fluctuations or power off
condition. In case vendor standard instrument has battery backed RAM, analyser shall
have facility to provide battery drain alarm as diagnostic maintenance message.
d. The span of the analyser shall be field adjustable from the analyser front without opening
the analyser enclosure. In case, separate device is required to make such a change the
same shall be included by contractor in their scope of supply.
e. Analysers and its related equipment directly connected to line and In-situ analysers shall
be capable of withstanding the process pressure and temperature conditions.
f. Chlorine di-oxide analyzer shall be a continuous measurement type analyzer without any
requirement for reagent. The complete analyzer system shall be mounted on the free
standing enclosure. The complete analyzer shall be sourced from Original Equipment
Manufacturer.
g. TOC/ Water quality analyzer shall be UV Persulphate oxidation with acid sparging for TIC
removal / Combustion Catalytic oxidation/ CO2 detection
h. pH/ Conductivity Analyser shall be On line, In-situ type. Measuring electrode shall be of
glass or metallic as governed by the process conditions indicated in the purchaser’s data
sheets. Reference electrode shall be ‘non-flowing type’. The electrode with electrolyte
replenishment or external pressurisation type shall not be used. The pre-amplifier and
transmitter shall be solid-state type with automatic temperature compensation.
i. Sample tubing shall be minimum SS316L and fittings shall be SS316. The filters used in
Sample Handling shall be dual type with DP gauge
j. Contractor shall supply calibration sample solutions/cylinders for zero & span calibration
for each analyzer.
xv. Local control panel:
a. Local control panel (LCP) shall be weatherproof to IP-55 as a minimum. For classified
area the LED cluster type Alarm Annunciator mounted on LCP shall be intrinsically safe
with, push button, lamp, selector switches shall be flame-proof “Exd” type and mounted on
LCP. Barriers for IS alarm annunciator shall be supplied by contractor along with IS

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 103 of 207

annunciator. The IS power supply module for alarm annunciator shall be installed in a
flameproof box in local panel.
b. Local control panel shall be provided with front & rear door as required and cable entry
shall be from bottom through gland plate.
c. Incoming power with power on indication and outgoing power for each consumer shall be
provided with switch and fuse/MCB arrangement.
d. Panel shall only house switches/pushbuttons, status lamps, important alarms and critical
indications only. No electronics/electronic devices or Instruments except intrinsically safe
indicators shall be located on the local panel.
e. Local control panel/panels shall be totally enclosed cubicles. Panel sizing shall be carried
out based on equipment being installed keeping in view the maintenance clearances and
easiness of operation. Although the panel dimensions shall be guided by the actual
requirements, typical dimensions shall be 2100 mm height x 1200 mm width x 1000 mm
depth.
f. Control panels shall be fabricated preferably from 3 mm thick cold rolled steel sheet. If
the same is not available, 4 mm thick hot rolled steel sheet shall be used. Angle iron
framework shall use a minimum section of 50 x 50 x 4 mm angle. Material for all hinges,
screws and other non-painted metallic parts shall be Stainless steel. Panel colour shall
be RAL 7035.
xvi. Miscellaneous Requirement:
a. Internal terminal blocks shall be provided for all instruments. They shall be anti-vibration
type, suitable for terminating a minimum of 1.5 mm2 size cable conductors. Flying leads
are not acceptable.
b. Single pair cables shall be 1.5 mm² twisted in pair individually shielded with aluminium
Mylar tape with drain wire and armoured. Cables shall be flame retardant as per IEC
60332 Cat. A. Power cable size shall be minimum 2.5 mm². Cable glands shall be
Nickel-plated brass, double compression type suitable for armoured cables. Slipper type
PVC sleeves (cable shrouds) shall be provided for all cable entries in junction boxes and
instruments. Cable entries shall generally be ½” NPTF for signal & ¾” NPTF for power.
Control cables, Signal and alarm cable shall be blue for IS and black for Non–IS.
c. Contractor shall supply the junction boxes suitable for 6 pair/ 12 pair cables for signal /
alarm / Control and 8 Triad cables for Gas Detector transmitters. Material of the junction
box shall be LM6 alloy as a minimum. All junction boxes shall be sized to keep at least
20% spare terminals in each considering that purchaser supplied multi-cables shall be
provided with individual pair / triad shield as well as overall shielding. All junction boxes
shall have terminals for termination of cable shield/ drain wires. Ferrules shall be heat
shrinkable printed sleeve type. Cable entries shall be from side for all single pair/triad
cables and bottom of the junction box for multipair / multitriad. All spare entries shall be
plugged.
d. Separate JBs for different type of signals shall be provided as per following philosophy:
1. Separate JBs for signals connected to DCS and PLC
2. Separate JBs for intrinsically safe & flameproof instruments
3. 4~20 mA signals
4. Contacts
5. Thermocouples/ RTDs
6. Gas Detector transmitters

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 104 of 207

e. Power Supply Requirement: 110 VAC UPS, 110 V DC (wherever required as per job
philosophy) and 240 VAC shall be provided by purchaser at one point in the field and
any further distribution and conversion to another voltage level shall be in the scope of
the contractor. Contractor shall give the power consumption requirement for 110VAC
UPS, 110 V DC and 240V AC along with the offer.
Following are the voltage levels that are to be considered:
Instruments & Control System: 110 V AC UPS
Interlock & Shutdown system: 110 V AC UPS
Interrogation Voltage for Contact inputs: 24 V DC / 110 V DC (as per job
specification)
Solenoid Valve: 24 V DC / 110 V DC (as per job
specification)
Transmitters (loop powered): 24 V DC
Proximity Type Limit switches: 24 V DC
Panel Lighting: 240 V AC
Level Gauge Illumination: 240 V AC
f. Instrument impulse lines shall be provided with all necessary pipe/ tube fittings as per
specification attached elsewhere in the bid. Piping material used in installation hook up
shall be as per PMS (Piping Material Specification). Tubing used in impulse lines shall be
minimum SS316L tube, ½” OD size with tube fittings of minimum SS316 material.
Instrument air supply tubing shall be 6mm OD SS 316L tube. Instrument valve manifold
shall be fabricated type.
Typical EIL installation standards shall be provided to successful contractor after order.
However, this should not have any cost or delivery implication. Based on these typical
EIL installation standards, contractor shall develop and submit Installation standards
(hook-up) for all instruments supplied and installed by the contractor, for owner’s review
g. Any instrument not accessible from grade/ platform shall be provided with a suitable
approach platform for access and maintenance.
h. Instrument drain points shall be connected to common drain pipe to be routed to the
nearest drain header.
i. Instrument connection sizes shall be as per 7-52-0001 and 7-52-0002.
j. Remote type mounting (at grade level) shall be considered for the instrument tapings
located inside the pit.
k. Contractor shall provide cable trays (wherever required) for cable routing. Cable trays
shall be made of GI mild steel sheets of 2.5 mm thickness. Ladder trays shall be MS hot
dip galvanized. Cable trench, wherever required (e.g. in case required for cable entry to
local panels) shall be provided by contractor. Buried trench shall not be considered.
Contractor shall provide RCC trench only. No electrical cable shall share the Instrument
Cable Tray. At least 40% spare space shall be considered in Instrument Cable Trays and
trench.
l. Instrument air shall be provided at single point at battery limit. Further distribution of air
within the battery limit shall be in contractor’s scope. Contractor shall indicate the
instrument air consumption for the package.
m. Special testing requirements shall be applicable as per PMS / P&ID attached with the
tender.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 105 of 207

n. SS tag plate shall be provided for all instruments, gauge boards and local panels.
o. Proven Track Record: The instruments as being offered / supplied should have been
operating successfully under similar process conditions for at least 4000 hours.
p. Specialty Services: Analyzers, PLC and special instruments installation, testing &
commissioning shall be done under supervision of manufacturer’s specialists. Contractor
to make specialist’s services available at their cost. Logistic support certificate (as per
format given below) shall be furnished from supplier of all types of Analyzers and PLC.
q. Contractor shall be responsible for residual engineering (Residual engineering includes
instrument sizing, Thermowell Wake frequency calculation, utility consumption,
specifying derived data in process data sheets, deriving process data for instruments
where specific data sheet for these are not included in MR, type and material selection of
instruments wherever required. Residual engineering shall also include actual transfer/
implementation of the information provided in the form of notes in P&ID and equipment
data sheets and other documents provided in tender document.
r. Sub-package PLC for chlorine di-oxide generation and dosing system shall be supplied
by contractor and its location shall be at Local control room (by contractor).. PLC shall be
with Dual redundant processor, dual redundant IOs with redundant power supply, dual
communication modules with redundant serial (protocol shall be MODBUS RTU with RS
485 link) interface with purchaser control system. One no. engineering cum operator
console along with one no. A4 laser printer shall be provided by contractor for the PLC
system.
s. Gas Detectors shall be supplied by Purchaser with an integral transmitter with 4-20mA
output. The gas detector shall be provided with aspirator arrangement.
Beacon and hooter along with reset push-button for gas detectors shall be provided by
purchaser wherever shown as per the approved P&ID. Beacon and hooters shall be
suitable for 24VDC / 110VAC.
Contractor shall be responsible for mounting the gas detectors along with aspirator and
Hooters/beacons with reset push-button.
xvii Inspection and Testing
a. All instruments and system oriented items like analyser, PLC shall undergo factory
testing and inspection by Contractor’s authorized representatives. Owner/PMC
participation shall be as per inspection categorisation of various items defined elsewhere
in the tender document.
b. The inspection and testing shall be carried out as per testing requirements mentioned in
related specifications/ ITP, international codes and practices/ standards, approved
documents and/ or any other document attached elsewhere in the tender document.
c. No system or system oriented item shall be dispatched without integrated factory testing.
The testing procedures shall be detailed out by Contractor as per above-mentioned
philosophy and shall be approved by owner/ PMC. Contractor must certify that the
system is actually ready before calling the Owner / PMC for FAT. Also all the necessary
approved documents and literature are to be submitted before calling for FAT.
d. Factory Acceptance Testing of Analyzer systems and PLC System shall be witnessed by
Client/ EIL at their discretion.
e. Acceptable criteria for Radiography and other NDT requirements for all the instruments/
instrument castings shall be in line with those specified in ‘valve / piping specifications’
for the similar service.
f. All sub packages shall be tested with the control system (in contractor’s scope), Local

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 106 of 207

control panel and gauge board etc.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 107 of 207

Formats for Logistic Support

a) Certificate For Logistic Support (by Principal)

(To be signed by Principal’s corporate level signatory on company’s letterhead)

I, on behalf of M/s _________________________________ confirm that the ______*_________

quoted by M/s _______________________ for Cooling Water Package of _______________
(Project) shall continue to be supported by us. The quoted item shall not be withdrawn from Indian
market as a matter of our corporate policy.
I further confirm that in case of placement of order by _________(Purchaser) on M/s
____________________ we shall continue to support _______________(Purchaser) in providing
back-up engineering, maintenance support and spare part to _________ for a period of 10 years from
the date of placement of order.

Signature with Seal

Authorized, Senior Management Level Signatory

* For all Analysers/PLC being supplied by Contractor.

b) Certificate For Logistics Support (by vendor)

(To be signed by Vendor’s corporate level signatory on company’s letterhead)

I, on behalf of M/s __________________________________ confirm that the ______*_________

quoted by M/s _______________________ for Cooling Water Package of __________________
Project shall continue to be supported by us and our principal(s). The quoted item shall not be
withdrawn from Indian market as a matter of our corporate policy as supported by attached certificate
from our principal(s) M/s _________________________.
I further confirm that in case of placement of order by _________(Purchaser) on us, we shall continue
to support _________(Purchaser) in providing back-up engineering, maintenance support and spare
part to _________(Purchaser) for a period of 10 years from the date of placement of order.

Signature with Seal

Authorized, Senior Management Level Signatory

* For all Analysers/PLC being supplied by Contractor.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 108 of 207

7.0 STATIC EQUIPMENT

7.1 General
This section covers Specifications for material, design, fabrication, erection and testing of
pressure vessels and atmospheric storage tanks.
7.1.1 Codes
Codes (As Applicable) – Latest edition shall apply
 ASME Sec.II
 ASME Sec.VIII Div.1
 ASME Sec.IX
 API 650 (For Atmospheric Storage Tanks)
 API 2000
 ASME B16.20
 ASME B 16.5
 ASME Sec X (For FRP)
 BS-EN-13121-3 (For FRP)
 BS-EN-13923(For FRP)
 IS 875
 IS-1893
 IS-4682 (For Rubber lining)
7.2 Pressure Vessels
7.2.1 Specifications of Carbon Steel Plates
7.2.1.1 Chemical Analysis
Plates used shall conform to latest issue of specification SA-20 with additional requirements
mentioned herein.
a) Only normalised plates free from injurious defects with workmanlike finish shall be used.
Reconditioning/repair of plates by welding shall not be permitted.
b) One product analysis of each heat shall be carried out and reported. Chemical analysis
shall be as per applicable specifications with carbon content not exceeding 0.23%.
Additionally, one of following requirements for carbon equivalents (Ceq) based on heat
analysis shall be satisfied.
Ceq = C + Mn/6 < 0.42 ...(1)
Ceq = C + Mn/6+(Cr + Mo + V)/5+(Cu+Ni)/15 < 0.43 ...(2)
Equation -(1) shall be used when applicable material specify C and Mn only.
Equation -(2) is applicable for restricted chemistry requirements or for supplementary
requirements of S19 & S21 of specification SA-20.
7.2.2 Ultrasonic Examinations of Plates
Plates having thickness 16 mm or more shall be examined ultrasonically as per specification
SA-435.
7.2.3 Simulated Heat Treatment of Test Coupons

- All Plates intended for hot One normalising* + one stress

rolling/forming. reliving as per UCS-56 of ASME
Sec. VIII Div.1 complying with UCS-
85 of ASME Sec. VIII Div.1

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 109 of 207

* Recommended Normalising Cycle :

(i) Soaking Temperature 900º C To 1000º C

(ii) Holding time one hour per 25 mm

thickness but not less than half an
hour
(iii) Cooling in still air

7.2.4 Material Certificates shall conform to EN 10204 Type 3.1 and shall be submitted to designated
inspector/ Owner
7.2.5 Material for Internal Lining/Painting
7.2.5.1 FRP Lining
i) Wherever FRP lining on inside of equipment is specified the resin used shall be vinyl ester,
equivalent or better to suit the intended service.
ii) The steel surface shall be abrasive blasted as per SSPC-SP-10 and anchor profile of surface
shall be 38 to 75 micron. Primer coat of polyamide cured epoxy (25 to 75 micron DFT) shall
be immediately applied after cleaning to prevent rust formation before application of FRP
lining.
7.2.5.2 Rubber Lining
i) Application of rubber lining on inside of vessels, shall be done as per IS 4682. Part-I.
ii) All weld joints to be ground smooth & finish before application of rubber lining.
7.2.5.3 Painting on Internal Surface
Surface preparation and application of Primer and Painting shall be in accordance with painting
specification for specified service or as per applicable process datasheet as applicable.
7.2.6 Heads
All carbon steel cold formed dished heads or knuckles shall be stress relieved. Hot formed dished ends
or knuckles which have not been uniformly heated in the normalizing range in the final stages
of manufacture shall be normalised. When completed vessel involves PWHT, heat treatment
intended above for cold formed dished heads or knuckles is not applicable.
7.2.7 Manholes/Handholes And Nozzles
a) Manholes shall be minimum 450 mm NB unless otherwise specified.
b) Manhole cover shall be provided with a davit or hinge.
c) Small vessels shall be provided with two pad type inspection opening of 150 NB. If it is not
possible for small vessel upto 300 mm diameter vessel a suitable spool pipe shall be provided
in the piping for inspection.
d) For vessels with diameter less than 900 mm and having removable internals, shell flanges
shall be provided.
e) As a general rule all nozzles attachment to shell/head shall be set in type.
7.2.8 Flanges
a) All flanges shall be as per ASME B-16.5. Flanges not covered by ASME B-16.5 shall be to

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 110 of 207

ASME B-16.47 (Series B).

b) Only weld neck flanges shall be used.
7.2.9 Pressure Testing
All vessels shall be hydrostatically tested as per the code. In order to safeguard against the
risk of brittle fracture during hydrostatic test, temperature of test fluid shall meet the
requirements of UG-99 of ASME Sec. VIII Div.1 and shall preferably not be less than 16º C.
7.2.10 Welding
Full penetration weld shall be employed for joining pressure parts. Where both sides are not
accessible for welding, root run by tungsten inert gas process or backing strip may be used to
ensure full penetration. Backing strip, if used, is to be removed after welding, wherever
possible.
7.2.11 Radiography/Non Destructive Testing
7.2.11.1 Spot radiography is the minimum requirement for all vessels.
7.2.11.2 When spot radiography is specified, the following requirements shall supplement the
requirements specified in ASME Section VIII Division I :
Each category A or B pressure containing welds shall be spot radiographed in accordance
with ASME Section VIII Div. 1, para UW-52 as a minimum requirement. Each spot radiograph
shall be a minimum of six inches (150 mm) in length and minimum one spot shall be selected
in each circumferential and longitudinal seam. Additionally, at least one T-joint in each
circumferential and longitudinal seam shall also be selected. Welds from each welding
procedure, Welder/Welding operator shall be examined.
7.2.11.3 All nozzles fabricated from plate, irrespective of thickness, shall be 100% radiographed.
7.2.11.4 Weld seams of formed ends shall be 100% radiographed after forming and heat treatment, if
any.
7.2.11.5 All nozzle to shell welds (Root and Final run) shall be examined by magnetic particle/Dye
penetrant test.
7.2.12 Cleaning And Painting
a) Vessels shall be cleaned internally to remove scale, rust, dirt, foreign material by wire
brushing.
b) All external surfaces shall be cleaned, primed and painted in accordance with painting
specification for specified environment.
7.3 Storage Tanks
7.3.1 Material Specification
7.3.1.1 All materials shall be as per applicable codes and EIL Standards. Material test
certificates/documents shall be submitted to Inspector for verification.
7.3.1.2 Plate material conforming to IS: 2062 or as listed in API 650 shall be used. Plates shall be in
killed or semi killed condition and shall be guaranteed for weld ability. Product analysis of each
heat shall be carried out.
7.3.1.3 Manhole necks and nozzle necks of 250 mm NB and above may be fabricated from same
plate material as used for shell.
7.3.1.4 All Nozzle flanges shall be forged type. Ring type flange fabricated from plate shall not be
used.
7.3.1.5 Pipes for nozzles shall conform to API 5L, IS: 1978, A-53 or A-106. Pipes for nozzle & heating
coil shall be of seamless quality.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 111 of 207

7.3.1.6 All clips and attachments shall be fabricated from carbon steel plates of weld-able quality.
7.3.1.7 Hand rails on stairway and tank top shall conform to IS: 1239 (medium) and galvanized.
7.3.1.8 Platforms, spiral stairways/ladders and gangways shall have Electro-forged gratings .
7.3.1.9 Gaskets for manholes and nozzles above 450NB shall be 3mm thick compressed non
asbestos. However, requirements of PMS (Approved Piping Material Specification) should be
complied with.
7.3.1.10 Studs/bolts and nuts for all nozzles fitted with blind flanges shall conform to ASME A-193 Gr.
B7/ A 194 Gr.2H. Bolts and nuts for all structural’s shall conform to IS: 1363.
7.3.1.11 Dimensions for nozzle flanges shall conform to ASME B16.5 for size upto 600 mm NB and to
ASME B16.47 Series B for sizes above 600 mm NB. Dimensions for manhole flanges and
covers shall be as per the design code.
7.3.2 Welding Consumables
7.3.2.1 Selection of welding consumables shall be based on the general chemistry of deposited filler
metal which shall be the same as that of the base metal. Welding electrode specification shall
conform to Indian Standard IS:814/ASME Boiler and Pressure Vessels Code Section II (C).
However, minimum requirement of applicable codes and Appendices shall be adhered to:
7.3.2.2 Low hydrogen electrodes shall be used for all manual metal arc welds of shell courses having
a thickness of 12mm and above.
7.3.2.3 Low hydrogen electrodes shall be used for attachment welds of shell to bottom or annular
plate and annular plate butt joints.
7.3.2.4 For all other welding, high cellulose/rutile type electrodes as per the AWS classification SFA
5.1 shall be used.
7.3.2.5 Based on above, fabricator shall furnish brand names of welding consumables to Inspecting
Authority for approval.
7.3.3 Fabrication And Erection
7.3.3.1 During fabrication, contractor shall provide guy ropes and other means to safeguard semi
finished storage tanks against damage due to severe winds.
7.3.3.2 All welding shall be in accordance with the applicable design code and welding process shall
be electric fusion shielded metal arc unless otherwise specified.
7.3.3.3 Welding procedure qualification shall be carried out as per IS: 823/ASME Boiler and Pressure
Vessels Code Section IX. Welders shall also be qualified in the approved procedure as per
the requirements of the Code. These qualification tests shall be arranged by the Contractor at
his cost and witnessed by EIL/Owner Inspector.
7.3.3.4 Bottom plates of tanks which are resting on pier/grillage for under-tank leak detection shall be
of butt welded construction.
7.3.3.5 Vertical joints in adjacent shell courses shall be offset by at least 1000mm. Vertical and
horizontal joints shall also clear the nozzle welds and reinforcement pad welds and minimum
distance between welds shall be as per Code.
7.3.3.6 Stiffening ring (wind girder) shall be provided on the tank as per requirements of the code. 15
mm diameter drain holes suitably staggered shall be provided on the horizontal part of the
stiffening ring.
7.3.4 Inspection And Testing
All tanks shall be subject to inspection by EIL/Owner or a third party. The Inspector shall have
free access to the contractor's shop/work site. The Contractor shall provide all facilities like
tools and tackles, instruments and personnel to inspector. Approval of Inspector shall in no

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 112 of 207

way relieve the contractor of his responsibility for proper execution of work.
7.3.4.1 The Inspection shall include but not be limited to:
a) Examination of materials of construction.
b) Welding procedure and Welder's qualification tests.
c) Various non-destructive tests like radiography etc. as per code.
d) Checking of dimensions
e) Pressure testing and certification etc.
f) Hardness testing
7.3.4.2 Wherever specified in code, dye penetrant/magnetic particle examination shall be carried out
on the welds. Shell weld seam as a minimum, shall be spot radiographed. Extent of
radiography and acceptance criteria shall be as per the relevant provisions of the code.
7.3.4.3 The inner fillet of bottom or annular plate to shell weld shall be leak tested with penetrating oil
after removal of slag prior to welding of outside fillet weld.
7.3.4.4 After completion, tank shall be hydrostatically tested by filling water and all weld joints shall be
hammered and inspected for any leakage. In case of any defect it shall be repaired and
retested as per the instructions of Inspector.
7.3.4.5 Tolerances
Fabrication tolerances on shell, bottom, foundation, etc. shall be as per applicable code.
7.3.5 Calibration
Strapping and calibration of tanks shall be done in accordance with Indian Standards IS: 2007
and IS:2008. Datum plate shall be welded to tank bottom vertically below the gauge hatch.

8.0 ROTATING EQUIPMENT

8.1 GENERAL

8.1.1 Scope
This Specification covers the minimum requirements for the purpose of carrying out
Engineering Activities for Procurement of Rotating Equipment required and their
auxillaries/accessories and the spare parts & special tools for Cooling Tower & CWTP, as
applicable.
The Contractor shall use data sheets / proformas as enclosed in this section of the bid
package, for carrying out engineering activities for procurement of rotating equipment at his
end.
For the equipment, for which no such data sheets/proformas are furnished by PMC/Owner, the
Contractor may use his standard data sheets/proformas or Equipment Manufacturer’s
standard data sheets/proformas.
8.1.2 Selection of Rotating Equipment
Selection of Rotating Equipment shall be based upon the following considerations:
- Suitability for the specified duty conditions, as defined in the process package.
- Standard Equipment Models under vendor's regular manufacturing range.
- Proven Track record in similar service as specified under acceptance criterion.
- Optimum operating and maintenance costs.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 113 of 207

- Maximum Interchangeability of parts.

- Ease of operation and maintenance.
8.1.3 Unit Responsibility
In addition to the overall responsibility of the Contractor for the complete package/plant, the
unit responsibility of each rotating equipment unit shall lie with the driven equipment
manufacturer, who shall also be the SPRV (Single Point Responsibility Vendor) for the
complete equipment unit including driver, driven equipment & all other associated auxiliary
systems, instrumentation & controls etc.
All Rotating Equipment drivers shall be procured, preferably from the respective driven
equipment manufacturers, complete with all associated auxiliary systems.
8.1.4 Unitisation
All rotating equipment shall be unitized with respective drivers at the rotating equipment
manufacturer’s shop before dispatch to check fit up of equipment, alignment, location of bolt
holes, interface locations / dimensions etc.
8.1.5 Associated Accessories and Auxiliary Systems
8.1.5.1 All rotating equipment, drivers, auxiliary systems, instrumentation and control systems, shall
be provided with all necessary electrical and safety devices as applicable or required for safe
and reliable operation of the unit
The Contractor in his scope of supply and work shall also include the hardware required over
and above what is specified, for safe and satisfactory operation of the equipment package.
8.1.5.2 Motors, electrical/instrument components and electrical/instrument installations shall be
suitable for the area classification specified by the purchaser, and shall meet the requirements
as defined in the electrical/instrument specification attached with the relevant sections of the
bid package /order.
8.1.5.3 All drains shall be terminated with a flanged valve at the equipment battery limit & shall be
routed to nearest underground drain facility, as defined in the process package.
8.1.5.4 All vents shall be taken to flare or a safe location, depending upon the properties of fluid to be
vented, as defined in the process package.
8.1.6 Drive Arrangement
All rotating equipment shall be either directly driven or driven through gear box. However, V-
Belt drive arrangement may be used for Roots Blower and Reciprocating Air Compressors.
V-belt, if provided, shall be Antistatic, oil resistant, nonconducting type certified suitable for the
intended area classification and equipped with a positive belt tensioning drive.
Gear Box, if offered, shall be as per API 677 and with minimum service factor of 1.5.
8.1.7 Couplings & Coupling Guards
8.1.7.1 Unless otherwise specified, Couplings shall be of metallic, non-lubricated, flexible element
type (i.e. either diaphragm or discs) with spacer, for all equipment. All coupling models shall be
selected for a minimum service factor of 1.5.
However spacer is not required to be provided for Vertical Pumps.
Further Flexible or Fleximetallic Couplings can be provided for Reciprocating Compressor, as
recommended by manufacturer.
8.1.7.2 Removable coupling guard for moving parts like coupling, belt drive, etc shall be provided
which shall be fabricated from non-sparking material, and shall be open at the bottom to permit
manual shaft rotation. The guard shall be sufficiently rigid to withstand deflections as a result

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 114 of 207

of bodily contact of nominally 100 kgs.

8.1.8 Allowable Noise Level
8.1.8.1 Equipment noise level (Driver + Driven equipment train + auxiliaries) shall not exceed 88 dBA
when measured at One-meter distance from the equipment skid in any direction.
8.1.8.2 Acoustic hoods shall not be used for any equipment except for roots blowers.
8.1.9 Equipment Storage
All rotating equipment shall be suitably packed for an outdoor storage period of six (6) months.
Rotating Equpment, procured from abroad, must be provided with sea worthy packing.
Contractor shall be responsible for proper storage & handling of equipment at site.
8.1.10 Applicable Codes And Standards
International Standards/Codes along with other applicable Specifications attached or referred
to, as per the Table - 1 shall be the basis of design, selection, manufacture, inspection/testing
of the equipment.
For design aspects not specifically covered by Data Sheets/Specifications, Codes and
Standards or Regulations, the design shall be based on good engineering practice.

Sl. No. Description International Standards /

Codes
PUMPS
1 Centrifugal Pumps (General Purpose Process National Standard of the
Service) country of origin of the
2 Centrifugal Pumps (General Water Service) equipment
3 Positive Displacement Pumps (Controlled API Std. 675
Volume)
AUXILIARIES
4 Shaft sealing for centrifugal pumps API 682
All other rotating equipment not listed above Mfr. Std.

Remarks:
(1) Centrifugal pumps for general purpose process service are classified as pumps for
applications where maximum pressure by all considerations does not exceed 16.0 kg/cm² g,
pumping temperature remains within -29°C to 205°C, Specific gravity is not less than 0.7 at
the specified operating conditions or when dual pressurised / un-pressurised mechanical seals
are not required/specified.
(2) Centrifugal pumps for general water service are classified as pumps for
applications such as Large Capacity Cooling Water Pumps, Auxiliary Cooling Water Pumps &
other centrifugal pumps handling clean & cold water.

8.1.11 Installation Criteria

8.1.11.1 All rotating equipment shall be suitable for outdoor installation at grade. No equipment shelter
is envisaged.
8.1.11.2 All rotating equipment shall be grouted using non shrink cementitious grout, unless
recommended otherwise by equipment vendor.
8.1.11.3 Only Stainless Steel shims shall be used for equipment alignment. Shim thickness shall be
maximum 3mm.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 115 of 207

8.1.12 Materials
The material of construction of the wetted parts of rotating equipment shall be as specified in
the process package.
8.1.13 Safety
8.1.13.1 Equipment design and engineering shall incorporate adequate safety features (as per
applicable specifications of respective equipment as well as Health, Safety and Environment
Codes & Standards applicable for the subject project) to provide protection to operating
personnel, equipment and environment.
8.1.13.2 All positive displacement machines shall be provided with Pressure Safety Valve.
8.1.13.3 Thermal relief valves shall be provided for each CW return circuit that may be blocked in by
isolation valves.
8.1.13.4 All electrical components & installations, instruments shall be suitable for the electrical area
classification and grouping in which the equipment is installed.
8.1.14 Inspection and Testing
8.1.14.1 Inspection and test specified in the bid package (Refer typical datasheets attached elsewhere)
shall be carried out by the Equipment Vendor at his works.
All tests specified as witnessed, shall be witnessed by TPI or EIL as per the bid package
requirements, specified elsewhere.
Performance tolerance, unless stated otherwise, for all rotating equipment shall be as follows:
Rated Capacity: -0%
Rated Diff. Pressure/Head : -0%
Rated Power: +0%
8.1.15 Erection of Equipment
Erection of all rotating equipment shall be carried out by the contractor preferably under the
supervision of equipment vendor.
8.2 Special Requirements
8.2.1 Special Requirements for Centrifugal Pumps (General Purpose Process / General Water
Service)
8.2.1.1 Equipment Qualification Criteria
Offered pump model and its manufacturer shall meet the following criteria:-
a) The pump vendor shall be an established centrifugal pump manufacturer having adequate
engineering, manufacturing and testing facilities for centrifugal pumps.
b) The pump model offered shall be from the existing regular manufacturing range of the
vendor. The mechanical as well as the hydraulic performance (including NPSHR) for the
complete range of operation of the offered model shall have been established in the
shop test.
The offered pump model shall meet the following minimum service and manufacturing
experience requirements:
Pumps shall be identical or validly similar in terms of Power rating, Hydraulic Performance
(including NPSHR), Inlet flow, Differential Head, Operating Pressure & Temperature, Speed,
Number & Type of Impellers, Mechanical Design, Materials, Column Length (applicable for
vertically suspended pumps) etc. as compared to at least TWO UNITS of the proposed model
which shall have been designed, manufactured, tested and supplied from the proposed

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 116 of 207

manufacturing plant in the last fifteen years and as a minimum ONE of these past references
shall have completed ONE year of satisfactory operation at site as on the date of issue of
invitation to bid.
8.2.1.2 Two stage pumps shall be of in-between bearing types.
8.2.1.3 Inducers shall not be used in pumps.
8.2.1.4 Pumps with constant speed drivers shall be capable of at-least 5 percent head increase at
rated condition and pump rated speed by replacing with a new impeller or impellers. Offered
impeller shall in no case be less than the minimum diameter impeller.
8.2.1.5 Pumps where difference between NPSHA and NPSHR from quoted minimum flow to rated
flow is less than 1 meter are not acceptable. The said NPSHR value shall correspond to the
maximum value of NPSHR from rated flow down to the recommended minimum continuous
stable flow specified by the vendor.
8.2.1.6 Pumps that have stable head/capacity curves (continuous head rise to shut-off) are required.
When parallel operation is specified, the head rise shall be at least 10% of the head at rated
capacity.
8.2.1.7 The best efficiency point for the furnished impeller is preferred between the rated point and the
normal point. However in no case the rated point shall be beyond 110% of the best efficiency
point of the rated impeller.
8.2.1.8 Pumps shall have suction and discharge flanges designed for same rating. Unless otherwise
stated, flanges shall be machined and drilled conforming to ANSI B16.5 standard.
8.2.1.9 Impellers shall be single piece castings. Fabricated impellers are not acceptable.
8.2.1.10 Pumps that handle liquids more viscous than water, shall have their performance corrected
with Performance Correction Chart of Hydraulic Institute Standard. Correction factors as
applicable shall be indicated by the manufacturer on the filled-in data sheet.
8.2.1.11 The setting depth of vertical submerged pumps shall be worked out to ensure that minimum
submergence of the pump is within the boot of vessel / pit.
8.2.1.12 Vertical Pumps & Motors that could be damaged due reverse rotation shall be provided with
non reverse ratchet or suitable device to prevent reverse rotation.
8.2.1.13 Packing/Mechanical Seals & Sealing System
8.2.1.13.1Pumps shall be provided with Packing/Seals, as specified in the process package.
8.2.1.13.2In case, the pump is to be supplied with packings, the stuffing box shall have minimum five
packing rings plus lantern ring. Packing ring size shall be 3/8" or larger.
8.2.1.13.3Mechanical Seal shall be of balanced type & preferably of Cartridge design. The type of
mechanical seal (i.e. single or dual un-pressurised / pressurised) shall be as defined in the
process package.
8.2.1.13.4 Shaft shall be provided with sleeves under the packing/seal. Sleeves shall be locked to the
shaft. The material of sleeve shall be 12 percent chrome steel (hardened). Where the size of
pump makes the use of shaft sleeve impracticable, the shaft shall be constructed of 12 percent
chrome steel (hardened). For vertical pumps, shaft material shall be 12 percent chrome steel.
8.2.1.13.5 Jackets shall be provided on pump seal chamber, in case the pumping temperature is above
120°C or with dead ended seal arrangement.
8.2.1.13.6 Requirement of the throat bushing shall be decided by the vendor to suit the operating
conditions.
8.2.1.14 Bearings & Bearing Housing
8.2.1.14.1 Antifriction bearings shall be of standard type and shall meet minimum L-10 rating life of either

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 117 of 207

25000 hours with continuous operation at rated conditions or 16000 hours at maximum axial
and radial loads and rated speed.
8.2.1.14.2 The rise in bearing grease/oil temperature with continuous running of the pump shall be within
the allowable limits which shall not exceed 30°C for grease and 39°C for oil lubricated
bearings above ambient temperature. Cooling arrangements shall be provided if required.
Bearings shall be equipped with constant level oilers, Bearing Isolators, vent breather & drain
point for oil lubricated arrangements.
8.2.1.14.3 Vertical pumps shall be provided with their own thrust bearing designed to carry rotor weight
and pump generated axial forces and shall not transmit any thrust to the bearings of driver.
8.2.1.15 Vibrations
Following vibration limits shall be applied at rated speed and at flow of ±10 percent of rated
flow:
a) Horizontal pumps
Unfiltered vibration velocity for horizontal pumps upto 3000 rpm with antifriction bearing and/or
sleeve bearings when measured at the bearing housing in horizontal or vertical direction shall
not exceed 4 mm/sec.
b) Vertical Pumps
Unfiltered vibration velocity for vertical pumps with antifriction and/or sleeve bearings when
measured at the top bearing housing of pump or top bearing housing of motor or mounting
flange for measuring points up to 3 meters above the mounting base shall not exceed the
following limit:
Pumps greater than 1500 rpm = 7 mm/sec.
Pumps upto & including 1500 rpm = 4 mm/sec.
The vibration limits specified vide above shall be applied for pumps only. The vibration limits
for the drivers shall be as per their respective applicable standards. Where respective
applicable standards do not specify such limits for the associated drivers, the driver
manufacturer’s recommendation shall be applied for acceptance of the driver.
8.2.1.16 Driver Sizing:
Electrical motor drivers as per (IEC/IS) shall be rated for continuous duty (Duty type S1)
whereas motor as per American Standards shall be designed to operate at a service factor of
1.0.Rating shall not be less than the following unless higher rating is dictated by the Note1.

Motor Name plate Motor MCR (% of Pump Rated BKW Guaranteed

Rating with +0% tolerance)

Less than 22 kW: To suit maximum BKW indicated on pump data sheet
or 125% of rated pump BKW, whichever is
higher.

22 kW - 55 kW: 115% of rated pump BKW.

Higher than 55 kW: 110% of rated pump BKW.

Note:
1. The motor nameplate rating for pumps under parallel operation shall not be less than the max.
BKW indicated on pump data sheet (i.e. the power at End of the curve for the rated impeller)
or shall have the specified margin as per this clause whichever is greater. The pump motors

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 118 of 207

shall also be suitable for start-up under open discharge valve condition.
2. The motor nameplate rating for applications where the specific gravity of the pumped fluid is
less than 1% shall either be 100% of the BKW of the pump at minimum continuous stable flow
with clean cold water of sp. gravity of 1.0 or shall have the specified margin as per this clause,
whichever is greater.
8.2.1.17 Inspection & Testing (for each pump)
Refer Typical Centrifugal Pump Datasheets attached elsewhere.
8.2.2 Special Requirements For Positive Displacement Pump (Controlled Volume)
8.2.2.1 Equipment Qualification Criteria
Offered pump model & its manufacturer shall meet the following criteria:-
a) The vendor shall be an established positive displacement (controlled volume) pump
manufacturer having adequate engineering, manufacturing and testing facilities for API 675
pumps.
c) The pump model offered shall be from the existing regular manufacturing range of the pump
manufacturer. The mechanical as well as the hydraulic performance for the complete range of
operation of the offered model shall have been established in the shop test.
The offered pump model shall meet the following minimum service and manufacturing
experience requirements.
Pumps shall be identical or validly similar in terms of Power rating, Hydraulic Performance,
Inlet flow, Differential Pressure, Operating Pressure & Temperature, Pumping Liquid, Speed,
Number & Type of Pump Heads (i.e. Simplex, Duplex, Triplex etc.), Mechanical Design,
Materials etc. as compared to at least TWO UNITS of the proposed model designed,
manufactured, tested and supplied from the proposed manufacturing plant in the last fifteen
years and as a minimum ONE of these past references shall have completed ONE year of
satisfactory operation at site as on the date of issue of invitation to bid.
8.2.2.2 The pump flow rate shall be adjustable over the range of 10% to 100% of rated capacity while
the pump is running.
8.2.2.3 The pump speed shall not exceed 100 strokes per minute.
8.2.2.4 For both suction and discharge double check valves shall be furnished.
8.2.2.5 Lost motion type pumps or Pumps with Spring Return Mechanism are not acceptable.
Unless specified otherwise in process package, Pumps shall be of positive displacement
(controlled volume) type having double / sandwich diaphragm. Mechanically actuated
diaphragm pumps are not acceptable.
8.2.2.6 All diaphragm pumps shall be provided with diaphragm rupture detection system. In case of
diaphragm rupture, diaphragm rupture indicator & a rupture sensor (required as per
instrumentation specifications) along with contacts for alarm in purchaser’s DCS shall be
supplied & mounted by the contractor/vendor.
8.2.2.7 For multihead pumps, ganging effect (power stroke of each pump head is out of phase with
the next pump head) shall not be considered while sizing the driver.
8.2.2.8 Pumps where difference between NPSHA and NPSHR is less than 1m are not acceptable.
8.2.2.9 Pulsation suppression shall be provided at the discharge of all metering pumps. When
necessary Pulsation dampener shall be provided at suction to maintain adequate margin
between NPSHA & NPSHR.
Vendor to calculate the NPSHA and acceleration head for each pump item, based on the
system configuration. Calculations for NPSHA, Acceleration head & NPSHR shall be furnished

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 119 of 207

during detailed engineering stage. Vendor to ensure that NPSHA is greater than “Acceleration
Head + NPSHR” by a margin of at least 1.0 meter, either by proper selection of pump speed or
by proper valve design or else by providing a suction side volume bottle.
8.2.2.10 Pump unit complete with speed reducer, driver, suction pulsation dampner (if required or
specified) & discharge pulsation dampner, suction and discharge manifolded piping duly pre-
fabricated for multi-head pumps, relief valves, instrumentation etc. shall be mounted on a
common skid.
8.2.2.11 For pulsation dampeners, the first preference shall be for volume bottle type dampener and if
the same is not sufficient a bladder type N2 precharged dampener shall be provided. In that
case Vendor shall also supply the N2 pressure regulator along with charging kit.
Pulsation dampeners shall be provided as per pump data sheets and P&ID.
The suction side pulsation dampener shall be as per the following details:
Design Code : ASME Sec. VIII Div.I
Allowable pulsation level : + / - 3%
Material of construction : As per applicable PMS indicated in P&IDs
Type of pulsation dampener : Inverted Bottle, Direct Contact type.
The discharge side pulsation dampener shall be as per the following details:
Design Code : ASME Sec. VIII Div.I
Allowable pulsation level : + / - 3%
Material of construction : As per applicable PMS indicated in P&IDs
Type of pulsation dampener : Volume Bottle type/Bladder type.
Accessory : 1 No. Gas charging kit common for all the pulsation
dampeners (if bladder type pulsation dampner is offered).
8.2.2.12 Driver Sizing:
Electrical motor drivers as per (IEC/IS) shall be rated for continuous duty (Duty type S1)
whereas motor as per American Standards shall be designed to operate at a service factor of
1.0.Rating shall not be less than the following:
Motor Name plate Rating Motor MCR (% of Pump Rated BKW
Guaranteed with +0% tolerance)
All Ratings 110% of Rated BKW or 105 % of BKW at RV Set
Pressure, whichever is higher.

8.2.2.13 Inspection & Testing (for each pump)

Refer Typical Controlled Volume Pump Datasheets attached elsewhere
8.3 Codes & Standards
Following is list of applicable codes& standards.

9.0 PACKAGED EQUIPMENT

9.1 General Consideration
9.1.1 Specific requirements and guidelines pertaining to individual equipment and system are listed
in subsequent sections, however, the following general considerations have to be kept in view

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 120 of 207

for all items formulating their specifications and procurement engineering activities:
- Facility for any known future expansion of plant capacity with a minimum of modifications or
shutdown.
9.2 Special Requirement
9.2.1 CONTRACTOR shall develop technical specification of equipment taking into consideration
the requirements defined in specifications, data sheets and the requirements given elsewhere
in the tender document.
9.2.2 Selection of material for each component of equipment shall be based on the design pressure,
temperature and other conditions of operation and in no case shall be inferior to the applicable
codes and standards.
9.2.3 Painting shall be as per Painting specifications.
9.3 Safety Requirements
9.3.1 Electrical devices shall meet the requirements for the area classifications in which they are
installed.
9.3.2 Couplings, gears and exposed rotating parts shall be provided with adequate guards of non-
sparking type, Drive belts, if used, shall be antistatic type.
9.3.3 The requirements of Noise Limits and Equipment Vibration as defined in the standard
specification shall be met. In general OSHA requirements shall be complied with.
9.4 Air-conditioning System
9.4.1 Basis of design & general requirements
9.4.1.1 Codes and standards
Latest revisions of the following Codes/Standards shall be referred:

IS:659 Safety code for Air conditioning.

IS:655 Specification for Metal Air ducts
IS:2494 (Part-2) V-belts - Endless V-belts for industrial purposes-Part 2 Fire resistant
and antistatic V-belts - Specification
IS:3142 Pulleys-V-Grooved Pulleys for Endless V-Belts Sections Z, A, B, C, D
and E and Endless Wedge Belts Sections SPZ, SPA, SPB and SPC -
Specification
IS:1239 (Part 1) Steel Tubes, Tubular and Other Wrought Steel Fittings - Specification -
Part 1 : Steel Tubes
IS:3589 Steel Pipes for Water and Sewage (168.3 to 2 540 mm Outside
Diameter) - Specification
IS:277 Galvanized Steel Sheets (Plain and Corrugated) - Specification
IS:2062 Hot Rolled low, medium and high tensile structural steel
IS:4894 Centrifugal fans
IS:7613 Method of testing panel type air filters for air-conditioning and ventilation
purposes
IS:8148 Packaged Air Conditioners – Specification
ANSI/ISA-S71.04 Environmental Conditions for Process Measurement and Control

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 121 of 207

Systems: Airborne Contaminants

ASTM B-111 Standard Specification for Copper and Copper Alloys Seamless
Condenser Tubes and Ferrule Stock.
ASTM B-359 Standard Specification for Copper and Copper Alloys Seamless
Condenser and Heat Exchanger Tubes with Integral Fins.
ASTM B-280 Standard Specification for Seamless Copper Tubes for Air Conditioning
and Refrigeration Field Service.
SMACNA Sheet Metal and Air Conditioning Contractors' National Association-
HVAC Duct Construction Standards-Metal and Flexible.
AMCA-210 Laboratory Methods of Testing Fans for Certified Aerodynamic
Performance Rating.
ASHRAE Handbooks of:
- Fundamentals.
- HVAC Systems and Equipment.
- HVAC Applications.
- Refrigeration.
BS EN 779 Particulate air filters for general ventilation – Determination of the
filtration performance.
UL-555 Specification for safety fire dampers
NFPA-90A Standard for Installation of Air-conditioning and Ventilation Systems
9.4.1.2 Outside design conditions shall be referred from the latest edition of ISHRAE Handbook.
9.4.1.3 Inside Design Conditions
DBT,°C % RH
i) Control Room 23 + 1 50 + 5
iii) Operator Room 24 + 1 -

9.4.1.4 Air conditioning system shall be through air-cooled type DX-Coil system. Air-cooled
condensers shall be selected for outdoor design DBT.
9.4.1.5 Air conditioning equipments (Packaged unit / split AC) as per manufacturer’s standard
specifications shall be acceptable.
9.4.1.6 Refrigerant for package VCR type AC system shall be R-134a/R407c. For smaller capacity
commercial split ACs, R-22 refrigerant may be used.
9.4.1.7 Air-conditioning system shall be selected based on following guidelines:-
i. Air-cooled type package air-conditioner units may be provided for smaller capacity
requirements (upto 45 TR), if agreed by the owner/consultant. For requirements upto 3
units one standby unit shall be provided and 2 standby units shall be provided if the
requirement is 4 to 6 units.
iii Air-conditioning requirements for Individual area/rooms up to 5 TR and where no
specific RH requirement is envisaged and no electronic equipment/panels are coming,
which cannot be fed by central air-conditioning system, may be provided with

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 122 of 207

single/multiple window or split air-conditioners as suitable per site conditions, if agreed

by the owner/consultant.
9.4.1.8 Air-conditioning system shall be designed for 24 hours/day and 365 days/year.
9.4.1.9 Minimum 1 air change / hr fresh air shall be considered for ventilation purpose for air-
conditioning system.
9.4.1.10 For all air-conditioned area housing electronic equipment (e.g. control room), Chemical air
filters are required to be installed in fresh air circuit.
9.4.1.11 Contractor shall consider Heat Dissipation from Electrical Equipment, Lighting Load &
Occupancy while estimating the capacity of air-conditioning system.
9.4.1.12 Reheating of air shall be provided to correct Relative Humidity in monsoon. Heating shall be
electric type. Electric heaters shall be provided inside the duct/plenum in properly distributed
number of banks.
9.4.1.13 Electric motorized failsafe type fire dampers shall be provided in supply air ducts and return air
paths.
9.4.1.14 Fire Dampers shall be selected for maximum face velocity limited to 1500 fpm when these are
installed at main supply air ducts and 1000 fpm when installed at return air paths/openings.
9.4.1.15 Two stage air filtration shall be provided.
9.4.1.16 Safety factor shall be considered as minimum 12.5% in respect of Room Sensible Heat and
minimum 10% in respect of Room Latent Heat.
9.4.1.17 Fresh Air arrangement for each building; comprising of Bird Screen, Louvers, Volume Control
Damper, electric operated Fire Damper, Ducting with pre & fine dust filter, Centrifugal Fan
shall be provided. For all air-conditioned buildings housing electronic equipment (e.g. control
room,), Chemical air filters are required to be installed in fresh air circuit. Chemical filter shall
be selected considering outside/ambient air quality as ‘Gx’ and inside/room air quality after
chemical filter as ‘G1’ as per ISA-71.04-1985.
9.4.1.18 Supply air ducts shall be provided with air flow switch which shall trigger alarm in case of no /
low air flow.
9.4.1.19 CONFIGURATION OF AIR-CONDITIONING SYSTEM WITH AIR COOLED PACKAGE UNIT
(EACH SYSTEM CONSISTING OF BUT NOT LIMITED TO THE FOLLOWING):-.
i. Air-cooled packaged units comprising reciprocating/ scroll compressor, electric motor
for the compressor, air-cooled condenser with supports, evaporator, interconnected
insulated refrigerant piping complete with necessary fittings, control and line
accessories, first charge of refrigerant gas and oil.
ii. Fresh air arrangement, comprising of Chemical filter with fresh air fan and drive, Intake
louvers, bird screen and volume control damper.
iii. Insulated supply air ducting as per IS:655 complete with volume control damper,
splitter damper, guide vanes, fire resistant flexible connection between Package Unit
and ducting, air flow switch in main supply air ducts, duct supporting arrangement with
anchor fasteners etc.
iv. Fine filter section comprising of 18 Gauge G.I. plenum with necessary maintenance
windows, filter mounting frame, fine filter, Manometer across fine filters, one pressure
switch and pilot light on panel to indicate dirty condition of filter.
v. Supply air diffusers with volume control dampers and return air grills (return air grilles
to be provided all along the slits).

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 123 of 207

vi. Electric operated fire dampers in supply air ducts and return air paths.
vii. Duct mounted strip finned electric heaters complete with heating and safety thermostat
with suitable inspection window for heater maintenance.
viii. Pan type Humidifier in stainless steel construction to meet specified humidity
requirement in winter season.
ix. Carbon steel (IS-1239, black, heavy schedule) piping network with fittings to collect
condensate from Package Units and discharge to nearest rainwater shaft/ drain
outside the building at grade level. Condensate line shall have water seal arrangement
and fully insulated.
x. Controls, Instruments and safety devices required for smooth and unattended
operation of equipment/plants.
xi. Foundation/ Fixing nuts and bolts.
xii. Civil structural and Electrical works
xiii. Self standing/ wall mounted audio -visual annunciation panel.
9.4.1.20 CONFIGURATION OF AIR-CONDITIONING SYSTEM WITH SPLIT AIR-CONDITIONERS
(EACH SYSTEM CONSISTING OF BUT NOT LIMITED TO THE FOLLOWING):-.
i. Split air cooled air conditioners can be used only in areas like operator room etc, where
RH control is not required and no electronic equipment is expected.
ii. Air-Cooled Split air conditioners complete with all accessories and fittings. Split unit shall
have wall/ floor mounted indoor unit and remotely located air cooled condenser (outdoor
unit) with insulated refrigerant piping, Controls and line accessories, Initial charge of
refrigerant, oil and lubricants, Electrical and civil works as required .
iii. For all areas requiring 24 hrs air conditioning shall be provided with 100% redundancy.
9.4.2 TECHNICAL SPECIFICATIONS
All equipment shall be suitable for continuous operation for 8000 hrs. per year. System shall
be designed for 20 years life unless otherwise specified.
Refrigerant Compressor:-
The compressor shall be as per manufacturer’s standard design and the offered model shall
have proven track record of satisfactory operation for a minimum period of 8000 hours for
similar application. Electric driver rating shall be minimum 110% of the maximum power
required (including transmission losses) at operating conditions.
Condenser:-
The tubes shall not be less than 12.5 mm diameter or as per manufacturer’s standard and
shall be adequately supported to prevent tube vibration. Air cooled condensers shall have
seamless tubes and shall be complete with all accessories including fan with drive motor,
refrigerant receiver, refrigerant headers, supports etc. Electric driver rating for fan shall be
minimum 110% of the maximum power required (including transmission losses) at operating
conditions.
Evaporator:-

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 124 of 207

Tubes shall not be less than 12.5 mm diameter or as per manufacturer’s standard. Tubes shall
be adequately supported to prevent tube vibration. Gas superheating in DX-evaporator it-self
shall be ensured. Liquid entrainment to compressor shall be restricted by suitably designed
arrangement for flooded chiller.
Refrigeration Package Assembly:-
Skid shall be designed so as to provide maintenance accessibility and operation ease of
valves and controls. Instruments shall be easily readable. Lifting hook/eye shall be provided
for handling of equipment during maintenance. Steel structural members of the skid shall
conform to IS-2062/ASTM A 36.
Filters:-
i. Fine filters shall be provided downstream of Package Unit. Filters shall be capable of
filtering dust up to 5 microns particle with an efficiency of 95%.
ii. Fine filters shall be selected for a pressure drop of 6.5 mm WG maximum in clean
conditions.
iii. Inclined tube manometer with tubing shall be provided for indication of pressure drop
across fine filters.
iv. Fresh air filters of panel type shall be provided in fresh air intake point. These shall be
capable of filtering particles of 5 micron with 95% efficiency.
v. Chemical Filter shall be provided in fresh air circuit as per the requirement specified in
design basis/philosophy. Filtered fresh air shall be mixed with room-recirculated air
before passing through air handling units.
vi. Chemical filters shall be able to achieve G1 environment inside the room from outside
GX environment as per ANSI ISA-71.04-1985 standard.
vii. Chemical filter unit shall be fabricated from adequately reinforced 16 G GI sheet and
shall be skid mounted suitable for horizontal installation complete with fresh air fan, drive
motor and accessories including suitable canopy hood for motor if installed outside.
viii. Chemical air filter shall be selected for the chemical media life of minimum 1 year. The
outside gas concentration specified above shall be considered while evaluating the life.
Chemical filter supplier to furnish the calculations and nomographs etc. in support of the
chemical media life duly vetted by media manufacturer at post order stage.
ix. Two stage deep bed chemical filters shall be provided by Bidder- one module containing
Puracarb or equivalent media and other module containing chemisorbant or equivalent
media.
x. The pre-filters at inlet & fine filters at outlet shall be capable of removing dust particles of
10 microns with 90% efficiency & of 5+ microns with minimum 95% efficiency
respectively.
xi. Chemical air filter unit shall be selected considering the velocity across filter as ~0.51
m/sec.
xii. For outdoor located chemical filter units, fan shall be in blow through mode with respect
to chemical media filters and other particulate filters. Fan may be provided in draw
through mode for chemical filter units located inside the AHU/Package Unit room.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 125 of 207

xiii. Unit shall be suitable for outdoor/indoor installation as applicable & continuous operation.
The complete unit shall be properly mounted on the foundation and shall be provided
with interconnecting ducting upto fresh air opening in the Package Unit Room. The fresh
air ducting shall be suitably supported.
xiv. Chemical filter unit should have adequate provision for easy removal & servicing of filter
packs.
xv. Unit shall be provided with inclined tube manometer for measurement of differential
pressure across the filters.
Heating Unit:-
Heating shall be re-heating type as per psychometric process requirement. Heating shall be
electric. Electric strip heaters shall be complete with heating thermostats, safety thermostats.
Humidifier Unit:-
Humidifier shall be steam pan type. Pan humidifier shall be complete with immersion type
electric heaters actuated by humidistat, water float valve, stop valve in water make up line,
level switch interlocked with heaters. Pan shall be in stainless steel construction. The outer
surface shall be thermally insulated. The humidifier shall be sized to deliver 110% of capacity
required.
Refrigerant Piping:-
Refrigerant piping shall be of copper as per manufacturer’s standards. All piping network shall
be leak tested with nitrogen at 1.1 times of design pressure using soap water solution. The
piping network shall be further pressure tested with nitrogen at 1.1 times of design pressure
for minimum 24 hours. After establishing the capability to withstand test pressure, the piping
network shall be dried and vacuumised to 2.5 mm Hg absolute. Vacuum shall be broken with
dry nitrogen and the system shall be re-vacuumised to 2.5 mm Hg absolute. This vacuum
shall be held for 12 hours before charging the refrigerant. After charging of refrigerant, leak
detection shall be done using electronic or halide torch leak detector.
Fire Dampers:-
Fire dampers shall be installed in supply air and return air path. These shall conform to UL-
555 for 1.5 hour fire rating. Type test certificate for fire dampers (equal or higher size of same
design) shall be furnished. The fire dampers shall be spring return, motorized & fail safe type
with indication for open/ close position.
Air Distribution, Ducting, Diffusers / Grilles:-
i. Ducts shall be designed, fabricated and flanged as per IS-655 for static pressure up to
65 mm WG. In case, static pressure is more than 65 mm WG, SMACNA code shall be
followed for design and fabrication of duct.
ii. Ducts shall be fabricated using GI sheets having minimum 120 g/m2 of zinc coating.
iii. Duct hangers shall be supported with anchor fasteners in the roof.
iv. All flange joints shall have 6 mm thick Neoprene packing as gasket stuck to the flanges
with adhesive (viz., resins like araldite or equivalent).
v. All the duct shall be made air tight with the help of sealant (Foster 32:17 or MIRACLE D
617 or equivalent). Leak test shall be conducted on the duct before insulation.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 126 of 207

vi. Ductwork shall be provided with following accessories.

- Turning Guide Vanes.
- Extractor with operating lever.
- Splitter Damper with control rod & locking device.
- Volume control Damper (opposed bladed type with 18 gauge blades and 16 gauge
casing of GSS).
- Fire resistant flexible connection between duct chute and diffuser (if required).
- Access doors for heaters, fire dampers and filters.
vii. Supply air diffusers or grilles, as required, shall be provided and shall be fitted with
sponge foam tape. Volume control damper shall be provided with each supply air
diffuser/grille. Volume control damper shall be key operated from the front of
diffuser/grille. Supply air grilles shall be provided with vertical & horizontal adjustable
louvers.
viii. All return air diffusers/grilles, if required, shall be without volume control damper.
ix. Diffusers/grilles shall be of powder coated steel/ anodised aluminium construction with
anodized aluminium angle frame.
x. Diffusers/grilles shall not be supported from False Ceiling.
xi. Both horizontal branch and low-pressure ducts shall be designed by the “Equal Friction"
method with a pressure drop less than 2.5 mm WG/30 m. Duct velocity shall not exceed
9.2 m/sec for main supply air duct and 6.1 m/sec for return air duct. For branch ducts
leading to diffusers, velocity shall be restricted to 5.1 m/sec.
xii. All outlets / diffusers shall be designed with a terminal velocity not exceeding 3.0 m/sec.
Manufacturers’ published data shall be taken into account for proper air
throw/distribution, noise, and pressure drop. Selection must be made to ensure sound
levels below NC 35. Sound attenuators shall be installed in ducts, as required.
xiii. Where a branch duct takes off from a main supply air duct, an extractor shall be
installed. Each extractor shall be adjustable to a fixed position to divert the required
volume of air to each branch duct.
xiv. Transition sections should be constructed such that the included angle for a converging
section is less than 15 degrees and for diverging section, less than 10 degrees. When
space limitations require transitions using larger angles, splitters shall be installed in the
transition (except for fan discharge). Duct transition through fire rated wall should not
impair the rating of wall.
xv. Duct work shall be substantially supported with a maximum spacing of 2.0 meter.
Provide hangers for all fittings.
xvi. All damper linkage arrangement (automatic/manual) shall be of SS-304 material.
Insulation:-
The surfaces to be insulated shall be thoroughly cleaned and allowed to dry. Leak test shall be
carried out before insulation.
Hot Insulation:-

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 127 of 207

i. Insulation for personnel protection is applicable where exposed surface temperatures

exceed 650 C in normal and short term operating conditions. Insulation is not desired for
piping and equipment for which heat loss is desired except for personnel protection and to
avoid thermal stress problem. Bare surfaces of pipe/equipment shall be provided with one
coat of 20 micron min. (dry film thickness) heat resistant primer up to 120 C operating
temperature.
ii. Resin bonded mineral wool conforming to IS-8183 shall be used for hot insulation with
thermal conductivity not to exceed 0.43 mW/cm 0C at 500C mean temperature. Preformed
pipe sections/mattresses of min. density 140 kg/m3 /128 kg/m3 respectively shall be used.
The minimum thickness of insulation shall be as per table given below.
iii. Moisture barrier shall be provided for application up to 1250 C. A 3 mm wet thick coating of
mastic shall be applied to the surface of the insulation as soon as possible after erection,
to reduce the time the insulation is exposed to the weather to a minimum. Whilst this coat
is still wet, glass cloth shall be laid over the surface and embedded in the mastic. Care
shall be taken to ensure that the glass cloth is laid smooth and free from wrinkles and that
no pockets of air are trapped beneath the surface. At junctions in the glass cloth, the
overlap shall not be less than 75 mm. A second 3 mm thick coat of mastic shall be applied
after approx. 12 hours. When dry, this coating shall be a minimum of 1.5 mm thick. Care
must be taken, however, to ensure that the individual coats are not greater than 3 mm
(especially in corners), otherwise some cracking of dried coat may result. The total dry film
thickness of moisture seal shall not be less than 2.5 mm with a tolerance of -0% to +50%.
The mastic shall not be applied over wet insulation or until the adhesive is dry. During this
drying time, the insulation shall be protected from the weather by tarpaulin or similar
materials.
iv. Hot insulation shall be cladded with 26 SWG aluminium sheeting.
Cold Insulation:-
i. The ducts shall be insulated and finished as per Figure-1.
ii. Exterior insulation of duct shall consist of fibre-glass duct wrap with thermal conductivity
not to exceed 0.3 cal. cm/hr. cm2 °C (0.24 Btu in/ft2 hr. °F or 0.035 W/m-K) at 23.8°C mean
temperature differential. Duct wrap to have, factory applied, fire rated aluminium foil and
vapour barrier. Insulation shall be wrapped tightly on the duct work with all circumferential
joints butted with longitudinal joints overlapped a minimum of 50mm.
iii. Pipe insulation material shall be polyurethane foam with thermal conductivity not to exceed
0.019 KCal/hr. m 0C (0.16 Btu in/ft2 hr. °F) at 100C mean temperature after ageing.
iv. Vapour barrier shall be provided for application up to 1250 C. A 3 mm wet thick coating of
vapour seal mastic shall be applied to the surface of the insulation as soon as possible
after erection, to reduce the time the insulation is exposed to the weather to a minimum.
Whilst this coat is still wet, glass cloth shall be laid over the surface and embedded in the
mastic. Care shall be taken to ensure that the glass cloth is laid smooth and free from
wrinkles and that no pockets of air are trapped beneath the surface. At junctions in the
glass cloth, the overlap shall not be less than 75 mm. A second 3 mm thick coat of mastic
shall be applied after approx. 12 hours. When dry, this coating shall be a minimum of 1.5
mm thick. Care must be taken, however, to ensure that the individual coats are not greater
than 3 mm (especially in corners), otherwise some cracking of dried coat may result. The

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 128 of 207

total dry film thickness of moisture seal shall not be less than 2.5 mm with a tolerance of -
0% to +50%. The mastic shall not be applied over wet insulation or until the adhesive is
dry. During this drying time, the insulation shall be protected from the weather by tarpaulin
or similar materials.
v. The application, insulation material and recommended thickness are given as per table
given below.
Acoustic Insulation:-
i. Duct liner material shall have a flame spread rating not to exceed 25 and a smoke
developed rating not higher than 50 (NFPA 255 or ASTM E 84). Duct lining should not
flame, glow, smolder, or smoke when tested in accordance with ASTM C 411 at a
temperature of 121°C.
ii. Insulation shall not absorb more than 1.13% moisture by weight at the end of 72 hours
exposure to air at 49°C and 96% relative humidity. Thermal conductivity shall not exceed
0.3 cal cm/hr cm2 °C (0.24 Btu in/ft2 hr. °F or 0.035 W/m-K) at 23.8°C mean temperature
differential. Material shall not have a surface coating and shall not erode at velocities of 20
metres/sec. (4000 fpm).
iii. The liner shall be adhered to the duct sheets before assembly using a rubber based
adhesive spread over the entire surface. Ducts over 600mm shall have liner additionally
secured with welded nails and speed clips on 300mm centers in both directions. It shall be
covered by 0.5 mm perforated aluminium sheets having 3 mm perforation at 6 mm
centres.
iv. For all inspection covers and hatches on equipment, pump casing, valve bodies & flanges
more than 100 mm dia, the insulation shall be applied so as to facilitate easy removal and
replacement maintaining continuity of vapour seal.
Insulation Material and Thickness

Insulation Material Thickness

S.No Application Form
(Density) (mm)

1. Supply / Return air Resin bonded Fiber- Slab/Roll Supply Duct -

duct glass (24 kg/m3) 50mm /Return
Duct -25 mm

2. Outdoor Exposed -Do- -Do- 50

supply/return duct

3. Refrigeration Piping Polyurethane (35-40 Pipe Section 50

kg/m3)

4. Drain pipe -Do- Pipe Section 15

5. Acoustic treatment Resin bonded fiber Slab/Roll 40

glass (48 kg/m3)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 129 of 207

Insulation Material Thickness

S.No Application Form
(Density) (mm)

6. Pan Humidifier Resin Bonded Mineral Slab 75

Wool (128 kg/m3)

FIGURE-1
DUCT INSULATION

1) Self adhesive fixing pins with self-locking washer

2) GSS duct
3) Duct sealent on duct joints, foster 32:17 or miracle D617 or equivalent
4) Adhesive, foster 81:10 or equivalent on entire duct surface
5) Factory laminated aluminium foil faced fibre glass insulation material with joints
staggered and tightly pressed together with adhesive
6) Self adhesive aluminium tape (75 mm wide) for sealing of insulation joints
7) Insulation joint
8) Vapour barrier treatment for internal ducting as specified above in this
specification.
9) Vapour barrier treatment for external ducting as specified above in this
specification..
10) Mechanical protection for insulation of external ducting and internal ducting
exposed to view - 24 SWG aluminium cladding.
Note:- All adhesives and sealants shall be asbestos - free and non-
inflammable.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 130 of 207

Controls and Instruments:-

Vendor shall include all controls & instruments as required for safety & operational
requirements of the plant.
a. Main HVAC Control Panel:-
i. Automatic operation of all controls, wherever feasible, is required, with manual overdrive
for maintenance etc. The “Hand/Off/Auto” select switch shall be located on the front of
HVAC Control Panel. The “Auto” mode means that HVAC equipment are controlled by a
standalone PLC/Microprocessor based HVAC control panel. The “Manual” mode shall be
used only for testing purpose & manual operation &control of HVAC system.
ii. Supply air fan of chemical filter unit shall be started from the HVAC control Panel. If
standby fan is provided, standby fan shall be change over automatically by the failure
signal of the running fan.
iii. Electric duct heaters shall be controlled in one or more steps by the return air temperature
and interlocked with the flow switch installed on each electric duct heater so that electric
duct heater cannot be operated without the supply air flow. An automatic reset thermal cut-
off shall stop the electric duct heater when the high limit temperature is reached. Electric
duct heater shall restart automatically when the related return air temperature drops below
the setting point.
iv. Humidistat shall also be provided for monsoon reheat control. One humidistat shall
activate the electric heaters (reheat) in case the space humidity rises beyond the preset
limit. Another humidistat shall energize the humidifier when the humidity falls below the
preset limit. These humidistats shall also de-energize these devices when the desired
humidity is reached. Humidifier heaters shall be actuated by humidistat located in return air
duct.
v. Monsoon re-heaters /winter heaters shall operate only on running of AHU blower.
vi. All electric motor driven equipment shall be provided with local Start/Stop Push button
stations for operational requirements.
b. Audio-visual Annunciation Panel:-
i. It shall consist of facia type Annunciators having translucent plastic window of 35 mm x 50
mm (min.) size engraved with appropriate function in block letters for each alarm trip point.
Annunciators shall be suitable for operation on 24V D.C. and shall have a single alarm
buzzer common to all points. Three push buttons for audible alarm acknowledge, reset
and test with appropriate name plates shall be provided common to all alarm points.
Annunciators shall be solid state type of reputed make. Annunciators shall operate
satisfactorily between 80 and 110% of rated supply voltage. Annunciators may be a part of
HVAC control panel itself.
ii. Annunciators shall be provided for all faults covering atleast the following:-
a. Low oil pressure.
b. Low evaporator pressure.
c. High condenser pressure.
d. Compressor motor overload.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 131 of 207

e. Low water level in humidifier tank.

f. Blower motors overload.
g. Crankcase heater.
h. Open/close position of fire dampers.
i. Air-conditioning unit status-Run/Stop.
j. Fresh Air fan(Chemical Filter Unit) status-Run/Stop.
k. Auto change-over of standby fan & air-conditioning unit
l. Any other as necessary.
In the event of a fault, the particular window shall glow and the window will remain lighted
till the fault is rectified.
iii. Minimum 20% spare windows shall be provided on annunciator.
Inspection and Testing:-
Equipment shall be subjected to expediting, inspection and testing at vendor's/sub-vendor's
Works by Purchaser/its authorised inspection agency. Vendor shall submit Quality Assurance
(QA) plan before commencement of fabrication. Approved QA plan shall form the basis for
equipment inspection. Following equipment/items shall be subject to inspection/test at works
as a minimum:
i. Package AC units shall be subjected to Type Test as per applicable Indian Standard,
Production Routine Test as per approved QAP.
ii. Other items, equipment shall be inspected/ tested at shop as per approved QAP.
For Inspection and Testing at Site, vendor must perform all inspection and tests of the system
as a whole and of components individually as required, in accordance with the provisions of
the applicable ASHRAE standards. Vendor shall comply with the following procedures:
i. Inspection of raw materials to be used for fabrication and assembly and inspection of
manufacturer's test certificates.
ii. Pressure testing of pipe fit ups for refrigerant (Pneumatic test with dry nitrogen) and water
services (hydro test).
iii. Pressure testing, leak testing of complete piping network for refrigerant services.
iv. Inspection of air distribution system for proper location and installation against design
drawings. Inspection of ducting supports, its location. Leak testing of ducting system
before application of insulation.
v. Inspection of duct insulation for its material, thickness, vapour barrier treatment and finish.
vi. Balancing of air distribution system to obtain the air quantities across various air terminals
as called for in the engineering drgs.
vii. Noise level test for various rotating/reciprocating equipment.
viii. Checking of electrical circuits (Power and control) and checking functioning of controls of
refrigerant system and other circuits of air conditioning plant.
ix. Checking of assemblies for MCC, control panel, local panel, annunciation panel etc.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 132 of 207

x. Checking of calibration of controls and instrumentation.

xi. Inspection of complete electrical installation at site and clearance from local authorities.
NOTE:
Inspection & testing procedure mentioned above is for general guidance & information of
vendor and inspection by purchaser/consultant is strictly not limited to these. Inspection
engineer of Purchaser/consultant will have full right to have detailed inspection of project as
desired by inspection engineer. Co-ordination of inspection agency of purchaser/consultant
with his factory/erection site will be sole responsibility of successful vendor after placement of
order for complete air conditioning plant covered under these specifications.
Any or all the tests, at Purchaser's option, shall be witnessed by Purchaser/its authorised
inspection agency. However, such inspection shall be regarded as check-up and in no way
absolve the vendor of his responsibility.
Performance Testing and Guarantees:-
Performance Testing:-
i. Vendor shall give three seasonal tests for (i) summer, (ii) monsoon & (iii) winter to
determine the equipment capacity and performance of the system in accordance with
applicable Standards. Period of each test shall be at least 72 hours and time for each test
will be fixed up mutually with the purchaser.
ii. The vendor shall operate, test and adjust all equipment and balance the system.
Following test readings shall be recorded during the performance testing:
Test Readings
1. Package AC unit
Air temperature – entering (D.B) (0C)
Air temperature – entering (W.B) (0C.)
Air temperature – leaving (D.B) (0C.)
Air temperature – leaving (W.B) (0C)
Blower air flow (m3 /hr.)
Blower Speed (RPM)
Blower Static/Total Pressure (mm WC)
Blower outlet velocity (m/s)
Direction of rotation CW/CCW
Velocity of air across various components of air handling unit.
Power consumption at 100% load and at each step of capacity regulation.
2. Electric motor
Starting current/No load current (A)
Motor terminal current (A)
Power factor

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 133 of 207

Supply voltage (volts)

kwh for compressor motor
3. Supply Air Grilles/ Diffusers
Air flow rate (m3 /hr.)
Air temperature (D.B) (0C)
Air temperature (W.B) (0C)
4. Room conditions
D.B.T (0C)
W.B.T (0C)
Differential Pressure with respect (mm WC)
to atmosphere/adjacent area (for pressurized area)
Vendor shall bring all required testing instruments at site duly calibrated. Plant shall be
formally taken over by purchaser after witnessing the seasonal performance tests
successfully.
Special Tools & Tackles:-
Vendor shall provide one set of following special tools & tackles as a minimum for operation &
maintenance along-with each Air-conditioning plant.

S.NO. DESCRIPTION QTY.

1. Flaring Tools up to 3/4" (19 mm) Size One Set

2. Gas Charging manifold with Cylinder Adopter One Set

3. Halide Leak Detector One

4. Digital Psychrometer One

Pressure Gauge 0-300 PSI and Compound Gauge 30"
5. One Set
Vacuum-150 PSI for Refrigerant Line
6. Digital Anemometer One

9.5 MATERIAL HANDLING EQUIPMENT

9.5.1 Basis of Design and General Requirements-EOT/HOT Cranes
a. These shall be installed in re-circulating cooling water pump house

b. Material handling facilities for normal maintenance of rotating equipment shall be provided
as per the following criteria:
S.No. Type of Eqpt. Type of Maintenance Facility Remarks
(i) Centrifugal Pumps Trolley mounted CP Block Refer Piping EDB.
+ Monorail

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 134 of 207

(ii) Reciprocating Pumps --- do --- Excluding Metering

Pumps
Note-1: Electric motor driver (if applicable) shall be considered as a single component for
maintenance except for single bearing electric motors where motor stator & rotor shall
be considered as individual components.
c. Hand Operated Travelling (HOT) cranes are used when the loads to be handled are within
10T and span not exceeding 10 mtr, the lift requirement is moderate, and frequent or fast
crane operation is not foreseen. Electrically Operated Travelling (EOT) cranes are used
where the requirements are more demanding.
d. The bridge structure of Overhead Travelling Cranes shall be made from box (double web)
type, plate type, or fabricated from rolled sections. The structure can be single girder or
double girder type. The use of single girder bridge is limited to lifting capacities upto 5T and
span lengths upto 10 metre. In case either of these values is exceeded, the double girder
bridge shall be used.
e. For cranes which are to operate in areas classified as hazardous, besides ensuring that all
electrical components are certified for use in the specified hazardous areas, materials of
construction for rubbing, non-lubricated metallic parts should be specified in such a way
that the possibility of sparking during operation is eliminated. This is done by having one
part in every such pair made from a suitable non-ferrous material such as HTB/ Aluminium
bronze.
f. Safe Working Load (SWL) shall be decided based on the maximum maintenance weight to
be lifted by crane. Accordingly next higher standard crane capacity shall be considered.
g. Cranes shall be designed for minimum head room above the highest hook position and for
closest approach of the hooks to each end stop.
9.5.2 Codes and Standards
9.5.2.1 Codes and Standards to be followed are based on following Indian Standards, and the
standards referred therein, which shall be deemed to be part of this standard:

IS-3177 Code of practice for Electric Overhead Travelling Cranes and

Gantry Cranes other than Steel Work Cranes.

IS-807 Code of practice for Design, Manufacture, Election and

Testing (Structural Portion) of Cranes and Hoists.

IS:3832 Hand-operated Chain Pulley Block-Specification.

IS: 15560 Specification for Point hooks with shank up to 160 Tonne.

IS:3443 Crane Rail Sections.

Latest revision of the above-mentioned standards as on the date of enquiry shall be applicable
9.5.2.2 Other international standards may also be acceptable subject to their being equivalent or
superior with prior approval of purchaser.
9.5.2.3 For provisions not covered by the above codes & standards, applicable good engineering
practices and norms of the industry shall be applicable.
9.5.2.4 Amendment to the above referred standards:-
9.5.2.5 Addition / Deletion / Modifications to IS-3177: 1999 (Reaffirmed 2006) applicable to EOT
a) Clause no. 7.4.8.2 (Addition): A full-length platform shall be provided on drive side girder.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 135 of 207

Two short platforms shall be provided on non-drive side girder at both ends.
b) Clause no. 8.1.1 (Modification): Lifting hooks shall comply with IS 15560 and IS 5749.
c) Clause no. 8.1.2 (Modification): Hook latch shall be provided on all hooks.
d) Clause no. 8.3.1 (Addition): Wire ropes shall be either 6x36 or 6x37 construction, unless
specified otherwise.
e) Clause no. 8.4.3 (Modification): The drum shall be flanged on both ends.
f) Clause no. 8.4.7 (Modification): Cast iron drum shall not be acceptable.
g) Clause no. 8.5.4 (Modification): Nylon sheaves shall not be acceptable.
h) Clause no. 8.6.3 (Modification): Wheel hardness value specified is not applicable for
hazardous area Cranes having HTB/Aluminium bronze tyres.
i) Clause no. 8.6.6 (Addition): For wheels with HTB/Aluminium bronze tyres, the minimum
core diameter of the wheel on which the HTB/Aluminium bronze tyre is shrunk, shall be
calculated as per the formula given in IS-3177.
j) Clause no. 8.6.11 (Addition): The width of wheel tread shall be 40mm and 20mm more
than the rail head, for Long travel and Cross travel wheels respectively, unless specified
otherwise.
k) Clause no. 8.7.1 (Modification): All bearings shall be anti friction type with dust proof
seals. Bearings L10 life shall be minimum 25000 hrs. All bearings shall be of
SKF/FAG/NTN make only.
l) Clause 8.7.3 (Deletion): Clause not applicable.
m) Clause 8.11.2 (Modification): Plastic/Rubber/Polyurethane buffers are not acceptable.
However, for hazardous area Cranes, the buffer striking surface shall be lined with
HTB/Aluminium bronze/Rubber/Polyurethane liner.
n) Clause 8.12.3 (Addition): In case electro-hydraulic thrustor type brake is provided for
hoisting motion, the same shall be provided with anti drop circuitry to arrest dropping of
load while brake is applied.
o) Clause 12 to 25 – Section-3 (Modification): In case of any conflict between Electrical
Specifications of Material Requisition/Tender and electrical requirements specified in the
above referred Indian Standard, the former shall prevail.
9.5.2.6 Addition / Deletion / Modifications to IS-3177: 1999 (Reaffirmed 2006) applicable to HOT
i) Clause no..4.2.b (Deletion): Clause deleted.
ii) Clause no..4.2.f (Deletion): The part “such as motors” from sentence deleted.
iii) Clause no. 7.4.8 (Deletion): Clause deleted.
iv) Clause no. 8.1.2 (Modification): Hook latch shall be provided on all hooks.
v) Clause no. 8.3 (Deletion): Clause deleted.
vi) Clause no. 8.4 (Deletion): Clause deleted.
vii) Clause no. 8.5 (Deletion): Clause deleted.
viii) Clause no. 8.6.1 (Addition): Wheels for Bridge shall be double flanged with tread and
flange machined accurately to size and flanges tapered and radiused. The wheels shall
be of single piece type. However for cranes working in hazardous area, wheels with
tyre of non ferrous metallurgy as specified in cl. no. 3.6 below shall be provided.
ix) Clause no. 8.6.3 (Modification): Wheel hardness shall not be applicable for hazardous
area Cranes having HTB/Aluminium bronze tyred wheels.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 136 of 207

x) Clause no. 8.6.4 (Modification): For Cranes working in hazardous areas, wheels shall
be provided with HTB/Aluminium bronze tyres. The minimum thickness of tyres shall be
30 mm at the tread.
xi) Clause no. 8.6.6 (Addition): For wheels with HTB/Aluminium bronze tyres, the minimum
tread diameter of the wheel on which the HTB/Aluminium bronze tyre is shrunk, shall
be calculated as per the formula given in IS-3177.
xii) Clause no. 8.6.11 (Addition): The width of wheel tread shall be 40mm and 20mm
greater than the rail head, for Long travel and Cross travel wheels respectively, unless
specified otherwise.
xiii) Clause no. 8.7.1 (Modification): Only anti-friction bearings shall be used. Bearing
enclosure shall be dust tight. All bearing make shall be of SKF/FAG/NTN make only.
Bearing caps/nipples shall be provided with fittings for lubrication.
xiv) Clause 8.7.3 (Deletion): Clause deleted.
xv) Clause 8.8.3 (Deletion): Clause deleted.
xvi) Clause 8.11.2 (Modification): Buffers shall be made from resilient plastic, rubber or
polyurethane.
xvii) Clause 8.12 (Deletion): Clause deleted.
xviii) Clause 9.1 (Deletion): From second paragraph the sentence “suitable guards shall be
provided on the down shop lead side to prevent accidental contact between wire ropes
or hook block or lifting attachments and live conductors” shall be deleted.
xix) Clause 9.2 (Deletion): The term “electrical” deleted.
xx) Clause 9.3 (Deletion): The term “electrical” deleted.
xxi) Clause 11.2.b (Deletion): Clause deleted.
xxii) Clause 11.4.f (Deletion): Clause deleted.
xxiii) Clause12 to 25 (Section 3) (Deletion): Clause deleted.
xxiv) Clause 26.2 (Deletion): The term “electrical” deleted.
xxv) Clause 26.3.10 to 26.3.17 (Deletion): Clause deleted.
xxvi) Clause 28.1 & 2(Deletion): Clause deleted.
xxvii) Clause 28.3 (Modification): Load test shall be carried out to the extent applicable for
H.O.T crane.
9.5.2.7 Addition / Deletion / Modification to IS 807: 2006
i) Clause no. 24.1 (Addition): End carriage shall be made from rolled steel sections
welded together to form a box. The design shall be such that the load is uniformly
distributed. For the attachment of end carriages to the main girders, gusset plates or
diagonal bracings shall be employed to provide lateral strength.
End carriages shall be designed so as to enable the track wheels to be withdrawn
readily. Jacking pads shall be provided for jacking up the crane for changing crane
wheels.
ii) Clause no. 24.2 (Addition): Square bar type rail may be provided for LT motion, if
specified in data sheet.
9.5.2.8 Addition / Deletion / Modification to IS 3832: 2005 (along with Amendment no. 1, December
2005)
i. Clause no. 4.2.1 (Modification): Mechanism class 2 shall be considered for design of

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 137 of 207

chain pulley Block unless otherwise specified in the data sheet.

ii. Clause no. 11.2 (Modification): The chain pulley block shall carry ISI (BIS) stamp.
iii. Clause no.5.1 (Addition): The frame shall be built from steel plates with bolted/welded
construction.
iv. Clause no. 5.2 (Addition): All gears shall be machine cut.
v. Clause no. 5.5 (Addition): Only anti friction bearing shall be used. Bearings L 10 life shall
be minimum 25000 hrs. All bearings shall be of SKF/FAG/NTN make only.
vi. Clause no. 5.6 (Modification): The block shall be provided with adequate facilities for
lubrication and same shall be clearly indicated in the maintenance manual.
vii. Clause no. 5.7.1 (Addition): Hooks (both top and bottom) shall be provided with safety
latches to prevent accidental unhooking unless otherwise stated.
viii. Clause no. 5.7.1.2 (Modification): First line to be modified as “Bottom hook shall be
provided with thrust bearing to enable it to rotate freely under load so as to prevent
twisting of the load chain.
ix. Clause no. 5.10.3 (Modification): The length of hand chain shall be such that the lowest
point of the suspended loop shall be 400 mm above operating level.
x. Clause no. 5.11 (Addition): The trolley for the chain pulley block shall be geared type,
fabricated construction, 4 wheeled, driven by hand chain and shall have provision for
mounting the chain pulley block. Trolley shall be designed to suit the suitable joist size
and the hoisting capacity.
9.5.3 TECHNICAL REQUIREMENTS:-
9.5.3.1 E.O.T. CRANES:-
9.5.3.1.1 Unless otherwise stated, the following hoisting and travel speeds with corresponding
acceleration shall be used:-
Speed Acceleration
Hoisting : 2.0 m/min. 7 cm/s2
Cross travel : 10.0 m/min. 7 cm/s2
Long travel : 15.0 m/min. 8 cm/s2
Higher operating speeds may be considered for higher lifts and longer bay lengths.
Suitable inching (creep) speed mechanisms shall be provided for main hook and auxiliary
hook (if applicable) to facilitate accurate spotting of the load. Creep speed for main hoist
and Auxiliary hoist shall be 10% of the main hoisting speed and Auxiliary speed
respectively.
9.5.3.1.2 EOT Crane shall be designed for duty class of M-5 as per IS: 3177 & IS: 807.
9.5.3.1.3 DC electromagnetic or AC electro- thrustor brake shall be used for the hoisting motion. Electro
hydraulic thrustor-operated brakes shall be used for the cross and long travel motions.
9.5.3.1.4 Auxiliary hoist shall be provided in case of cranes having capacity 15T and above. Capacity of
Auxiliary hook shall be 20% of the main hook capacity.
9.5.3.1.5 Maintenance walkways shall be provided on both sides along the long travel.
9.5.3.2 H.O.T CRANES
9.5.3.2.1 The Crane may be under slung type if specifically asked in data sheet. For under slung
cranes, geared type four wheeled trolley shall be provided. The wheels/runner shall be
suitable for the flange of the I sections used for the girders.
9.5.3.2.2 The bridge drive assembly shall consist of reduction gear assemblies with shaft extensions

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 138 of 207

and couplings to connect the bridge cross shaft extensions to truck wheels. The travelling
motion shall be communicated by endless hand chain wheel to a steel cross shaft, positively
driving one travelling wheel in each end carriage. The cross shaft shall be suitably supported.
The wheels and cross shaft shall have roller/ball bearings.
9.5.3.2.3 Cross traversing motion shall be transmitted through suitable gearing by an endless hand
chain and chain wheel.
9.5.3.2.4 The following material shall be used for construction of various parts of the crane.

SL
Name of Part Material
No.
1. Girder CS weldable quality as per IS 2062 (100%
Radiography to be taken on all Butt welded joints)
2. End carriage CS weldable quality as per IS 2062
3. Hand chain wheel CI grade 25 of IS 210, or fabricated steel or pressed
for trolley steel metal.
4. Hand chain for LT Grade L3 as per IS 2429
and Trolley
5. CT trolley CS weldable quality as per IS:2062
6. Rails for LT Crane rails as per IS: 3443 or Square Bar as per IS:
2062, as applicable.
7. Wheels for LT 55C8 (Old designation:C55Mn75) as per IS:1570
(part 2/sec 1)
8. Gears 45C8 (Old designation :C45) as per IS:1570 (part
2/sec 1)
9. Pinions 50C4 (Old designation:C50 ) as per IS:1570 (part
2/sec 1)
10. Shafts 30C8 (Old designation :C30) as per IS:1570 (part
2/sec 1)
11. Axles 45C8 (Old designation :C45) as per IS:1570 (part
2/sec 1)
12. Couplings Forged steel as per IS:1570
13. Suspension pin in 50C4 (Old designation:C50 ) as per IS:1570 (part
the trolley 2/sec 1)

All materials shall be of tested quality and shall conform to the standards as mentioned
above.
9.5.3.2.5 HOT cranes shall be designed for minimum head room above the highest hook position and
for closest approach of the hooks to each end stop.
9.5.3.2.6 The cranes shall be designed for installation in shed/house and all the components shall be
designed according to the area classification as specified in the Electrical specifications.
9.5.3.2.7 The cranes shall be designed, engineered, manufactured, inspected & tested (at
manufacturer’s work & at site) as per IS: 3177 standard, wherever applicable.
9.5.3.2.8 For site testing of cranes, purchaser shall provide the test load. The vendor shall make his
own arrangements for shifting of test loads available at various locations inside the plant, to
the erection place where load testing will be carried out for the crane and return back the same
as per instructions of Engineer-In-Charge.
9.5.3.3 CHAIN PULLEY BLOCK
9.5.3.3.1 Special Requirements for Hazardous Area Chain Pulley Block

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 139 of 207

The materials for non-lubricated rubbing parts shall be of non-sparking type (non-ferrous).
The suggested materials for such components are as follows:

Part/Component Material of Construction

A Lifting Mechanism

Ratchet wheel, chain Solid construction in Aluminium Bronze (IS -305)/

guides High Tensile Brass (IS - 304)

Hand chain wheel Solid construction of Aluminium Bronze/ High Tensile

Brass (IS- 304)/ Phosphor Bronze (IS-28)
Load chain wheel Solid construction in Aluminium Bronze (IS -305)/
High Tensile Brass (IS - 304)
Hook (Top & bottom) Bronze coated forged alloy steel/Forged Stainless
Steel.
B Trolley Mechanism

Hand chain wheel guides Solid construction in Aluminium Bronze (IS-305)/ High
Tensile Brass (IS-304)/ Phosphor Bronze (IS-28).
Hand chain wheel Solid construction of Aluminium Bronze (IS-305)/
High Tensile Brass (IS-304)/ Phosphor Bronze (IS-
28).
Ungeared and geared Solid construction in Aluminium Bronze (IS-305)/High
wheels Tensile Brass (IS-304) or Tyres of Aluminium Bronze
(IS-305)/High Tensile Brass (IS-304) on solid CI /CS/
alloy steel wheels.
C Hook Bronze coated forged alloy steel/forged stainless
steel.

9.5.3.3.2 Minimum Safe Working Load (SWL) shall be decided based on the maximum maintenance
weight to be lifted by crane. Accordingly next higher standard crane capacity shall be
considered.
9.5.3.3.3 Chain Pulley Block with geared trolley or hook mounted depending on service requirement
shall be provided for areas with equipment / component to be lifted for erection and
maintenance weighing 0.5 MT to 5 MT and lift is less than 5 m.
9.5.3.3.4 As a minimum, CP Blocks (trolley-mounted type) shall be provided for normal maintenance
work on cooling tower fan, gearbox, motor and handling chemicals.
9.5.3.3.5 Chain pulley blocks shall be of standard capacities.
9.5.3.3.6 CP Blocks shall be of detachable type suitable for mounting on trolleys of same rating /
Capacities.
9.5.3.3.7 CP Blocks shall be designed for duty Class-2 as per IS: 3832.
9.5.3.3.8 Wherever two chain pulley blocks are required, each of 75% capacity of the total weight shall
be provided.
9.5.3.3.9 All Chain Pulley Blocks shall be spark proof construction irrespective of hazardous area
classifications.
9.5.3.4 Inspection and Testing

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 140 of 207

Equipment shall be subjected to stage-wise expediting, inspection and testing at vendor's/sub-

vendor's works by purchaser/its authorised inspection agency. Vendor shall submit Quality
Assurance (QA) plan before commencement of fabrication. Approved QA plan shall form the
basis for equipment inspection.
Testing at Works:-
9.5.3.4.1 E.O.T Crane
a) Vendor shall perform tests and inspection necessary to ensure that the material and
workmanship conform to the requirement of Clause 26 and 27 of IS-3177. Load and
over load tests shall also be carried out at vendor’s works.
b) Any or all the tests, at purchaser's option, shall be witnessed by purchaser/its
authorised inspection agency. However, such inspection shall be regarded as check-up
and shall in no way absolve the vendor of his responsibility.
9.5.3.4.2 H.O.T Crane
a) Vendor shall perform tests and inspection necessary to ensure that the material and
workmanship confirm to the requirement of this specification.
b) Testing at vendors works shall be carried out in accordance with IS:3177 and 3832 and
shall include following tests as minimum:
- Full load and 125% overload test for hoist & cross travel motions at works (chain pulley
block shall be separately tested for operational proof as per cl. No. 9.2 of IS 38382).
- Deflection Test at Works.
c) Any or all the tests, at purchaser’s option, shall be witnessed by purchaser/its
authorised inspection agency. However, such inspection shall be regarded as check-up
and in no way absolve the vendor of his responsibility.
9.5.3.4.3 Chain Pulley Block
a) Vendor shall perform operational Proof Test, as a minimum, necessary to ensure that
the material and workmanship conform to the requirement of Clause 9.2 of IS- 3832.
b) The trolley (if applicable) shall be tested for smooth operation under loaded
condition.
c) Certificate of test and examination shall be issued with all the chain pulley blocks as
specified in clause 10.2 of IS – 3832.
d) Any or all the tests, at purchaser’s option, shall be witnessed by purchaser/its
authorized inspection agency. However, such inspection shall be regarded as check-up
and in no way absolve the vendor of his responsibility.
9.5.3.5 Performance Testing and Guarantees
9.5.3.5.1 E.O.T Crane
a) A field performance test shall be conducted by the vendor to demonstrate the
performance of the equipment after commissioning in accordance with PG test
procedure.
b) The procedure of performance testing shall be submitted for Purchaser's review and
shall be mutually agreed between the purchaser and the vendor.
c) A field performance test shall be conducted by the vendor to demonstrate the
performance of the Crane after commissioning as per clause 28 of IS-3177. Following
parameters shall be guaranteed.
i. SWL of Main and Auxiliary Hoists

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 141 of 207

ii. LT, CT and Hoisting Speeds.

iii. Deflection of bridge girder
9.5.3.5.2 H.O.T Crane
a) A field performance test shall be conducted by the vendor to demonstrate the
performance of the equipment after commissioning in accordance with test procedure.
The procedure of performance testing shall be submitted for Purchaser's review and
shall be mutually agreed between the purchaser and the vendor.
b) Testing at site shall be carried out in accordance with IS: 3177. Following parameters
shall be guaranteed and demonstrated during the performance testing.
i) SWL of Hoist
ii) Deflection of bridge girder
c) All parts of the crane shall operate satisfactorily with no undue friction, noise or display
of any other unfavourable characteristics during the performance test.
9.5.3.5.3 General
a) All parts of the hoist shall operate satisfactorily with no undue friction, noise or display
of any other unfavourable characteristics during the performance test.
b) All equipment and component parts shall be guaranteed by the vendor against
defective material and design for a period as specified in Purchaser’s general purchase
conditions.
c) If any defect occurs during the guaranteed period the Vendor shall make all necessary
alterations, repairs and replacement at their own cost.
Necessary instruments for the performance testing shall be arranged by the vendor,
and shall be tested and calibrated before undertaking the performance test. Only test
load shall be provided by purchaser near test site.
10.0 PIPING

10.1 FABRICATION AND ERECTION OF PIPING

10.1.1 SCOPE OF WORK OF CONTRACTOR
Generally the scope of work of contractor shall include the following:
Transportation of required piping materials , pipe support and all other necessary piping
materials from Owner's storage point or contractor’s storage point (in case of contractor's
scope of supply) to work site/shop including raising store requisitions for issue of materials in
the prescribed format & maintaining an account of the materials received from Owner's stores.
Piping materials include the following but not limited to the same.
a. Pipes (All sizes and schedule)
a. Flanges (All sizes, types & Pressure ratings)
b. Fittings (All sizes, types and schedule)
c. Valves (All sizes, types and Ratings)
d. Gaskets (All sizes, types & Ratings)
e. Bolts, Nuts or M/C Bolts (All types)
f. Expansion Joint/Bellows (All types)
g. Speciality items like steam traps, strainers etc.
h. Online instruments like control valve, orifice flange, rotameter, safety valves etc.

- Fabrication and erection of pipe supports like shoe, saddle, guide, stops, anchors, clips,

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 142 of 207

cradles, hangers, turn buckles, supporting fixtures, bracket cantilevers, struts, tee-posts
including erection of spring supports.
- Fabrication of piping specials like reducers & mitres etc.
- Fabrication of plain and threaded nipples from pipes as required during erection.
- Fabrication of swage nipples as and when required.
- Fabrication of flange, reducing flange, blind flange, spectacle blinds as and when required.
- Fabrication of stub-in connection with or without reinforcement.
- Grinding of edges of pipes, fittings, flanges etc. to match mating edges of uneven/different
thickness wherever required.
- Obtaining approval for drawings prepared by contractor from statutory authority, if required.
- Spun concrete lining of the inside of pipes 3" NB & above including fittings and flanges as
required in accordance with specification.
- Radiography, stress relieving, dye penetration, magnetic particle test etc. as required in
specification.
- Casting of concrete pedestals and fabrication & erection of small structures for pipe supports
including supply of necessary materials.
- Providing insert plates from concrete structures and repair of platform gratings around pipe
openings.
- Making material reconciliation statement and return of Owner's supply left over materials to
Owner's storage.
- Flushing and testing of all piping systems.
- Submission of job execution procedure for review and approval of Engineer-in-charge covering
all above activities.
10.1.2 FABRICATION
10.1.2.1 Piping Material
Pipe, pipe fittings, flanges, valves, gaskets, studs bolts etc. used in a given piping system
shall be strictly as per the "Piping Material Specification" for the "Pipe Class" specified for that
system. To ensure the above requirement, all piping material shall have proper identification
marks as per relevant standards / EIL specifications. Contractor shall provide identification
marks on left over pipe lengths wherever marked up pipe lengths have been fabricated /
erected.
10.1.2.2 IBR Piping
Contractor shall be supplied generally with all drawings for steam piping falling under the
purview of Indian Boiler Regulations duly approved by Boiler Inspectorate. The Contractor
shall carry out the fabrications, erection and testing of this piping as per requirements of Indian
Boiler Regulations and to the entire satisfaction of the local Boiler Inspector. The Contractor
shall also get the approval of IBR inspector for all fabrication and testing done by him at his
own cost. All certificates of approval shall be in proper IBR forms.
Approval of boiler inspector on the drawings prepared by the contractor shall be obtained by
the contractor at his own cost.
10.1.2.3 Pipe Joints
The piping class of each line specifies the type of pipe joints to be adopted. In general, joining
of lines 2" and above in process and utility piping shall be accomplished by butt-welds. Joining
of lines 1-1/2" and below shall be by socket welding/butt welding/threaded joints as specified
in "Piping Material Specifications".
Flange joints shall be used at connections to Vessels, Equipment’s, Valves and where
required for ease of erection and maintenance as indicated in drawings.
10.1.2.3.1Butt Welded and Socket Welded Piping
End preparation, alignment and fit-up of pipe pieces to be welded, welding, pre-heating, post-

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 143 of 207

heating and heat treatment shall be as per procedure.

10.1.2.3.2Screwed Piping
In general, Galvanized piping shall have threads as per IS:554 or ANSI B2.l NPT as required
to match threads on fittings, valves etc. All other piping shall have threads as per ANSI B2.l,
tapered unless specified otherwise.
Threads shall be clean cut, without any burrs or stripping and the ends shall be reamed.
Threading of pipes shall be done preferably after bending, forging or heat treating operations.
If this is not possible, threads shall be gauge checked and chased after welding heat treatment
etc.
During assembly of threaded joints, all threads of pipes and fittings shall be thoroughly
cleaned of cuttings, dirt, oil or any other foreign matter. The male threads shall be coated with
thread sealant and the joint tightened sufficiently for the threads to seize and give a leak proof
joint.
Threaded joints to be seal-welded shall be cleaned of all foreign matter, including sealant and
made up to full thread engagement before seal welding.
10.1.2.3.3Flange Connections
All flange facings shall be true and perpendicular to the axis of pipe to which they are
attached. Flanged bolt holes shall straddle the normal centerlines unless different orientation is
shown in the drawing.
Wherever a spectacle blind is to be provided, drilling and tapping for the jack screws in the
flange, shall be done before welding it to the pipe.
10.1.2.3.4Branch Connections
Branch connections shall be as indicated in the piping material specifications. For end
preparation, alignment, spacing, fit-up and welding of branch connections refer welding
specifications. Templates shall be used wherever required to ensure accurate cutting and
proper fit-up.
For all branch connections accomplished either by pipe to pipe connections or by using forged
tees the rates quoted for piping shall be inclusive of this work.
Reinforcement pads shall be provided wherever indicated in drawings/ specifications etc.
10.1.2.4 Mitre Bends and Fabricated Reducers
The specific application of welded mitre bends and fabricated reducers shall be governed by
the Piping Material Specifications. Generally all 90 deg. mitres shall be 4-piece 3-weld type
and 45 deg. mitres shall be 3-piece 2-weld type as per EIL Standard unless otherwise
specified. Reducers shall be fabricated as per directions of Engineer-in-Charge. The
radiographic requirements shall be as per Material Specifications for process and utility
systems and NDT Specification for steam piping under IBR, radiographic requirements of IBR
shall be complied with.
10.1.2.5 Cutting and Trimming of Standard Fittings & Pipes
Components like pipes, elbows, couplings, half-couplings etc. shall be cut / trimmed / edge
prepared wherever required to meet fabrication and erection requirements, as per drawings
and instructions of Engineer-in-Charge. Nipples as required shall be prepared from straight
length piping.
10.1.2.6 Galvanised Piping
Galvanised carbon steel piping shall be completely cold worked, so as not to damage
galvanised surfaces. This piping involves only threaded joints and additional external threading

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 144 of 207

on pipes may be required to be done as per requirement.

10.1.2.7 Miscellaneous
Contractor shall fabricate miscellaneous elements like supporting elements like turn buckles,
extension of spindles and interlocking arrangement of valves, operating platforms as required.
Spun Concrete Lining: The work of inside spun concrete lining of pipes and specials of
diameter 3" and above shall be done as per material specifications and special condition
contract.
10.1.3 ERECTION
10.1.3.1 Cleaning of Piping before Erection
Before erection all pre-fabricated spool pieces, pipes, fittings etc. shall be cleaned inside and
outside by suitable means. The cleaning process shall include removal of all foreign matter
such as scale, sand, weld spatter chips etc. by wire brushes, cleaning tools etc. and blowing
with compressed air/or flushing out with water.
10.1.3.2 Flange Connections
- While fitting up mating flanges, care shall be exercised to properly align the pipes and to
check the flanges for trueness, so that faces of the flanges can be pulled together, without
inducing any stresses in the pipes and the equipment nozzles. Extra care shall be taken
for flange connections to pumps, turbines etc. The flange connections to these equipment
shall be checked for misalignment, excessive gap etc. after the final alignment of the
equipment is over.
- Temporary protective covers shall be retained on all flange connections of pumps,
turbines, and other similar equipment, until the piping is finally connected, so as to avoid
any foreign material from entering these equipment.
- The assembly of a flange joint shall be done in such a way that the gasket between these
flange faces is uniformly compressed. To achieve this the bolts shall be tightened in a
proper sequence. All bolts shall extend completely through their nuts but not more than
1/4".
- Steel to C.I. flange joints shall be made up with extreme care, tightening the bolts
uniformly after bringing flange flush with gaskets with accurate pattern and lateral
alignment.
10.1.3.3 Vents and Drains
High point vents and low point drains shall be provided. The details of vents and drains shall
be as per piping material specifications / job standards.
10.1.3.4 Valves
Valves shall be installed with spindle / actuator orientation / position as shown in the layout
drawings. Care shall be exercised to ensure that globe valves, check valves, and other uni-
directional valves are installed with the "Flow direction arrow "on the valve body pointing in the
correct direction.
10.1.3.5 Bolts and Nuts
The Contractor shall apply molycoat grease mixed with graphite powder (unless otherwise
specified in piping classes) all bolts and nuts during storage, after erection and wherever
flange connections are broken and made-up for any purpose whatsoever. The grease and
graphite powder shall be supplied by the Contractor within the rates for piping work.
10.1.3.6 Pipe Supports
Pipe supports are designed and located to effectively sustain the weight and thermal effects
of the piping system and to prevent its vibrations. Location and design of pipe supports will be

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 145 of 207

shown in drawings.
10.1.4 Welding
Welding procedure qualification, welder’s qualification, all welding work, equipment for
welding, heat treatment, other auxiliary functions and the welding personnel shall meet the
requirements of the accepted national/international standards and practices.
Applicable Codes & Standards
i) ASME Code for Pressure Piping -ASME B31.3
ii) ASME Boiler & Pressure Vessel Code, Sec II Part C, Material Specifications: Welding
Rods, Electrodes and Filler metals.
iii) ASME Boiler & Pressure Vessel Code, Section V, Non destructive examination.
iv) ASME Boiler & Pressure Vessel Code, Section IX, Welding and Brazing Qualifications.
10.2 Inspection Methodology
The Owner’s inspector shall have free access to all concerned areas, where the actual
work is being performed. The contractor shall also accord the Owner’s Inspector all
means and facilities necessary to carry out inspection.
10.2.1 Visual Inspection
Inspection of all welds shall be carried out as per the latest editions of the applicable
codes and specifications. All finished welds shall be visually inspected for parallel and
axial alignment of the work, excessive reinforcement, concavity of welds, shrinkage
cracks, inadequate penetration, unrepaired burn-through, under cuts, dimensions of the
weld, surface porosity and other surface defects.
10.2.2 Radiographic Examination
The radiographic technique and procedure adopted shall conform of the requirements
mentioned in Article 2 as well as Article 22 (SE 94, 142, 747, 999 & 1025) of ASME
Sec.V. The IQI sensitivity obtained shall be equal to or better than the requirements
mentioned in Article 2 of ASME Sec.V. The acceptance criteria shall be as per the
relevant codes of Fabrication and over riding requirements if mentioned else where in
the technical specifications of the contract. The Contractor shall be responsible for
carrying out Radiography; rectification of defects and re-radiography of welds
repaired/rectified at his cost.
10.2.3 Liquid Penetrant & Magnetic Particle Examination
Whenever such tests are specified, the tests shall be carried out on joints chosen by
the Owner’s inspector, as per ASME Section V article 6 and 7 respectively.
For austenitic stainless steels and other nonmagnetic materials, liquid (dye) penetrant
test shall be carried out. For carrying out this test, the materials shall be brought within
a temperature limit of 150 to 500C.
10.2.4 Proof Test
Hydrostatic and pneumatic tests shall be performed as per the requirements laid down
by respective flushing and Testing specification/applicable codes to demonstrate the
soundness of the welds. The tests shall be conducted after fulfilling the requirement of
visual examinations radiography etc., and after the entire work has been certified by
the Owner’s inspector to be fit for being subjected to such tests.
10.2.5 Repairs Of Welds
Defects ascertained, through the inspection methods, which are beyond acceptable
limits shall be removed after the joint is completely radiographed by the process of

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 146 of 207

chipping and grinding.

When the entire joint is judged unacceptable, the welding shall be completely cut and
edges suitably prepared as per required alignment tolerances. The rewelded joint shall
again be examined following standard practices.
No repair shall be carried out without prior permission of the Owner’s inspector.
Repairs and/or work of defective welds shall be done in time to avoid difficulties in
meeting the construction schedules.
10.3 Flushing
- Flushing of all lines shall be done before pressure testing.
- Flushing shall be done by ‘fresh potable water’ or by ‘dry compressed air wherever water
flushing is not desirable’ to clean the pipe of all dirt, debris or loose foreign material.
- Required pressure for water flushing shall meet the fire hydrant pressure or utility water
pressure. For air flushing, the line/system shall be pressurized by compressed air at the
required pressure which shall be 50 psi maximum. The pressure shall then be released
by quick opening of a valve, already in line or installed temporarily for this purpose. This
procedure shall be repeated as many times as required till the inside of the pipe is fully
cleaned.
- In line instruments like control valves, orifice plates, rotameters, safety valves and other
instruments like thermo wells which may interfere with flushing shall not be included in
flushing circuit.
- The screens/meshes shall be removed from all permanent strainers before flushing.
Screens/meshes shall be reinstalled after flushing but before testing.
- During flushing temporary strainers shall be retained. These shall be removed, cleaned
and reinstalled after flushing, but, before testing.
- In case any equipment such as column, vessel, exchanger etc. form part of a piping
circuit during flushing, this shall be done with the approval of Engineer-In-Charge.
However, equipment thus included in the circuit shall be completely drained and dried
with compressed air after flushing is completed.
- During flushing discharged water/air shall be drained to the place directed by the
Engineer-In-Charge. If necessary, proper temporary drainage shall be provided by the
contractor.
- Care shall be taken during flushing so as not to damage/spoil work of other agencies.
Precautions shall also be taken to prevent entry of water/foreign matter into equipment,
electric motors, instruments, electrical installations etc. in the vicinity of lines being
flushed.
- The contractor shall carry out all the activities required before, during and after the
flushing operation, arising because of flushing requirements, such as but not limited to
the following:
- Dropping of valves, specials, distance pieces, inline instruments and any other piping
part before flushing. The flanges to be disengaged for this purpose shall be envisaged
by the contractor and approved by the Engineer-In-Charge. These flanges shall be
provided with temporary gaskets at the time of flushing.
- After flushing is completed and approved, the valve distance pieces, piping specials etc.
shall be reinstalled by the contractor with permanent gaskets. However, flanges at
equipment nozzles and other places where isolation is required during testing, only
temporary gaskets shall be provided.
- Records in triplicate shall be prepared and submitted by the contractor for each piping
system for the flushing done in the proforma provided/approved by the Engineer-in-
Charge.
10.4 Pressure Testing
Pressure testing, in general shall be as per clause 345 of ASME B31.3, unless otherwise

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 147 of 207

specified, herein. Lines carrying highly hazardous/poisonous fluids must have a sensitive leak
test. For IBR lines, ‘IBR Regulations’ shall also be followed.
10.5 Extent Of Testing
- With the exclusion of instrumentation, piping systems fabricated or assembled in the
field shall be tested irrespective of whether or not they have been pressure tested
prior to site welding or fabrication.
- To facilitate the testing of piping systems, vessels and other equipment may be included
in the system with the prior approval of Engineer-In-Charge if the test pressure specified
is equal to or less than that for the vessels and other equipment.
- Pumps, compressors and other rotary equipment shall not be subjected to field test
pressure.
- Lines which are directly open to atmosphere such as vents, drains, safety valves
discharge need not be tested, but all joints shall be visually inspected. Wherever
necessary, such lines shall be tested by continuous flow of fluid to eliminate the
possibility of blockage. However, such lines if provided with block valve shall be pressure
tested up to the last block valve.
- Seats of all valves shall not be subjected to a pressure in excess of the maximum cold
working pressure of the valve. Test pressure applied to valves shall not be greater than
the manufacturer's recommendation nor less than that required by the applicable code.
Where allowable seat pressure is less than test pressure, test shall be made through an
open valve.
- Instruments in the system to be tested shall be excluded from the test by isolation or
removals, unless approved otherwise by the Engineer-In-Charge.
- Restrictions which interfere with filling, venting, draining such as orifice plates etc. shall
not be installed unless testing is complete.
- Control valves shall not be included in the test system. Where bypasses are provided
test shall be performed through the bypass and/or necessary spool shall be used in
place of the control valve.
- Pressure gauges which are part of the finished system, but cannot withstand test
pressure shall not be installed until the system has been tested. Where piping systems
to be tested are directly connected at the battery limits to piping for which the
responsibility rests with other agencies, the piping to be tested shall be isolated from
such piping by physical disconnection such as valve or blinds.
10.6 Testing Media, Test Pressure & Test Pressure Gauges
10.6.1 Testing Media
- In general all pressure tests shall be hydrostatic using iron free water, which is clean and
free of silt. Maximum chloride content in water for hydrostatic testing for SS piping shall
be 15- 20 ppm.
- Air shall be used for testing only if water would cause corrosion of the system or
overloading of supports etc. in special cases as directed by Engineer-in-Charge.
- If operating fluid in the line is much lighter than testing fluid, the additional weight of
testing fluid may render piping supports (as designed) inadequate. This will call for
additional temporary supports. The typical examples are flare and vapor lines. It is
preferable that hydrostatic testing is avoided in such systems and instead pneumatic
testing may be specified.
- Where air/water tests are undesirable, substitute fluids such as gas oil, kerosene,
methanol etc. shall be used as the testing medium, with due consideration to the
hazards involved. These test fluids shall be specified in the line list given to the
contractor.
10.6.2 Test Pressure
- The hydrostatic/ pneumatic test pressure shall be as indicated in the line list or as per the

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 148 of 207

instruction of Engineer-in-Charge.
- The selection of the piping system for one individual test shall be based on the following:
- Test pressure required as per line list.
- Maximum allowable pressure for the material of construction of piping.
Depending upon the above requirements and based on construction progress, maximum
length of piping shall be included in each test.
10.6.3 Test Pressure Gauge
All gauges used for field testing shall have suitable range so that the test pressure of various
systems falls in 35% to 65% of gauge scale range. Pressure gage dial shall be minimum of
150 mm. Size of Bourdon shall not be less than 75% of nominal diameter of dial range. Gauge
shall be of a good quality and in first class working condition.
Prior to the start of any test or periodically during the field test programme, all test gauges
shall be calibrated using a standard dead weight gauge tester or other suitable approved
testing apparatus. Any gauge showing an incorrect zero reading or error of more than ± 2% of
full scale range shall be discarded .The Engineer-in-Charge shall check the accuracy of
master pressure gauge used for calibration. Calibration certificate shall be furnished for the
pressure gages.
10.7 Testing Procedure
10.7.1 Hydrostatic Test
- All vents and other connections used as vents shall be left open while filling the line with
test fluid for complete removal of air. In all lines for pressurizing and depressurizing the
system, temporary isolation valves shall be provided if valved vents, drains do not exist
in the system.
- Pressure shall be applied only after the system / line is ready and approved by the
Engineer-in-charge.
- Pressure shall be applied by means of a suitable test pump or other pressure source
which shall be isolated from the system as soon as test pressure is reached and
stabilized in the system.
- A pressure gauge shall be provided at the pump discharge for guidance in bringing the
system to the required pressure.
- The pump shall be attended constantly during the test by an authorized person. The
pump shall be isolated from the system whenever the pump is to be left unattended.
- Test pressure shall be maintained for a sufficient length of time to permit thorough
inspection of all joints for leakage or signs of failure. Any joint found leaking during a
pressure test shall be retested to the specified pressure after repair. Test period shall be
maintained for a minimum of three hours.
- The pump and the piping system to be tested are to be provided with separate pressure
indicating test gauges.
- Care shall be taken to avoid increase in the pressure due to temperature variation during
the test.
10.7.2 Pneumatic Test
- When testing with air, pressure shall be supplied by means of a compressor. The
compressor shall be portable type with a receiver, after cooler and oil separator.
- Piping to be tested by air shall have joints covered with a soap and water solution so that
the joints can be examined for leaks.
- All other details shall be same as per hydrotesting procedure (specified above).

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 149 of 207

SECTION – F
(GEOTECHNICAL SPECIFICATIONS)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 150 of 207

GEOTECHNICAL SPECIFICATIONS

1.0 GENERAL
This specification deals with the geotechnical requirements.
2.0 Scope of Work
2.1 Preparation of “Comprehensive Geotechnical Recommendation Document/ Foundation
Design Basis (Geotechnical)” as per available information provided in the bid and/or soil
data generated by carrying out confirmatory soil investigation out, giving all back-up
calculations and submitting the same for Owner/PMC review/approval before execution.
2.2 It is incumbent upon the bidder to seek all technical clarifications concerning the job prior to
the bid preparation. No such clarifications shall be entertained after the award of job.
Notwithstanding this, the decision of Engineer-in-Charge, in case of any disputes shall be final.
However, it must be clearly understood by the contractor that any extra claim and/or time
extension shall not be granted under any circumstances.
3.0 Sub-Soil Profile
For details regarding Sub-soil profile of the proposed area, refer job specific “Geotechnical
Data”.
4.0 Ground Water Table
For details regarding design ground water table to be considered for foundation design
purpose refer job specific “Geotechnical Data”.
5.0 Foundation Recommendations
Indicative foundation system for the various proposed structures/facilities/equipment covered
under the proposed plant has been enumerated in the job specific “Geotechnical Data”.
Foundations for various major/minor structures/facilities/equipment etc. shall be designed as
per “Comprehensive Geotechnical Recommendation Document/ Foundation Design Basis
(Geotechnical)” which shall be prepared by bidder as per clause no. 2.1 above.
6.0 Tankages (If Applicable)
6.1 Tanks (Diameter more than 10m)
Tanks are generally placed on sand pad foundation in normal soil condition.
Ground improvement/strengthening may be required owing to prevailing poor/weak sub-soil
conditions. Detailed soil treatment below tank foundation shall be as specified in job specific
“Geotechnical Data”.
Contractor shall calculate the tank settlement (at tank center and periphery) as per individual
tank diameter and height of the tank for hydro-test condition as per available information
and/or soil data generated by carrying out confirmatory soil investigation giving all back-up
calculations and submit the same for Owner/PMC review before execution.
The Tank foundation (fixed roof type) shall fulfill the following settlement criteria:
Total Settlement at edge - 300mm
Differential settlement along periphery - 1 in 300
In case, anchoring is required for any of the proposed tanks, then those tanks may be
placed on ring wall foundation.
6.2 Tanks (Diameter Up To 10m)
Tanks up to 10m diameter shall be placed on ring wall type of foundations. Net allowable

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 151 of 207

bearing capacity shall be as per job specific “Geotechnical Data”.

7.0 Under Ground Piping
Soil parameters required for design of underground piping shall be as per job specific
“Geotechnical Data”.
8.0 Deep Excavations
In case of deep excavations, high water table conditions (if any) special measures like side
supports and appropriate dewatering system may have to be resorted to. It shall be
contractor’s responsibility to mobilize necessary equipment and carryout deep excavations
wherever required without any extra cost and time implication to the Owner.
9.0 Road and Pavement
For laying road and pavement crust, formation shall be prepared as per IRC-37. Proper
cambering and top sealing of the road and pavement shall be provided to restrict the ingress
of rain-water in sub-grade. Ground improvement/strengthening below road/pavement, if
required shall be as specified in the job specific “Geotechnical Data”.
10.0 Aggressiveness of Soil and Ground Water to Foundation Concrete
Type of cement, minimum cement content and any special precautions/remedial measures for
protection of concreting of sub-structures against chloride, sulphate, adverse environmental
conditions etc. shall be as per provided as specified in the job specific “Geotechnical Data”.
11.0 Back Filling
Back filling in foundations shall be done with suitable non-expansive/uncontaminated soil as
approved by Engineer-in-charge. This shall be compacted in layers not exceeding 150mm
thickness to 90% maximum laboratory dry density as per IS 2720 Part-VIII. For ascertaining
suitability of available excavated soil, refer job specific “Geotechnical Data”.
12.0 Submittals
Contractor shall submit the design document/drawings to PMC/Owner for review prepared
based on the approved Comprehensive Geotechnical Recommendation Document/
Foundation Design Basis (Geotechnical) before execution.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 152 of 207

SECTION – G
PRE-COMMISSIONING, COMMISSIONING &
START-UP GUIDELINES
FOR
COOLING TOWER AND COOLING WATER
TREATMENT PLANT

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 153 of 207

1.0 INTRODUCTION
The cooling water system is envisaged to cater the cooling water demand for the Cooling
water requirements of Process units, Offsite and Utility systems.
This document provides pre-commissioning, commissioning & Start-up responsibilities of the
Package CONTRACTOR.
2.0 SCOPE
The CONTRACTOR shall be responsible to carry out pre-commissioning & commissioning,
trial runs and performance test run of the Cooling Water System.
Detailed procedure for mechanical completion, pre-commissioning, commissioning, start-up
and performance test shall be developed by CONTRACTOR based on guidelines provided in
this document. CONTRACTOR shall also prepare detailed operating manual based on the
guidelines provided. The contractor will get these documents approved by OWNER/ EIL.
FOLLOWING SHALL BE ENCLOSED BY BIDDER IN HIS OFFER
 An organisation chart of bidder's proposed commissioning team indicating the positions
with the required qualifications and experience. Adequate manpower should be provided
in each shift, to carry out pre-commissioning / commissioning/ plant run stabilization/
performance test run activities.
 CV’s of key personnel comprising the pre- commissioning & commissioning team shall be
included in the bid. The format of CV is enclosed as Annexure-I.
 Track record of bidder related to commissioning experiences of similar systems.
 Clause wise list of deviations, if any, in the format given in Annexure-II. In the absence of
Annexure-II, it shall be assumed that bidder has no deviations.
3.0 DEFINITIONS
3.1 Mechanical Completion
Mechanical Completion of systems shall mean that all installation works of the system have been
completed and hydro tested in accordance with approved construction drawings, specifications,
applicable code, and internationally accepted good engineering practices in a comprehensive
manner by the CONTRACTOR. CONTRACTOR’S competent representative shall check the
system/sub-system so that it meets the process requirement and is constructed as per the
approved drawings. After liquidating the checklist CONTRACTOR shall submit certificate as per
FORMAT-I (attached in Annexure-III) stating system/sub-system, which is mechanically
completed. Checklist generated by CONTRACTOR representative and test certificates
connected with the system/sub-system shall form a part of the FORMAT-I. Certificates of various
statutory bodies for relevant portion of the work completed shall be made available by the
CONTRACTOR as part of mechanical completion. OWNER/EIL’S representative shall check the
system along with CONTRACTOR’S representative and shall issue FORMAT-II which includes
deficiencies / modifications required for the portion of the work that is declared by the
CONTRACTOR as mechanically complete. Once the system/equipment is ready for Pre-
commissioning, CONTRACTOR shall issue certificate (FORMAT-III) to the effect that
system/equipment is ready for Pre-commissioning.
3.2 Pre-Commissioning Activities
Pre-commissioning activities (As detailed in Annexure-IV) are defined as those activities, which
are required to be performed after completion of installation, inspection, hydro testing etc. of an
equipment / system to make it ready for commissioning. CONTRACTOR shall raise FORMAT–III
certifying that all checklist points are liquidated and the system/sub-system is ready for pre-
commissioning. CONTRACTOR shall start pre-commissioning activities after acceptance of
FORMAT-III by EIL/OWNER. This shall include but shall not be limited to activities such as

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 154 of 207

system checking as per P&IDs/drawings and operational requirements, site modifications,

internal inspection of equipment/vessels, flushing/air blowing of pipeline including card board
blasting, leak test, calibration of instruments, checking of the electrical equipment for proper
earthing, continuity, insulation resistance, conducting operability test on individual
equipment/system, charging of lubes & other chemicals. Fabrication and supply of temporary
facilities, for example, temporary bypasses, spools, blinds, jump-overs, vents, gaskets, strainers
etc. required to carry out pre-commissioning activities shall be in the scope of the
CONTRACTOR. All the pre-commissioning activities shall be carried out by CONTRACTOR.
Prior to pre-commissioning activities, safety audit to be conducted by CONTRACTOR and
OWNER/EIL for entire plant. Checklist/deficiency generated by safety audit team shall be
corrected/rectified by CONTRACTOR at no time & cost impact.
3.3 Ready for Commissioning
The Cooling Water System shall be considered `Ready for Commissioning' when pre-
commissioning activities of all the facilities have been completed along with their auxiliaries
and support facilities in every respect including charging of lubes, chemicals, preparation of
solution, last minute modifications, if any, as recommended by the OWNER/EIL. All temporary
structures, scaffolding etc. used for carrying out the pre-commissioning work have been
removed, all the blinds have been put into position as required by P& ID, all the pre-
commissioning and other documents including blinds list, set pressures of PSVs and TSVs
along with test certificates etc. (Testing shall be done at site) shall be handed over to the
OWNER/EIL.
The CONTRACTOR shall issue a certificate of ‘Ready for commissioning’ of Cooling Water
System for acceptance by the OWNER/EIL in standard format, FORMAT-IV (as per format
given in Annexure-III) with all exceptions resolved.
After the Cooling water system has been declared as `Ready for Commissioning', the
CONTRACTOR shall not carry out any hot work in the plant without prior written permission of
the OWNER.
4.0 DOCUMENTS FOR PRE COMMISSIONING / COMMISSIONING
4.1 Operating Manual
The CONTRACTOR shall prepare plant specific draft-operating manual of the Cooling water
system and submit to OWNER/EIL for review at least 120 days prior to mechanical completion.
Minimum five copies of draft operating manual shall be submitted by the CONTRACTOR for
review.
In particular, following information shall be covered as a minimum.
 Design basis of Cooling Water system.
 Passivation procedure for cooling water system
 Detailed process description.
 Pre-start checks.
 Pre-commissioning procedures
 Start-up procedure.
 Normal operating procedure.
 Shutdown procedure (Normal & Emergency).
 Vendor instructions for all equipment for maintenance start up, shut down, normal
operation and trouble shooting
 Operating parameters and set points of alarms and trips.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 155 of 207

 Operating conditions
 Effect of operating variables on the process.
 Details of interlock logic, trip etc.
 Functional description of safe shut down systems.
 List of emergencies and emergency handling procedures.
 Dosage rate of chemicals used and other related operating information.
 Initial requirement of chemicals for first start-up.
 Safe-handling precautions for chemicals used. (MSDS)
 List of equipment and their major details
 List of all instruments like control valves. transmitters etc.
 Relief valve schedule, tag numbers, set pressure, capacity basis, failure scenarios
considered etc.
 Approved/ final PFDs/P&IDs and drawings
 Any other special conditions / instructions / information, etc.
 Summary of chemical consumption.
 Summary of utility consumption.
 Lubrication schedule (with equivalent lubricant available in India).
 Hydrocarbon/chlorine detection and associated safety system.
 Laboratory analysis requirement and procedure with sampling schedule.
 Procedure for preparation of equipment hand over
 Safe handling of chemicals
 Chemical solution preparation procedures
 MSDS of chemicals
Review of operating manuals shall be done by OWNER/EIL after receipt of draft operating
manuals. All the changes, additions, deletion required by the OWNER/EIL shall be
communicated to CONTRACTOR and same shall be incorporated in the final operating manual
by the CONTRACTOR. Ten copies of final operating manual shall be submitted by
CONTRACTOR. The same shall also be forwarded in CD. The final manuals shall be submitted
to OWNER at least 90 days prior to mechanical completion. These operating manuals shall be
followed during start-up and commissioning of the Cooling water system. Vendor’s operating
manual shall not be a part of this operating manual and shall be submitted separately.
In case of any revisions due to any reason, the same shall be incorporated and submitted as
revised sheets during the start-up and commissioning stage along with updated CDs. However,
revised operating manual incorporating changes shall be submitted within one month after the
commissioning has been completed.
4.2 Pre-Commissioning and Commissioning Network
The CONTRACTOR shall submit the pre-commissioning and commissioning schedule in the
form of network detailing therein the sequence of all the pre-commissioning and commissioning
activities and duration of each activity to be carried out in each equipment / sub-system of the
units. This shall be submitted to OWNER prior to start of pre-commissioning activities.
CONTRACTOR shall submit weekly progress report and the status of pre-commissioning and
commissioning activities, likely slippage and action being taken by the CONTRACTOR to contain

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 156 of 207

these slippages.
4.3 Pre-Commissioning Documents
It shall be the responsibility of the CONTRACTOR to prepare detailed checklist of pre-
commissioning and commissioning activities for Cooling Water System. The CONTRACTOR
shall submit the said format for approval to the OWNER/EIL.
Representative of CONTRACTOR shall be available for carrying out check listing. All the
checklist points shall be liquidated by the CONTRACTOR. System readiness for Pre-
commissioning shall be determined based on the completion of relevant portion of checklist as
per approved format and all balance work completed by CONTRACTOR.
For the purpose of execution of these pre-commissioning activities, the Cooling Water system
shall be divided into system and sub-systems so that pre-commissioning activities of each
system/sub-system can be progressively carried out along with the construction activities. The
pre-commissioning document shall contain the following as a minimum:
1) System identifications on P&IDs.
2) Pre-commissioning and start-up schedule
3) Detailed procedure for the various pre-commissioning activities i.e. flushing, blowing,
drying, leak checking, system tightness, equipment operability test with format to record
the observation of each of the activities to be carried out.
4) Procedure and format for operability tests of equipment and system as a whole, wherever
applicable.
5) Lube schedule indicating manufacturer (Indian equivalent to lubes, quality, initial fill as
recommended, and frequency of changing the lube oil).
6) Detailed procedure for pre-commissioning of Cooling Water System
The CONTRACTOR shall submit the draft copy of above mentioned pre-commissioning
documents 90 days before the activities are to be carried out. The document shall be reviewed by
the OWNER/EIL.. After incorporating OWNER/EIL's comments, the CONTRACTOR shall submit
revised document 60 days prior to start of activities. The documents shall be followed till the
project is completed.
CONTRACTOR shall arrange Manpower, instruments and tools required for carrying out pre-
commissioning activities. Estimated requirement of raw water, power and plant air which needs
to be supplied by OWNER during pre-commissioning and start-up is to be given by
CONTRACTOR. After completion of pre-commissioning activities of the facilities CONTRACTOR
will submit request to the OWNER for permission for start-up of the system.
Commissioning of the facilities shall not be permitted till all the documents have been submitted
by the CONTRACTOR to the OWNER/EIL. Any delay in commissioning on this account shall be
considered as a delay in commissioning by the CONTRACTOR.
5.0 OTHER REQUIREMENTS
CONTRACTOR shall ensure that all safety devices like pressure safety valves, emergency
shutdown valves are tested, witnessed and certified in the presence of representatives of
OWNER/EIL. These certificates are to be handed over to OWNER/EIL prior to start-up of the
system. The CONTRACTOR along with Ready for Commissioning Certificate shall submit to
the OWNER/EIL the master blind list and record of set pressures of all PSV's provided in the
unit. CONTRACTOR is required to maintain and follow all safety practices, equivalent or better
than those being practiced by OWNER for the complex during pre-commissioning and
commissioning.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 157 of 207

6.0 MANUFACTURER'S REPRESENTATIVE

It shall be the responsibility of the CONTRACTOR to arrange for services of manufacturer's
installation / commissioning engineer at site during mechanical completion / pre-commissioning &
commissioning of all the major equipment and systems for the Cooling water listed as under:

1. All pumps i.e. chemical injection pumps, etc.

2. All package type items.
3. Specialist for supervision of cooling water system passivation.
4. Any other critical/proprietary equipment, for which it is felt necessary to call Vendor’s
representative for proper commissioning.
7.0 REVIEW / CHECKLISTING / INSPECTION CO-ORDINATION
A general guideline on OWNER/EIL interaction with respect to cooling water system pre-start up
activities is given below. However, OWNER reserves right to witness entire work at any stage.
 Review of pre-commissioning documents and network (as detailed in section 3.2 and 3.3
above).
 Review of operating manual (as detailed in section 3.1 above).
 Check listing (system-wise)
a) Preliminary checklist on system completion.
b) Final checklist before start of pre-commissioning activities.

8.0 A TYPICAL APPROACH TO WITNESS / INSPECTION OF PRE-COMMISSIONING

ACTIVITY BY OWNER/ EIL
Activities Witness/Inspection
a) Installation of safety device Complete
b) Provision of temporary strainers and blind at critical locations Random
c) Water flushing and air blowing of pipelines Random
d) Instrumentation interlock checks Complete
e) Operability test for a system/equipment Complete
f) Cleaning of vessels and Internal Flushing of vessels Complete
g) Blind list as per start-up requirement/normal operation Complete
Witness/ inspection / approval of OWNER/EIL is not an obligation but a right with no change in
CONTRACTOR's liabilities.
At the discretion of OWNER/EIL, the extent of witness / inspection may be extended/ reduced as
deemed fit.
9.0 FINAL INSPECTION BEFORE START OF COMMISSIONING
OWNER/EIL/CONTRACTOR shall carry out a final inspection of the system before starting the
commissioning activity.
Record of liquidation of checklist points, test records etc, shall be submitted by the
CONTRACTOR to OWNER/EIL. Any deficiency/ changes required in the offered system shall be
liquidated by the CONTRACTOR.
10.0 COMMISSIONING
It shall be the responsibility of the CONTRACTOR to commission the system under the scope of
the CONTRACTOR. Commissioning shall be carried out after mechanical completion is over

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 158 of 207

successfully, all pre-commissioning activities are carried out and certificate of “Ready for
commissioning” is accepted by OWNER/EIL. Representatives of vendor/designer shall provide
necessary co-ordination during start-up and they shall furnish technical clarifications, as and
when required.
Commissioning of Cooling water system shall mean taking the water in the system , passing it
through normal route; establishing the process control parameters first at turn down & then at
design value stipulated in the process package along with supplementary instructions if any
from OWNER/EIL.
The Cooling water system shall be considered to be commissioned successfully with
instrumentation/control systems; process, utilities and support systems have been on
uninterrupted stable operation for a specified period of not less than 72 hrs (or as mentioned
elsewhere in the bid document). Whether operation for the specified period has been successful
or not, shall be decided by the OWNER based on observations recorded. The countdown for the
specified period shall start only after system has been on stable operation with all controls and
safety systems in normal operation for a period of not less than 48 hours. OWNER will issue
acceptance certificate (FORMAT- V) accordingly.

Upon successful commissioning of the Cooling water system the same shall be taken over by the
OWNER for day-to-day operation, control and maintenance. Final takeover shall be subject to
compliance to all the contractual obligations by the CONTRACTOR. Once the Cooling water
system is successfully commissioned CONTRACTOR shall issue FORMAT-V to OWNER for
take over of the unit from CONTRACTOR.
11.0 SPARES AND CONSUMABLES
CONTRACTOR shall be responsible for supply of spares and other consumables for start-up and
Pre-commissioning/commissioning activities. Also CONTRACTOR shall be responsible for
supply of all chemicals and consumables including Lubricants etc. actually required during
commissioning, trial runs and stabilization and successful performance guarantee test run before
handing over to Client. CONTRACTOR shall submit catalogues for all the lubricants and
chemicals being used for start-up, pre-commissioning, commissioning and performance
guarantee test run and smooth running of the plant.
The Raw water required for water flushing etc shall be provided to the CONTRACTOR at the
battery limit of cooling water system by OWNER.
12.0 SPECIAL REQUIREMENT
All utilities like air, raw water, power, instrument air etc. shall be provided at the conditions and
locations given in the package and drawings. Any upgrade, if required, either for pre-
commissioning or commissioning shall be carried out by the CONTRACTOR at his own cost.
13.0 SAFETY
The CONTRACTOR shall follow OWNER's safety practices during execution of pre-
commissioning / commissioning works. CONTRACTOR is required to maintain and follow all
safety practices equivalent or better than those being practiced by OWNER for the complex
during pre-commissioning and commissioning.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 159 of 207

14.0 ANNEXURES

ANNEXURE I
FORMAT FOR BIO-DATA OF KEY PERSONNEL FOR COMMISSIONING

1. PURPOSED POSITION IN ORGANISATION CHART:

2. NAME:

3. QUALIFICATION:

4. TOTAL YEAR OF EXPERIENCE

IN PLANT OPERATION / COMMISSIONING:

5. DETAILS OF COMMISSIONING EXPERIENCE:

SI. PROJECT PLANT YEAR OF DURATION OF

OWNER
No. DESCRIPTION CAPACITY COMMISS. STAY AT SITE

ANNEXURE-II

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 160 of 207

QUESTIONNAIRE

CLAUSE DESCRIPTION OF CLAUSE AGREED NOT REMARK

NO. AGREED
1.0 SCOPE

2.0 DEFINITIONS

3.0 DOCUMENT FOR PRE-COMMISSIONING

AND COMMISSIONING
4.0 OTHERS REQUIREMENTS
5.0 MANUFACTURER REPRESENTATIVE

6.0 REVIEW / CHECKLISTING/INSPECTION/

CO-ORDINATION
7.0 A TYPICAL APPROACH TO WITNESS/
INSPECTION
8.0 FINAL INSPECTION
9.0 COMMISSIONING

10.0 CONSUMABLES

11.0 SPECIAL REQUIREMENTS

ANNEXURE-III
FORMAT TO BE USED DURING PRE-COMMISSIONING AND COMMISSIONING
(TOTAL 5 FORMATS)

FORMAT-I

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 161 of 207

INTIMATION REGARDING SYSTEM COMPLETION

PROJECT:____________________ CUSTOMER:_________________UNIT:_________________

Following system/sub-system has been mechanically completed in all respects with exceptions noted
below. The system/sub-system can be taken up for checking and preparation of checklist.

SYSTEM NO.:

SYSTEM DESCRIPTION:

EXCEPTIONS:

SIGNATURE DATE

CONTRACTOR’S CONSTRUCTION:
CO-ORDINATOR
_______________________________________________________________________________

The system is ready/ not ready for Check listing

OWNER/EIL:

F O R M A T – II

. CHECKLIST

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 162 of 207

PROJECT: ________________CUSTOMER: __________________UNIT: ___________________

SYSTEM/SUB-SYSTEM___________________________________________________________

CHECKLIST TYPE PRELIMINARY/FINAL

SL.NO. CHECKLIST ITEMS REMARKS

SIGNATURE DATE
______________________________________________________________________________

EIL :

OWNER :

F O R M A T - III

READY FOR PRE-COMMISSIONING CERTIFICATE

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 163 of 207

PROJECT: __________________CUSTOMER:__________________ UNIT:__________________

SYSTEM/SUB-SYSTEM___________________________________________________________

This is to certify that the following plant/system/sub- system as detailed below is completely installed
and all the Checklist points are carried out except for minor details as given in the attached list.

DESCRIPTION ON PLANT/SECTION/SUB-SECTION____________________________________

______________________________________________________________________________

SIGNATURE DATE

CONTRACTOR’S CONSTRUCTION
CO-ORDINATOR:

CONTRACTOR’S COMMISSIONING
CO-ORDINATOR
______________________________________________________________________________

The system is ready/ not ready for pre-commissioning

EIL :

OWNER:

F O R M A T - IV

READY FOR COMMISSIONING CERTIFICATE

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 164 of 207

PROJECT:__________________CUSTOMER:___________________UNIT:_________________

SYSTEM/SUB-SYSTEM___________________________________________________________

This is to certify that all the necessary pre-commissioning activities for the system/sub-system as
detailed below have been completed and the system/sub-system is ready for commissioning except
for the minor details as given below which shall not affect the commissioning trial runs.

DESCRIPTION OF SYSTEM/SUB-SYSTEM____________________________________________

______________________________________________________________________________

SIGNATURE DATE

CONTRACTOR’S COMMISSIONING:
CO-ORDINATOR

______________________________________________________________________________

EIL:

OWNER:

FORMAT-V

COMPLETION OF COMMISSIONING CERTIFICATE

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 165 of 207

PROJECT:_______________CUSTOMER:__________________UNIT:_____________________

SYSTEM/SUB-SYSTEM___________________________________________________________

This is to certify that the system/sub-system as detailed below has been successfully commissioned
and is under operational control of Client's Production department. The minor items, which shall not
affect the normal operation of the system/sub-system, are given in the attached list.

DESCRIPTION OF SYSTEM/SUB-SYSTEM____________________________________________

______________________________________________________________________________

SIGNATURE DATE

CONTRACTOR’S COMMISSIONING:
CO-ORDINATOR
______________________________________________________________________________

EIL’S COMMISSIONING:
CO-ORDINATOR

OWNER'S COMMISSIONING:
CO-ORDINATOR

ANNEXURE -IV

PRE-COMMISSIONING ACTIVITIES

The checklist represents the minimum work, which has to be performed by the CONTRACTOR
prior to commissioning of the facilities. However, it is not intended to be a complete list of
activities required to be carried out by the CONTRACTOR.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 166 of 207

Manufacturer's/Vendor’s instructions for pre-commissioning checks, testing must also be followed

for all equipment.

A. General Procedure for Pre-Commissioning

The general work procedures listed below outline the work to be performed by the
CONTRACTOR. Procedures applicable to specific system or items of equipment are covered
separately.

A-1 Installation of Seals and Packing

 Install mechanical seals, permanent packing and accessories, wherever required.

 Adjust and replace mechanical seals, packing and accessories, as necessary during pre-
commissioning / commissioning period.

A-2 Removal of Temporary Bracing

 Remove all temporary supports, bracing, or other foreign objects that were installed in vessels,
transformers, piping, rotating machinery or other equipment to prevent damage during shipping,
storage and erection.

A-3 Rotation and Alignment

 Check rotating machinery for correct direction of rotation and for freedom of moving parts before
connecting driver.
 Make cold alignment to the manufacturer's tolerances along with OWNER/ EIL. Provide all the
alignment readings records to OWNER.
 Check all lubricants and their quality, fill etc. before operating the equipment.
 Carry out no load run of motors etc.
 Check bearing temperatures, vibration, over speed trips function of different safety device and
other relevant tests. Carry out adjustments as required.
 Make hot alignments and any adjustments required after equipment has been put in operation.
 Arrange for manufacturer representative for equipment as required during installation and/or pre-
commissioning and commissioning.

A-4 Tie-ins at Unit Battery Limits

 Prepare all systems for safe tie-ins with utilities and auxiliary system. CONTRACTOR shall
prepare the existing operating systems for tie-ins in consultation with OWNER and shall be
responsible for safety during tie-ins is being made. CONTRACTOR shall take approval of
OWNER/EIL for the safety measures to be taken by him before any tie-in work is taken-up.

A-5 System Check / Inspection

 Provide inspection facilities to the OWNER/EIL to check that installed facilities confirm to the
approved piping and instrumentation diagrams, construction drawings, vendor drawings and
specifications approved for construction. Note exceptions, if any on the separate list.

A-6 Site Modifications

 Carry out site modifications as found necessary during system check/ inspection from operability
point of view, maintenance and safety of the plant.

A-7 Flushing and Blowing

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 167 of 207

 Flushing schemes for various systems / subsystems / equipment should be prepared well in
advance and to be submitted to OWNER/EIL for approval.
 Perform flushing using water and/or air of all piping to remove dirt, welding slag, etc. after hydro
testing (along with gasket / sheet blasting).
 Arrange for cleaning media for carrying out flushing / blowing and disposal of the cleaning media
in accordance with procedures to be adopted by the CONTRACTOR and approved by
OWNER/EIL.
 Following rates of cleaning media may be maintained:
 Air - 2.4 – 2.7 m/sec.
 Water - 1 – 1.2 m/sec.
 Adequate arrangements to be made by CONTRACTOR to avoid flooding of existing facilities
during flushing operation.
 System flushing with water shall be followed by air drying for removal of free water. (Ensure
complete drying particularly for chlorination system/acid/caustic dosing system).

A-8 Temporary Spools, Strainers, Screens and Blinds

 Provide and install all strainers, both temporary and permanent.

 Clean strainers as required during pre-commissioning and commissioning.
 Provide, install and remove all blinds required for flushing or operation. (Install and dismantle
temporary pipe pools as and when required for pre-commissioning and commissioning).

A-9 Leak, Vacuum and Pressure Tests

 Make non-operating leak tests and pressure tests on piping and all equipment, including field-
fabricated equipment.
 Conduct all tests in accordance with applicable statutory/safety/ other applicable design codes
and specifications. Detailed procedure for leak and pressure tests on piping and field-fabricated
equipment shall be submitted by CONTRACTOR to the OWNER/EIL for approval.
 Notify the OWNER of test schedule at least two days in advance. All the tests are to be witnessed
and the test record on satisfactory completion of the test to be signed by OWNER/OWNER's
Representative.
 Provide 4 copies of all the test records to the OWNER.
 Conduct all tightness testing after leak test.

A-10 Safety Devices

 Provide a list of proper settings for safety devices to the OWNER.

 Install all safety devices (including pressure relief valves) on the equipment after calibration test
and adjust all safety devices wherever necessary or desirable.

A-11 House Keeping

 Construction and operational area shall be properly cleaned up.

 Remove excess materials, temporary facilities and scaffolding and pick-up trash.
 Floor washing may be carried out to keep the area clean.

A-12 Equipment Protection and Spare Parts

 Protect equipment from normal weather conditions, corrosion, or damage before commissioning.

A-13 Chemical Cleaning/Pickling

 Perform special chemical cleaning or pickling of the piping as required by specification.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 168 of 207

A-14 Miscellaneous

 To carry out any other check / test as required by OWNER/EIL and provide all test certificates as
required by the OWNER/EIL.

A-15 Operability Test for a System / Equipment

 Each system / equipment shall be given operability test for sufficient duration (not less than 4
hours) to demonstrate worthiness of the system for normal operation.
 The CONTRACTOR shall provide his proposal / procedures for carrying out the operability test of
each equipment / system to prove that the equipment system installed meet the design
specification. This shall also include the supply of log sheets wherein the operating parameters
shall be recorded hourly. The operability test shall be carried out by the CONTRACTOR in
presence of OWNER’s/EIL's Representative and the Vendor representative wherever applicable.
 The CONTRACTOR shall make necessary checks, adjustments, repairs required for normal
operation of the system / equipment.
 All the safety devices shall be tried for their proper operation.
 Upon completion of the operability test the log sheet with all observations shall be signed by the
CONTRACTOR, Vendor, OWNER's/EIL’s Representative. The performance shall be evaluated
based on the data and observations made during the operability test.

B. SPECIFIC PROCEDURES

In addition to the work to be performed in accordance with the above, the detailed procedures
outlined below further define the work responsibilities of the CONTRACTOR for specific systems
and items of equipment.

B-1 Vessels and Columns

Vessel/Columns after erection and put in place have internals requiring field installations. These
internals shall be inspected before and after installation. Open manways for inspection of vessel
for OWNER/OWNER's Representative inspection.

NOTE :
Vessels that have been pressure tested in the shop may require retesting if felt necessary by the
OWNER. The same may be included during the testing of connecting piping systems wherever
possible and approved by the OWNER/EIL.

B-2 Pumps, Compressors, Fans and Drivers

 Use Level base plates and sole plates. Alleviate any excess piping stresses that may be imposed
on pumps, compressors and drivers.
 Chemically clean complete lube and seal oil system when specified. Dispose off waste and
cleaning media as per OWNER instructions.
 Check alignment and ensure that levels of supports, etc are in order.
 Charge the lube oil, seal oil and cooling systems with flushing oil and circulate for cleaning
purposes. Dispose of any flushing oil in accordance with the OWNER's approved procedure.
 Charge the lube oil, grease, seal oil and oil cooling system as recommended by the
manufacturer.
 Ensure that all fittings supplied by vendor are installed in proper condition
 Ensure that there is no high vibration after equipment is put on rotation.
 Obtain service engineer for technical assistance during installation and / or pre-commissioning
and commissioning as specified.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 169 of 207

B-3 Piping System

 Notify the OWNER, of hydro test schedule at least two days in advance system by system during
mechanical construction stage.
 Orifice plates, control valves and any other online instruments should not be installed before
testing and flushing. If installed, they shall be removed and necessary spool pieces shall be
provided in their place wherever required during flushing to avoid damage.
 Piping system shall be thoroughly flushed and cleaned to the satisfaction of the OWNER/EIL.
 Hydrostatically or pneumatically test all piping as required by the drawings or specifications.
 After testing, drain and dispose of the test media as per the OWNER's instructions.
 Piping will be dried as may be required using air.
 Check pipe hangers, supports, guides and pipe specialities for hot settings and make minor
adjustments as necessary.
 Install seals on valves where necessary. Replacement of dry up graphite seals with fresh ones
shall be in CONTRACTOR's scope of work.
 Correct support, vibration and problems detected during commissioning.

B-4 Instrument System

 The CONTRACTOR shall make all non-operating checks that shall ensure instrument operability
i.e. remove all shipping stops, check pointer travels, and verify instrument capability to measure,
operate and stroke in the direction and manner required by the process application.
 Clean all impulse lines (etc.) by blowing with cooled and filtered clean air compatible with
instrument components.
 Clean all air supply headers by blowing with clean air and check them for tightness.
 Leak test pneumatic control circuits.
 Functional check of all instrument and controllers.
 Check all loops for proper functioning.
 Checking and recording positions of all valves.
 Check piping from instruments to process piping for tightness.
 Install and connect all system components and verify their conformance to specifications and
design criteria for functional and range using dummy transmission signals as needed.
 Check all electrical signals and alarm wiring for continuity, correct source of power and polarity.
 Check thermocouple for proper joining of wires, position of elements in wells, proper polarity and
continuity of receiving instruments.
 Identify orifice plates by tagging and check for proper installation of upstream side of plates.
 Isolate or remove if necessary, the components such as control valves, positive displacement
meters, and turbine meters for pressure testing. Reinstall these items after testing the system.
 Check bore of orifice plates and install these plates after completion of flushing operations.
 Calibrate instruments with standard test equipment and make all required adjustments and
control point settings. Fully pressurize and energize the transmitting and control signal system by
opening process connections at primary sensors and final regulators and by making control mode
settings for automatic operation of equipment as the plant is charged and brought on-stream.
 Check setting of all alarm and shutdown switches.
 Check all shutdown/TRIP systems before commissioning.
 The CONTRACTOR shall arrange for testing and recalibration of all the safety valves settings at
site.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 170 of 207

SECTION – H
CONSTRUCTION SUPERVISION AND
MANAGEMENT

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 171 of 207

1.0 GENERAL

1.1 The CONTRACTOR shall engage a Third Party Inspection Agency for Construction Supervision &
Management at site. The scope of TPI shall be as follows:-

i. Organize, plan and manage the installation work as a package contract.

ii. Development of QA plans, procedures, ITPs in line with contract.
iii. Implementation of overall Quality Assurance and Quality Control system.
iv. Incoming material certification as per specification/drawing/contract.
v. Fix installation programs, targets etc with agency and periodical review of the same
in consultation with Owner/EIL
vi. All necessary services and site inspection for rectification of faulty works.
vii. Certifying quality and quantity of wok performed by agency and maintain necessary
records required for verifying contractor bills/ Invoice according to the conditions of
contract.
viii. Reporting of NCR and resolution thereof to Owner/EIL.
ix. Auditing at various phases of construction.
x. Review and certify as built drawings and final documents made by contractor.
Note: The engagement of TPI doesn’t absolve the contractor from his responsibilities as
defined in this document.

1.2 The CONTRACTOR shall construct Plant/Facilities in accordance with the requirements of the
Technical Standards/ Specifications, with proven/good engineering practices and procedures.
Such Facilities shall be safe, reliable and suitable for their intended purpose.
1.3 The CONTRACTOR shall provide all supervision, labour, construction equipments, tools &
tackles, materials and consumables, temporary facilities, etc. and render all support services
necessary for the construction. Provision of construction power and water shall be as per
Special Conditions of Contract (SCC)/ General Conditions of Contract (GCC).
1.4 The CONTRACTOR shall plan, execute, manage and control all the construction activities for the
facilities forming a part of this contract.
1.5 The CONTRACTOR shall arrange insurance coverage for all the personnel engaged by him for
the work as per statutory rules, regulations and local laws.
1.6 The CONTRACTOR shall insure all the materials and equipments against fire, flood, earthquake,
theft, etc. as per SCC/ GCC brought for the job till the Plant/Facilities are commissioned and
handed over to the OWNER.
1.7 The CONTRACTOR to ensure mechanizing the construction activities to the maximum.
1.8 The CONTRACTOR is deemed to have full knowledge of the applicable laws and regulations,
conditions of labour, local conditions, the SITE conditions, environmental aspects and shall
comply with the requirements thereof.
1.9 The CONTRACTOR is required to organize and mobilize Construction Management Services in a
systematic and sequential manner to ensure that the Plant installation is carried out in
accordance with the approved engineering drawings, specifications, standards, QA/QC
procedures etc. and its mechanical completion is achieved within targeted time schedule.
Construction Management and Supervision is to be carried out by the CONTRACTOR himself
by deploying persons on his rolls and this activity is not to be sub-contracted in any case.
For this purpose, the CONTRACTOR shall deploy a Construction Management Team headed
by a qualified & experienced person at site. The Construction Management team shall include
engineers/ specialists in QA/QC, Project Control (Planning, scheduling, monitoring), contracts,

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 172 of 207

construction supervision, progress measurement/billing, safety, warehousing, purchasing etc.

Key personnel including the Head should have sufficient qualification/experience and should
not be changed without concurrence from OWNER/PMC.
Curriculum vitae of all key Construction Personnel shall be submitted to Owner/PMC at least 3
months before deployment. Owner/PMC reserve the right to interview these personnel before
their mobilization.
1.10 The CONTRACTOR shall ensure delegation of adequate and sufficient powers (including
financial) to the Head of his Construction Team for effective and smooth functioning of the
construction management. HO support shall be provided to the Head of Construction Team at
site during construction on all matters of project execution including the following:
- Field engineering.
- Vendor specialists required during construction.
- Rectification/replacement of defective supplies, if any, noticed during construction.
- Expediting replacement of imported items found short/damaged.
- Required documentation for the material inspection at site
- Compilation and submission of Field Inspection documents in requisite copies as per
contract
- Documentation to meet Statutory requirements.
1.11 The construction supervision, co-ordination and management activities shall be carried out by
the CONTRACTOR in accordance with the construction procedures developed and submitted
by the CONTRACTOR and approved by OWNER/PMC. CONTRACTOR shall prepare
construction schedules within the framework of overall contract schedule and submit to
OWNER/PMC for approval. CONTRACTOR shall plan, execute, monitor and control
construction activities as per the approved construction schedule.
CONTRACTOR shall depute a project team at site during construction phase under a project
coordinator for providing above-mentioned support to the Head of Construction Team.
1.12 Most of the civil construction materials like cement, reinforcement bars, aggregates, bricks,
and structural steel are available locally. However, the material like cement, reinforcement
bars and structural steel shall be procured from approved vendors only. The CONTRACTOR
shall establish and maintain a material testing laboratory for carrying on field tests during
execution of contracts under different disciplines by sub-contractor’s, at no extra cost to
OWNER. The entire test equipments deployed shall have valid test/calibration certificates
traceable to relevant national/ international standards. Such material tests, for which testing
facility at site is not established, shall be carried out by CONTRACTOR at testing laboratories
approved by OWNER/ PMC at no extra cost. CONTRACTOR shall maintain the test records
and the same shall be made available for review/ inspection of OWNER/ PMC/TPIA. Further,
OWNER/PMC reserve the right to witness/ inspect testing at the laboratory at no extra cost to
OWNER/PMC.
1.13 Construction supervision and management functions to be performed by the CONTRACTOR
shall include the following as key functions for effective execution, monitoring and control:
- Planning, scheduling, monitoring & reporting.
- Construction supervision, discipline wise.
- Quality assurance and quality control, discipline wise.
- Shipping, custom clearances, inland transportation
- Warehouse management and material control.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 173 of 207

- Field engineering/Purchase.
- Health, Safety and Environment (HSE) Management
- Statutory clearances and enforcement of statutory rules/ regulations and Labour Laws
- Personnel/administration/Industrial Relations
- Finance and Accounts
- Security
1.14 Whenever the hookup is to be done with the facilities under operation, efforts shall be made by
the CONTRACTOR to complete the work and restore the system expeditiously. If required the
work shall be continued round the clock.
1.15 Over Dimensional cargo movement to the erection site is included in the scope of the
CONTRACTOR. The CONTRACTOR shall carry out the route survey and report shall be
submitted to OWNER/PMC well in advance. All the clearances, approval from government
agencies, local bodies, private parties, police, electricity / telephone departments, Railway
authorities, PWD, Highway authorities, various departments of OWNER etc. for moving the
ODC cargo is included in the CONTRACTOR’s scope. Before each movement, copy of the
major clearance obtained shall be forwarded to OWNER/PMC. The cost /deposits of such
approval, which may be incurred by the CONTRACTOR, shall be included in the lump sum
price.
1.16 Any modification, dismantling, re-routing etc. of the permanent / temporary facilities belonging
to OWNER, private parties, public / government facilities including provision of ramps at
bridges to enable the ODC movement are in CONTRACTOR’s scope.
1.17 Restoration of the all the modified, dismantled facilities to original condition is in the scope of
the CONTRACTOR. CONTRACTOR shall obtain no claim certificates from such parties.

2.0 EXECUTION OF WORKS

The CONTRACTOR'S work during construction shall include but not be limited to the
following:
i) Prepare and submit all the Plans, Procedures and documents to OWNER/PMC as
specified in the contract.
ii) Establish requisite site organization staffed by competent and experienced specialists,
supervisors and inspectors.
iii) Supervise, Coordinate and manage the activities performed at site by him and by his
sub-contractors for execution of work and render all technical/specialist services.
v) Plan and schedule the construction work, monitor and take timely corrective action
when required to adhere to approved execution schedule.
vi) Plan, allocate and mobilize required resources, manpower, and construction
equipment/materials, commensurate with construction plan/schedule.
vii) Provide all temporary facilities required for Construction including drinking water,
lighting, office space, electronic transmission of drawings & documents, printing
facilities, rest rooms, crèches, first-aid, fire protection system, toilets, canteen facilities,
labour hutments, transport facilities for the workers and staff.
viii) Prepare & implement Quality Control and Quality Assurance plan.
ix) Prepare & implement Health, Safety & Environment (HSE) plan.
x) Report beforehand and take approval from OWNER/PMC regarding use of any

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 174 of 207

equipment and/or material not conforming to the contract, drawings and specifications.
xi) Execute and supervise all additional works and modification works as required or
suggested by OWNER/PMC as a part of approved change orders.
xii) Erect and install the equipments and materials according to the approved
specifications and procedures.
xiii) Establish required Field Inspection and Testing Laboratories at site to carryout tests as
specified in the standards/specifications of the contract.
xiv) To organize and obtain all applicable clearances/approvals from statutory
bodies/authorities, as required by the laws of land for the work executed at site shall be
the responsibility of the CONTRACTOR under the contract.
xv) Obtain approval of OWNER/ PMC for Welding Procedure Specifications (WPS)/
Procedure Qualification Records (PQR) as required. Carry out inspection, non-
destructive tests and analyze and certify acceptability of all welds and materials in
accordance with specified Technical Standards. Carry out inspection and testing of
incoming materials as per agreed procedures.
xvi) Prepare detailed schemes for Heavy/Critical Equipments' movement / erection / lifting /
rigging and submit the same for review / approval to OWNER/PMC before undertaking
such Critical/Heavy lifts/movements. Any modifications required including dismantling
and re-erection of structures/piping, etc for the existing facilities for smooth flow of such
heavy equipment shall be carried out by the CONTRACTOR at his own cost. However,
prior approval for such modifications shall be required from the OWNER.
xvii) Organize and conduct Weekly Project Review meeting related to site construction
activities.
xviii) Provide daily work progress reports and detailed weekly and monthly progress reports
summarizing percentage completion of the work including status of drawings, materials
and effects on approved schedule, areas of concern and corrective actions required
thereof. CONTRACTOR shall also identify any foreseeable delays in any aspect of the
WORK and take corrective actions to eliminate/minimize the effect on Overall
Completion Schedule. All progress shall be quantified.
xix) Take photographs and video recording of Project Construction Progress on regular
basis and submit the same to OWNER/PMC on monthly basis along with the Monthly
Progress Report.
xx) Prepare and submit records of all site meetings and any other related documents to all
parties concerned within two (2) days of the meeting.
xxi) Prepare and submit safety and labour relation procedures in line with all applicable
codes, regulations and OWNER'S requirements.
xxii) Supervise and monitor all safety and labour relation functions as per agreed
procedures and applicable laws of the land and report to OWNER immediately for any
violations and injuries.
xxiii) If any part of the facilities is completed and is under operation, while other parts of the
facilities are under construction, or work is to be carried in running Plant , it is essential
that rigid safety rules be prepared and maintained for all WORKS in accordance with
the requirements of OWNER/PMC.
xxiv) Maintaining all the records generated during project execution up-to-date and made
available to OWNER/PMC whenever requested. These records shall be handed over
to OWNER on completion of the work at no extra cost to OWNER.
xxv) Carryout warehouse management and material control in accordance with approved

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 175 of 207

procedure.
xxvi) Take all necessary precautions and required actions to protect construction work and
materials from damage by local weather conditions and ongoing construction activities
in the vicinity, theft and pilferage etc. till handing over of the plant to OWNER.
xxvii) Take insurance policies for materials in transit and storage-cum-erection risk and other
insurance covers required for men and materials at site as per SCC/ GCC in
consultation with OWNER.
xxviii) Undertake housekeeping including sweeping, clean up to maintain cleanliness,
sanitation, removing excess materials, temporary facilities, scaffolding, etc. on regular
basis till handed over to OWNER.
xxix) Prepare and submit to OWNER/PMC the following daily reports for construction
activities covering the following:
a. Weather
b. Manpower deployment category wise
c. Construction Equipments
d. Work Progress
xxx) Ensure the control of all works with regard to its impact on the surrounding environment.
xxxi) Ensure all hot works are performed outside hazardous areas and in compliance with
OWNER'S Safety Permit System requirements wherever applicable.
xxxii) Arrange and coordinate the visits of suppliers representatives/specialists at site.
xxxiii) All material handling equipment, tools, tackles, hoisting and lifting equipments/
machineries should be subjected to required load test initially and then periodically, to
ensure safe/stable operation.
xxxiv) Organize field engineering work, wherever required and ensure timely resolution of
interface problems / site constraints in consultation with OWNER/PMC.
xxxv) Prepare and certify material reconciliation statement on completion of work to enable
OWNER to take over the surplus materials, as applicable.
xxxvi) Organize the codification and handing over of surplus materials (as applicable) and
spares/ tools and tackles to the OWNER on completion of work.
xxxvii) Provide weekly/daily activity plan for site inspection.
xxxviii) Develop a phased mechanical completion program to facilitate sequential Pre-
commissioning/Commissioning activities in a logical manner to meet the Overall
Project Schedule.
xxxviii) Remove / demolish all temporary structures/ establishments/ facilities created by the
CONTRACTOR / his sub-contractors during the execution of the work and restore the
site to its original condition.
xxxix) Estimate monthly consumption of following utilities (if provided by OWNER):
a. Industrial water
b. Drinking water
c. Electricity

xl) Organize and conduct Positive Material Identification (PMI) of incoming materials and
of materials & welds after erection/installation, but prior to hydro testing of facilities,

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 176 of 207

using Portable Alloy Analyzer with print out facility as per procedure approved by
OWNER/PMC (Refer Document No. 6-82-0002). Any non-conformance detected shall
be removed and replaced prior to final hydro testing.
xli) Develop colour coding scheme (to avoid mix up during fabrication and erection) for
piping material and get it approved from OWNER/PMC.
xlii) Carry out tightening of flange joints by using hydraulic tensioner/ torque wrench as per
specifications. CONTRACTOR shall ensure that stud bolts are ordered extra long to
facilitate tensioning.
xliii) Organize safety induction programme for their manpower before deployment on work
and at regular intervals thereafter.
CONTRACTOR shall draw up a detailed activity list of pre shutdown activities and shutdown
activities (wherever applicable) and submit the same for the approval of the OWNER/PMC. All
endeavors shall be made to maximize the pre-fabrication before the planned shut down and to
minimize the work during shutdown period. All such activities shall be identified and
appropriately planned for temporary supports, scaffolding, clamping arrangements, enabling
works, etc. so that the quantum of the work during the shutdown can be minimized.

3.0 EXECUTION PLANS

CONTRACTOR shall submit Construction Execution Plan to OWNER/PMC for
review/approval during kick-off meeting. The Plan shall detail the execution methodology of
the CONTRACTOR during construction phase of the PROJECT covering following aspects as
minimum –
3.1 Construction Management Plan
CONTRACTOR shall submit Construction Management Plan to OWNER/PMC for approval
during kick-off meeting. The Plan shall detail the management methodology to be applied
during the construction phase of the PROJECT, along with a list of procedures to be utilized in
undertaking the work.
All reference procedures and detail work plans referred to in this document must be submitted
for review and approval by OWNER/PMC at least (4) four weeks in advance of actual
commencement of the activity concerned.
3.2 Construction Execution Plan:
It shall include the following as minimum:
3.2.1 Contractor’s manpower and man-hour histogram by major section and discipline and their
manpower deployment schedule on monthly basis.
3.2.2 Major equipment mobilization plan on monthly basis with short description. CONTRACTOR to
develop this plan with due consideration to maximize the mechanization of construction
activities.
Other plans of CONTRACTOR and procedures to be submitted at least four (4) weeks prior to
start of respective activity at site, include the following as a minimum:
a. Develop/ prepare pre-shut down/ shut down and post shut down plan including
resource mobilization plan and submit to OWNER/PMC for approval(where applicable).
b. Develop/ prepare construction/erection plan/procedures and submit to OWNER/ PMC
for approval.
c. Temporary facilities, etc.
d. Piling plan (if applicable)

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 177 of 207

e. Barricading Plan
f. Scaffolding plan
g. Excavation and underground work plan
h. Heavy transport and heavy lifting plan (Rigging Plan), If applicable
i. Pre-fabrication plan
j. Other activity plans e.g. piping, equipment and steel structure erection plan etc.
k. Monsoon counter measures and preparation
l. Emergency Evacuation Procedure
m. Storm Management Plan
n. Schemes to carry out works in inclement weather
Contractor shall ensure that lay down area (as applicable) given to him shall be utilized
optimally.

3.3 Sub-Contracting Plan

If CONTRACTOR proposes to engage sub-contractor(s) for the execution of some of the
activities at site, a preliminary sub-contracting plan along with the identified scope of work for
each sub-contract shall be furnished by the CONTRACTOR to the Owner/PMC at the time of
bid submission. However, the credentials of proposed Sub-contractor(s)’s shall be submitted
by the CONTRACTOR on award of work, which shall be evaluated by OWNER/PMC at SITE
for acceptance. CONTRACTOR shall not be permitted to change the sub-contractor under any
circumstances without prior approval of OWNER/PMC. Non-compliance of the above shall be
strictly dealt within relevant provision(s) of the contract.
The sub-contracting plan shall cover
i) Sub-contracting philosophy
ii) List and scope of work of each subcontract
iii) Subcontract administration plan
iv) Organization chart of each sub-contractor.
The list and major scope of each subcontract shall not be changed from those of the
CONTRACTOR’S plan unless specially approved by OWNER.

4.0 TEMPORARY FACILITIES

The CONTRACTOR shall arrange the following temporary facilities as the minimum (including
for his sub-contractors also):
i) Exact location of temporary work area, access and general layout inside the area.
ii) Planning and description of the temporary facilities such as:
a. Identification of borrow earth area (if required)/excess earth dumping yards
b. Site office and Fabrication yards, Open storage area and Warehouse
c. Miscellaneous workshops including maintenance area for construction
equipments.
d. Temporary roads including access road to Plant, fencing and gates

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 178 of 207

e. Security, watch & ward, security gates, etc.

f. Utility supply systems viz. Construction power with DG Sets, construction
water, drinking water etc.
g. Area lighting
h. Fire fighting equipments
i. Drainage and Sanitation
j. Camp Accommodation
k. Field Testing Laboratory
l. Radiography Source Pit as per BARC Guidelines
m. Film processing and viewing labs
n. Communication facilities viz. Telephone, Fax, E-mail, electronic transmission of
drawings./ documents, etc.
o. Hutments, transport, Pantry and Canteen for staff and workers. Hutments/
labour colony shall not be allowed inside the petrochemical complex.
p. Vehicle parking area including construction equipments.
q. First aid arrangement/ medical and health care facilities
r. Gate pass for workmen/officials/ vehicles as per OWNER security system.
s. Work Permits as per Owner’s prevailing system.
CONTRACTOR shall develop the temporary facilities layout for approval of OWNER/PMC.
5.0 CONSTRUCTION PLANNING, SCHEDULING, MONITORING & REPORTING
The CONTRACTOR shall be responsible for construction Planning, Scheduling, Monitoring
and Reporting activities at site in line with the overall master schedule and details stipulated
elsewhere in the PACKAGE.
6.0 QUALITY ASSURANCE AND QUALITY CONTROL (QA/QC)
The CONTRACTOR shall be responsible for ensuring quality of construction (including
materials) carried out by him/his approved sub-contractors in accordance with the
requirements given in section for Quality Assurance / Quality Control (QA/QC) during
construction including all documents referred therein.
7.0 WAREHOUSE MANAGEMENT & MATERIAL CONTROL
The CONTRACTOR shall construct/ build warehousing facilities (both covered and open)
appropriate for storing materials required for the job. The facilities shall include proper
lighting, fire protection system, office/rest rooms/toilets for warehouse personnel.
The CONTRACTOR shall obtain all statutory approvals from concerned authorities for all
warehouse equipment, instruments etc. The CONTRACTOR shall comply with statutory
regulations for storage of any material covered under Explosives rules.
The CONTRACTOR shall be responsible for carrying out the Warehouse Management and
Material Control in accordance with the approved warehousing procedure and material control
procedure, which is to be submitted by the CONTRACTOR during kick-off meeting. The
activities shall include but not limited to:
- Transport Liaison, both for imported materials as well as materials procured
indigenously, from the time of dispatch up to receipt at site.
- Transportation Plan (i) from source to site (ii) site to erection location.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 179 of 207

- Filing of insurance Claims and follow up.

- Documentation for control and accounting of materials.
- Generation and upkeep of Traceability Records for materials.
- Materials Control & Issue.
- Inventory Checks.
- Field Requisition and Purchase.
- Spare & Tools including handing over of mandatory Spares/Tools to the OWNER as
per the terms of the contract.
- Material Appropriation and Handing Over of all items to OWNER with Owner’s
codification system.
- Security.
- Taking up with suppliers on short supplied items and placing replacement orders for
lost/damaged items.
- Intimating short/lost/damaged items received at site and further replacement action, as
applicable.
CONTRACTOR shall generate and issue following reports:
- Fortnightly statement of consignments in transit.
- Daily report of material received.
- Material receipt status and inventory status w.r.t. material delivery schedule
- Material Inspection Report with respect to materials received at site
- Report on Over/Short/Reject/Damage (OSRD) receipts against each consignment on
receipt at warehouse.
- Weekly status of consignments, Material Receipt Report (MRRs)
- Monthly status of field purchase.
- Monthly status of over, short, reject & damage (OSRD) settlement.
- Monthly status of piping material MTO V/s Actual receipt.
- Log Register of Rotating Equipments maintenance
- Daily Stock Position of Cement
- Any other report as desired by OWNER/PMC.
8.0 FIELD ENGINEERING
CONTRACTOR shall be responsible for controlling and issue of technical drawings and
documents, preparation of field sketches, field modifications, checking/preparation of as-built
drawings, etc. CONTRACTOR should have adequate facilities for incorporating field changes,
preparation of As-built drawings, Printing machines and Drawing & Document Control System.
9.0 FIELD TENDERING
CONTRACTOR shall be responsible for carrying out field tendering activities, as required from
the site itself.
10.0 FIELD PURCHASE
CONTRACTOR shall be responsible for carrying out field purchase activities, as required.
Field Purchase items are restricted to those required for running and maintenance of the field

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 180 of 207

offices, items required to expedite construction work and items found short, missing or
damaged against the main order when received at the site. Any material purchased from field
for usage in the plant should have proper inspection certificate and should be purchased from
OWNER/PMC approved suppliers. If required by OWNER/ PMC, check testing of the material
samples selected by OWNER/PMC shall be carried out by CONTRACTOR without any extra
commercial implication.
11.0 HEALTH, SAFETY AND ENVIRONMENT (HSE) MANAGEMENT
The CONTRACTOR shall be responsible for Health, Safety and Environment (HSE)
Management at construction site for the construction activities to be carried out by the him/his
approved sub-contractors in accordance with the requirements mentioned in section for
Health, Safety and Environment Management during construction.
12.0 HOUSE KEEPING
It is the responsibility of the CONTRACTOR to maintain general cleanliness and proper
housekeeping at work site. CONTRACTOR shall organize disposal of excavated earth
/garbage/ rubbish/scrap, etc. on day to day basis to identified disposal areas/safe areas and
forward daily report for the same indicating the details of men and machinery deployed for the
purpose; if asked by OWNER/PMC.
Wastage and serviceable/ unserviceable scrap generated during dismantling and regular
works shall be segregated and dumped in designated locations in consultation with
OWNER/PMC. Earth and landfill materials shall be dumped at locations identified by
OWNER/PMC, otherwise outside the Project Site and the required fees charged by the local
authorities shall be borne by the CONTRACTOR without any extra cost to OWNER.
13.0 INDUSTRIAL LABOUR RELATIONS
CONTRACTOR shall be responsible for industrial relation functions and implementation of
labour laws at site. CONTRACTOR'S staff shall be suitably trained and experienced in Labour
Relation functions so as to ensure a good relationship with labour and to prevent the
occurrence of industrial disputes resulting in subsequent delays or work stoppages. In
particular, CONTRACTOR shall maintain close liaison with OWNER/PMC .
CONTRACTOR shall maintain proper liaison with Statutory Authorities and local bodies and
shall be responsible to implement and observe all statutory laws at site. CONTRACTOR must
have in his staff; a well experienced Labour Relation Officer.
CONTRACTOR shall maintain the records of wages paid in a wage register, PF, etc. as per
statutory regulations.
CONTRACTOR shall report immediately to OWNER/PMC any problems including labour
disputes, fight, and work stoppages. A written report shall be submitted to OWNER/PMC
within 24 hours of the incident.
CONTRACTOR must submit a Labour Relation Plan including their sub-contractor(s) prior to
the start of the work/within one month of award of the contract, whichever is earlier,
mentioning as a minimum:
A detailed estimate of the number of labour, both indirect and direct, sorted by craft.
a. Outline recruiting plans for all manpower requirements.
b. Identify personnel involved with labour relations and outline procedures to mitigate labour
disputes & problems.
c. Labour welfare plan
CONTRACTOR shall hold labour relations meeting twice a month with their work force as well
as a separate meeting with the OWNER.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 181 of 207

14.0 CONSTRUCTION EQUIPMENTS

The CONTRACTOR is required to organize and mobilize the construction equipments and
other tools/tackles in a sequential manner and ensure that plant installation is carried out in a
mechanized manner to the extent possible and its mechanical completion is achieved within
targeted time schedule.
CONTRACTOR shall ensure deployment of the following construction equipment as a
minimum as per requirement to the maximum extent –
i. Cranes of different capacities
ii. Tower crane
iii. Portable Alloy Analyzers with print out facility
iv. X-ray and Radiography sources
v. Stress Relieving Equipments with Recording facility
vi. All weather fabrication sheds
vii. Blast cleaning and Painting Shop
viii. Welding machines
ix. DG sets
x. Electrical and Instrumentation equipments/measuring devices etc.
xi. Concrete Vibrators
xii. Bevel Cutting Machines
xiii. Test Pumps
xiv. Compressors
xv. Gas and Mechanical cutting devices
xvi. Various inspection / measuring devices
In order to minimize fabrication at site, all (major) fabricated equipment like Columns/Towers,
Vessels shall be transported preferably in single piece due to limitation of space at site.
Deviation to this shall be specified at the bidding stage itself. CONTRACTOR shall carry out
the route survey for transportation of 'Over Dimensioned Consignments' including waterways
from source of manufacture/supply to site well in advance of placement of order to ensure
unhindered transportation of the same to construction site. CONTRACTOR shall arrange
Cranes of suitable capacities to match with the erection requirements and inform the source
and ownership of the same.
Crane movement roads are to be clearly identified and marked on the plot plan before
planning of such movement. Construction of hard stands for positioning of crane in the
fabrication yard and at erection site/locations including approach roads to the hard stands from
the plant roads shall be CONTRACTOR’S responsibility. The hard stands shall be suitable for
the crane loads (self load + equipment load) to facilitate erection works and to be tested for
any settlement.
For the purpose of Equipment Erection, the CONTRACTOR shall deploy a Rigging team
headed by a Rigging Foreman/Engineer reporting to concerned Area Engineer. Area Engineer
should be well conversant with various erection techniques and shall be
responsible for preparing erection schemes in accordance with the approved procedures and
based on crane manuals and suiting to plant layout. Area Engineer shall have to foresee
various other construction activities in the surroundings areas while planning erection
schemes including safety aspects of man and machinery also.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 182 of 207

CONTRACTOR shall prepare erection schedule in line with the overall project schedule of the
Plant in phased manner with erection schemes of various equipments, vessels and submit to
OWNER/PMC for approval, Monitoring and control of erection schedule and erection activities
shall be carried out by the contractor as per the approved construction procedures.
For efficient working and maintenance of construction aids, CONTRACTOR shall establish
and maintain crane yard / workshop equipped with regular maintenance facilities for various
construction aids for carrying out routine field maintenance during performance of the contract.
Temporary approach road and hard stands, wherever required for the movement of the
Cranes and other vehicles for equipment erection and transportation of material shall be
properly planned and made by the CONTRACTOR. Weekly/fortnightly maintenance shall be
planned in such a way that the same does not hamper the erection schedule.
During performances of the work, CONTRACTOR must ensure that structures, materials and
equipments are adequately braced with Guys, Struts or any other means as deemed fit &
approved by Owner/PMC. Such means shall be supplied and installed by the
CONTRACTORS as required till the erection works is satisfactorily completed. Such guys,
shoring, bracing, strutting, planking supports etc. shall not interfere with the work of other
agencies and shall not damage or cause distortion to works executed by other agencies. All
lifting tools, tackles and cranes shall be tested periodically by statutory/ competent authorities
for their load carrying capacity. Such relevant valid/test certificates shall be submitted to
OWNER/PMC for review before actual use of the tools, tackles and cranes.
CONTRACTOR shall submit the construction equipment deployment schedule. Daily
construction equipment deployment report will also be submitted by the CONTRACTOR to
OWNER/PMC.
CONTRACTOR shall ensure the timely augmentation of the men, equipments and machinery
depending upon the exigencies of the work to meet the overall project schedule and as per
instructions of PMC/OWNER.
15.0 CONSTRUCTION MANPOWER
The CONTRACTOR is required to organize and mobilize construction staff/ manpower in a
sequential manner to ensure that the work is carried out in accordance with the construction
schedule. Mobilization of construction staff should be such that the progress achieved in
phased manner should match with the overall Project Schedule.
For this purpose, the CONTRACTOR shall clearly indicate in his construction methodology
whether work shall be done departmentally or by engaging sub-contractor or the combination
of both. CONTRACTOR shall prepare detailed methodology for the work to be carried out
departmentally as well as through sub-contractors clearly, defining the scope and re-
sponsibility of CONTRACTOR and his sub-contractors.
The works of all sub-contractors shall be managed by the construction staff of the main
CONTRACTOR who shall perform the duties of construction management and shall
administer, coordinate, and inspect the works of the sub-contractor(s) and be responsible for
the Quality and timely completion of respective works. The CONTRACTOR shall establish the
pre-requisites for successful completion of sub-contractor (s) work. However, by deploying the
sub-contractor (s), as approved by OWNER/PMC for any discipline, does not absolve the
CONTRACTOR of his total responsibility under the subject contract.
The CONTRACTOR must note that in case of any sub-contractors' failure to execute the
works as per standards/specifications/drawings and/or negligence & disobedience in carrying
out any order or instruction of OWNER/PMC, the same shall be viewed very seriously and any
action as deemed fit in accordance with provision(s) of the contract shall be taken by
OWNER/PMC.
CONTRACTOR must submit the construction manpower deployment schedule along with the

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 183 of 207

bid. Daily construction manpower deployment report shall also be submitted by the
CONTRACTOR to OWNER/PMC on approved format. Any additional manpower of any
category required to be deployed during the actual execution of the work to meet the Project
time schedule and as instructed by OWNER/PMC, shall be mobilized by the CONTRACTOR
within a reasonable time. Mobilization of such additional manpower by the CONTRACTOR
shall not entitle him for any additional compensation at all.
All construction supervision, coordination and management activities shall be carried out by
the CONTRACTOR in accordance with the construction procedures approved by
OWNER/PMC. CONTRACTOR shall prepare construction schedules based on the Overall
Project Schedule of the PLANT and submit the same to OWNER/PMC for approval.
Monitoring and control of the construction activities shall be carried out as per the approved
construction schedule & procedures.
During the execution of works at site, if the CONTRACTOR engages sub-contractor (s) for
execution of works at site as per approval obtained from OWNER/PMC in line with contract
provision(s) and in the event sub-contractor complains in writing to the OWNER with regard to
the non-payment of their dues from the CONTRACTOR for the works executed by them
(excluding final payments and payments due after termination of sub-contractors' services by
the main CONTRACTOR), OWNER/PMC reserves the right
to make such payment to the sub-contractors directly based on approved measurements with
due notice to the CONTRACTOR. OWNER/PMC shall release such payments to sub-
contractor at the cost and risk of the CONTRACTOR in order to ensure smooth execution of
work at site. All such payments made by OWNER/PMC to the sub-contractor(s) shall be
deducted from the running account bills or any other payments due to the CONTRACTOR.
The above provisions shall also be applicable in case of construction materials procured at
site by the CONTRACTOR from the suppliers.
16.0 INTERFACE WITH OTHER CONTRACTORS
CONTRACTOR shall ensure that his interface with other CONTRACTORS is smooth and
cordial. In case of any dispute, OWNER/PMC decision shall be binding.
OWNER/PMC may arrange weekly/fortnightly/monthly interface meetings. The
CONTRACTOR shall depute concerned personnel to attend these meetings.
Generally, the following interfaces may be present:
 CONTRACTOR shall allow movement of persons/ material/ equipment/ vehicles
belonging to other CONTRACTORS or OWNER/PMC through the roads constructed
by him.
 CONTRACTOR shall coordinate with ‘neighboring’ contractors for maintaining
elevations/levels of various interconnecting services.
 CONTRACTOR shall not dump his earth, scrap or any material in other Contractors’
area. He shall cooperate with OWNER/PMC in maintaining good housekeeping
throughout the complex.
 CONTRACTOR shall ensure proper drainage and no water logging in his area/other
areas.

 If requested by the OWNER/PMC, CONTRACTOR shall allow testing of materials of

other Contractors in his laboratory, in case of emergency.
 CONTRACTOR shall clearly define in the interface meeting with other contractors their
erection / construction interface at their Battery limits.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 184 of 207

17.0 CHECKLIST FOR INSPECTION OF FLANGED JOINTS

Standard Procedure for boxing of interface joints, not subjected to hydrostatic tests at site,
shall be strictly followed (Refer Procedure No. 5-7700-0120).
18.0 COLOUR CODING OF PIPING MATERIAL
Specification for colour coding of Stored Piping Material No. 6-82-0003 shall be uniformly
followed for the entire facilities
.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 185 of 207

SECTION – I
HEALTH, SAFETY AND ENVIRONMENT
(HSE) MANAGEMENT DURING
CONSTRUCTION

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 186 of 207

GENERAL REQUIREMENTS

1.0 Specification for Health, Safety and Environment (HSE) Management (Spec. No. 6-82-0001),
is required to be followed by CONTRACTOR during Construction Phase at site.
2.0 CONTRACTOR shall have a documented HSE policy to cover commitment of the organization
to ensure Health, Safety and Environment aspects in the line of operation.

3.0 It is the responsibility of the CONTRACTOR to ensure that safe construction procedures are
complied with. CONTRACTOR will also ensure that adequate First Aid medical facilities are
available for emergency purpose and that safety practices as per the approved safety
procedure are followed by his sub-contractors also.
CONTRACTOR to ensure safety measures at the minimum like:
a) The use of safety gadgets, viz. safety goggles, helmets, safety shoes, full body
harness, provision of safety net for construction at higher elevations and provision of
toe boards in scaffolding platforms, etc.
b) All hot works must be performed by ensuring compliance to the requirements as
specified by the Owner from time to time.
c) Barricading of crane movement areas / Radiography areas
d) Proper earthing of equipments.
e) Proper shoring / strutting of Excavated Areas, as applicable.
f) Cylinders of inflammable gases to be stacked upright.
To assist in the development of an effective safety program, a safety checklist for various jobs
shall be developed by the CONTRACTOR and the same shall be adhered to by the
Contractor's Site-In-charge.
The responsibilities of the CONTRACTOR will include but not limited to:
- Coordination and supervision of the details of the job safety programme.
- Initiation of accident reporting, investigation and follow-up actions.
- Preparation of periodic accident summaries.
- Periodic Accident Analysis Reports
- Tallying safety inspection of the job and submission of summary inspection report to
OWNER/PMC.
- Obtaining work permits from the OWNER, wherever applicable.
- Check the fitness of cranes and other hoisting equipments on periodic basis/before all
major lifts and submit to Owner/PMC valid/latest test certificates of tackles used for
lifting.
- Submission of any other report required by Owner/ PMC.
4.0 Guidelines on Safety Practices during Construction and Contractor Safety prepared by Oil
Industry Safety Directorate (OISD) Nos. OISD-GDN-192 & OISD-GDN-207 shall be followed
by the contractor at site. Safety Recommended Practices for Electrical System (OISD-RP-
147) shall be followed by the contractor at site. These are supplementary requirements in
addition to specification for Health, Safety and Environment (HSE) Management (Spec. No. 6-
82-0001) to be followed by the CONTRACTOR at site. In addition, the CONTRACTOR is

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 187 of 207

required to maintain and submit Safety Statistics for last three years along with the bid as
per Performa enclosed.
5.0 Any Observation on Safety aspects ,EIL/PMC shall raise OSA format which has to be
acknowledged & compliance to be done by the contractor within the agreed time period.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 188 of 207

Exhibit - Safety Statistics

Sr. Description Year xxxx Year xxxx Year xxxx

No.
1 Number of Fatal Accidents
2 Number of Reportable Lost
Time Injuries (RLTI)
3 Number of Near Miss
Accidents / Dangerous
Occurrences
4 Number of First Aid
Accidents
5 Number of Man Hours
Worked without (RLTI)
6 Number of Man hours lost
due to Accidents
7 Frequency Rate
8 Severity Rate

 Only construction site to be considered for statistics and not the office.
 For every site separate sheet with above details to be submitted for the aforesaid periods.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 189 of 207

OBSERVATION ON SAFETY ASPECTS

Job No: Name of Work: No:

FOI/LOANo:
Issued To : M/s Date of issue:
Location Of Work:
Item Of Work:
Details Of Lapses/Shortfalls/Hazards Identified Recommended Course Of Action

Suspension of work required till resolution.

(Yes/No)

Time Allowed For Correction:

Issued By: Received by:

Name : Name:
Designation: Signature:
Signature: Date and Time:
Corrective Action Report By Contractor/Vendor:

Date: Name And Signature:

Distribution Before Resolution:

RCM/ Area Coordinator/QA Mgr :
Verification Of Resolution By Issuer/Area Coordinator/RCM (EIL):

Name:
Date: Signature:
Distribution After Resolution:
: RCM/ Area Coordinator /QA Mgr:

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 190 of 207

SECTION – J
QUALITY ASSURANCE / QUALITY
CONTROL (QA/QC) DURING
CONSTRUCTION

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 191 of 207

1.0 SCOPE
This document shall be applicable to all construction works to be executed by CONTRACTOR.
2.0 RESPONSIBILITY
It is Contractor’s prime responsibility to arrange/produce the product conforming to contract
specifications and inspect all equipment, materials and works at various stages of execution
as per the approved QA Plans. In addition, they have to coordinate all efforts in this regard
directly with the OWNER/ PMC and other involved agencies to give adequate confidence that
the activities are performed as per agreed ITPs and necessary documentation is available.
Verification by Owner/PMC or his representative at any stage shall not relieve
CONTRACTOR of his responsibility towards quality of the product.
The CONTRACTOR shall comply with all statutory rules & regulations in force during
execution of work and interface with such authorities as required.
3.0 METHODOLOGY
The management of construction quality control is divided into the following categories:-
(1) Procurement of materials required for the construction work.
(2) Execution of work
(3) QA/QC Audits
3.1 PROCUREMENT OF MATERIALS REQUIRED FOR THE CONSTRUCTION WORK
The CONTRACTOR shall develop list(s) defining the items to be procured along with
proposed Vendors for approval of the Owner/PMC. The list shall comprise of all items except
vessels, equipments, pumps, electrical/ instrumentation panels etc. which may be available
directly ready for installation or requiring small fabrication as per requirement. The vendor list
shall be in line with the contract document. In case, no vendor list exists in the contract for a
particular item, the CONTRACTOR shall propose a list of Vendors to Owner/PMC.
CONTRACTOR has to satisfy himself with the capability of the vendor to deliver the product in
time with quality before proposing him as a prospective vendor. CONTRACTOR shall submit
the QA/QC plans for all major items and carry out their procurement in line with the approved
plans. The CONTRACTOR can either provide his own adequate qualified staff for inspection
or employ a separate third- party inspection agency with prior approval to carry out these
functions. Involvement of OWNER/ PMC in the quality control plan, if required, shall be
defined during approval of the same.
3.2 EXECUTION OF WORK
(i) The QA plans for execution shall be developed by the CONTRACTOR in consultation
with Third party Inspection agency. OWNER/ PMC’s approval for the same shall be
taken well before start of the work. The final Inspection & Test Plans (ITPs) and
formats, shall be developed by the CONTRACTOR in consultation with Third party
Inspection agency as per contract specifications for approval by OWNER/ PMC.
CONTRACTOR shall be completely responsible for management of approved quality
plans and OWNER/PMC involvement will be only of Surveillance in nature to randomly
check the works at selective/critical junctures. Their role shall be to monitor that the
CONTRACTOR/ TPIA is executing the quality plans as per the approved drawings,
employing adequately qualified staff, third-party inspection agency and other resources
for various items of works. Any deviation to the specifications shall be brought to the
notice of OWNER/ PMC in prescribed formats by CONTRACTOR for approval.
(ii) It is likely that the CONTRACTOR may engage sub-contractor(s)/vendors for
performance of the work. CONTRACTOR shall be responsible for ensuring the
implementation of approved QA plan, contract specifications and contract conditions

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 192 of 207

through their sub-contractors to achieve the quality during all stages of construction. It
shall be the responsibility of the CONTRACTOR to ensure proper coordination
between his sub- contractor(s) and other agencies working at site.
The sub-contractor(s)/vendors selection shall be done after evaluation by the
CONTRACTOR in line with contract requirements and shall be got approved by
Owner/PMC before engaging them for the works.
(iii) Storage
All the materials procured shall be stored/stacked as per the standard norms and as
recommended in various clauses of relevant codes and contract document. The
storage of material shall be such as to avoid damage to life/properties (physical and
chemical) of the materials. The storage shall not cause deterioration, rusting, mix-up
etc. and hamper the other related works in any way. CONTRACTOR shall submit his
detailed warehouse plan for OWNER/ PMC approval to manage the above in
open/covered areas.
The materials susceptible to fire shall be kept away in a separate protected place.
In general, the materials shall be kept systematically in order of their class, batch
number and identification number, so that they are accessible for the inspection by
OWNER/ PMC whenever required and to avoid the mix up in those materials.
(iv) Use
The materials shall be stacked in such a way that the lot, which is procured first, will be
consumed first. For materials which are having specific expiry date/ shelf life shall not
be used beyond that date and shall be removed from site. Wherever there is any doubt
about the change in properties of the materials, such materials shall be sent to reputed
approved laboratory for testing and acceptance.
(v) Inspection
The CONTRACTOR shall be responsible for carrying out inspection of the materials
brought at site and conducting tests/ checks (at site or in approved laboratories) at
predefined frequencies as per contract. It is the responsibility of the CONTRACTOR to
ensure that the materials used at site shall conform to relevant codes/ standards and
Manufacturer Test Certificates are available for correlation as and when required. The
CONTRACTOR shall maintain the records of all materials brought at site and tests
conducted on them duly endorsed by TPIA.
(vi) In process and final Inspection
CONTRACTOR shall be responsible to arrange verification of products during in-
process and final inspection. Relevant checks and tests shall be arranged for the
works performed and records maintained. Tolerances achieved with respect to
contract specification and execution drawings for various activities/processes shall be
ascertained and submitted to OWNER/ PMC for approval. Efforts shall be made to
keep checks and controls in such a way that a non-conforming product is avoided.
However, if in an isolated case, the tolerances are beyond the acceptable values given
in the contract/execution drawings/codes, non-conformance resolution/Deviation permit
need to be raised by the CONTRACTOR and got approved/resolved from OWNER/
PMC. The CONTRACTOR shall maintain the records of all process and inspections
conducted by them duly endorsed by TPIA.
The CONTRACTOR shall arrange verification of ingredients used and validation of the
software used at the batching plant(s). OWNER/ PMC reserve the right to inspect the
working of batching plant including validation of the software used and calibration of
measuring & monitoring devices any time. The CONTRACTOR shall ensure the

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 193 of 207

quality of the concrete delivered by the transit mixers, as applicable and maintain
verifiable records.
CONTRACTOR shall mobilize Portable Alloy Analyser(s) with printout facility and
carry out 'Positive Material Identification (PMI)' of materials and welds after
erection/installation but prior to hydro-testing. Any non-conformance detected shall be
removed and replaced prior to final hydro testing.
The CONTRACTOR shall develop color coding scheme of stored piping materials to
avoid mixing up of material at different stages of construction and submit it to
OWNER/PMC for approval
vii) Any Observation on quality aspects ,EIL/PMC shall raise OQA format which has to be
acknowledged & compliance to be done by the contractor within the agreed time
period.
viii) The CONTRACTOR shall follow the requirements given for control of monitoring and
measuring devices as per table-1.
3.3 QA/QC AUDITS
During the execution of the works, CONTRACTOR shall carry out periodical Quality Audits at
least quarterly in all areas of work. These audits will be conducted by a team of specialists in
the respective areas. The auditors shall not be directly involved in the jobs being audited.
The CONTRACTOR shall prepare an Audit Plan and Procedure and submit the same to
OWNER/ PMC for approval.
A copy of the Audit Report containing the findings of the Audit team will be submitted to
OWNER/ PMC. After completion of rectification/modifications/corrective actions on the issues
indicated in Audit Report, Compliance Report shall be submitted by the CONTRACTOR to
OWNER/ PMC for review.
Over and above the Contractor’s Internal QA/QC Audits outlined above, OWNER/ PMC shall
also reserve the right to conduct QA/QC audits at the frequency decided by them.
CONTRACTOR shall participate and provide full support to the Audit Team and furnish all
documents/reports/records as desired by the Audit Team. The CONTRACTOR shall take all
actions required to comply with the findings of the Audit Report and issue regular Compliance
Reports for the same to OWNER/ PMC till all the findings of the Audit Report are fully
complied.
In case major Non conformities are observed during execution of the works OWNER/ PMC
reserve the right to appoint an independent person/Third Party Agency to conduct QA/QC
Systems Audit for full/part of the facilities being executed by the CONTRACTOR. This
audit will be in addition to the audits described above and may be carried out
intermittently/continuously for all or part of the facilities being executed by the
CONTRACTOR. CONTRACTOR shall bear the total cost of such audits and shall participate
& provide full support to the Audit Team and ensure compliance of the audit observations.

4.0 DOCUMENTATION AND RECORDS

All the necessary documentation & records shall be maintained by CONTRACTOR till
completion of project and handed over to OWNER/ PMC in requisite copies as a part of
completion documents. Wherever OWNER/ PMC personnel were directly involved particularly
in witness and hold point, the copies of the records shall also be provided to personnel on
completing inspection of those activities. All the documentation & records shall be endorsed
by TPIA which shall include the following as a minimum but not limited to:
i) Approved Quality Assurance Plan

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 194 of 207

ii) Approved Inspection and Test Plans

iii) Inspection and test documents covering
a) Manufacturer Test Certificate
b) Material Receipt Report including Inspection Release Note, if applicable and
Site Inspection and acceptance Report on quality and quantity of material
c) Site test/laboratory test Report reviewed by CONTRACTOR for acceptance vis-
à-vis to contract/code requirements for materials/including PMI report at
warehouse
d) In process Verification reports of CONTRACTOR representative and OWNER/
PMC as applicable
e) Final verification report including any test checks done for compliance
f) As-built vis-à-vis to contract/drawings including tolerances
g) As-built for erection
h) Non conformance resolution raised by CONTRACTOR/OWNER/ PMC
i) Concession/Deviation approval by OWNER/ PMC
j) Change order approval by OWNER/ PMC incase there is variation from
contract
k) QA/QC Audit Reports and compliance Reports thereof
l) Mechanical Completion formats

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 195 of 207

OBSERVATION ON QUALITY ASPECTS

Job No: Name of Work: No:

FOI/LOA No:
Issued To : M/s Date of Issue:
Location Of Work:
Item Of Work:
Details Of Observation( Deficiency) Recommended Course Of Action

Time Allowed For Correction

Issued By: Received by:

Name : Name:
Designation: Signature:
Signature: Date and Time:
Corrective Action Report By Contractor/Vendor:

Name
Date: Signature:

Distribution Before Resolution:

RCM/ Area Coordinator /QA Mgr:
Verification Of Resolution By Issuer/Area Coordinator/RCM(EIL):

Name:
Date: Signature:
Distribution After Resolution:
RCM/ Area Coordinator /QA Mgr:

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 196 of 207

TABLE -1
Requirement for control of monitoring and measuring devices

Sl.
Description Calibration requirements Frequency Remarks
No.
Civil-Survey

1. Theodolite To check for permanent once in a year or Record to be

adjustments by traversing project duration maintained
and observing the closing whichever is (See note
error earlier below)

2. Levels To check by Backsight/ Every use Record to

Foresight readings, the be maintained
temporary adjustments of (See note
level below)
3. Steel a. "Freemans" make ---- ---
measurement or BIS approved
tapes make shall be used
b. Mutilated, or
broken tapes shall
not be used
c. Legible markings
4. Cross staff Same as 3b&3c above --- ---

5. Distomat Actual Physical Before using Records to be

Verification at Site first time at site maintained
6. Total Station To check for permanent once in a year or Record to be
adjustments by traversing project duration maintained
and observing the closing whichever is (See note
error,etc. earlier below)

Civil Laboratory

7. All balances- Check for zero error Whenever used ---

Mechanical
8. Weigh Calibration of scales Once in three Records to be
Batcher/Batching months maintained

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 197 of 207

Sl.
Description Calibration requirements Frequency Remarks
No.
Plant
9. Cube testing Calibration certificate from As per Records to be
machine manufacturers or from manufacturer maintained
reputed calibrating agency. specification or
once a year
whichever is
earlier
10 Moisture Meter Calibration of scales 6 months Records to be
maintained

Mechanical/
Electrical/
Welding
11 Pressure Gauges Calibration certificate from Once in 6 months Records to be
reputed laboratories or maintained
calibrate by dead weight
testers with standard
weights or with master
Gauge
12 Dial gauges Check for Zero Error Whenever used ---

13 Dead Weight Calibration from As per Records

Tester manufacturer or reputed manufacturer's (Calibration
calibrating agency and recommendation certificate) to
calibration certificate shall or once in a six be maintained
not be older than one month whichever
month from the date of is earlier.
mobilization.
14 Vernier caliper/ Check for Zero error Whenever used ---
screw gauge

15 Holiday tester Calibration from Once in 6 months Records to

manufacturer or reputed be maintained
calibrating agency or by
calibrating by zeep meter.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 198 of 207

Sl.
Description Calibration requirements Frequency Remarks
No.
15 Elcometer Check with standard test Before use Records to
films supplied by the be maintained
manufactures
16 Universal Testing Calibration Certificate As per Records to
Machine from any reputed third party manufacturer's be maintained
inspection agency. viz, recommendation
CEIL, LRS, BV, ABS, DNV or once a year
or IRS. whichever is
earlier
17 Charpy V-notch Calibration Certificate As per Records to be
Impact testing from any reputed third party manufacturer's maintained
machine inspection recommendation
agency. viz, CEIL, LRS, BV, or once in a year
ABS, DNV or IRS. whichever is
earlier
18. Hardness Testing Check with the standard Before use Records to be
Machine test block supplied with the maintained
machine as per
manufacturer's
Recommendation
19. Chemical Analysis Check with the Before use Records to be
,ex :PMI etc. standard samples maintained

20. Various Digital Calibration Certificate from Once in Six Records to be

and Analog reputed laboratories or the Months or as per maintained
meters manufacturer manufacturer’s
recommendation
whichever is
earlier.
21. Variable current, Calibration Certificate from Once in Six Records to be
voltage and reputed months maintained
resistance laboratories
generators
22. Temperature/ Calibration from Once in Six Records to be
Pressure manufacturer or any months maintained
Recorders reputed calibrating

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 199 of 207

Sl.
Description Calibration requirements Frequency Remarks
No.
agency
23. Temperature Calibration Certificate Once in Six To be discarded
gauges from reputed months in case of
laboratories damage or
malfunctioning
24. Thermocouples Manufacturer’s Certificate --- ---
or Chemical Check

25. Vibration probes Calibration from Once in a year To be discarded

reputed laboratory in case of
damage or
malfunctioning
26 Decibel-meter Calibration from Once in a Year - do -
reputed laboratory

Note: If Error is found, it has to be sent to manufacturers or their agents for rectification and
certification & reputed laboratory shall be NABL accredited for relevant testing.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 200 of 207

SECTION – K
LIST OF ATTACHMENTS

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 201 of 207

LIST OF ATTACHEMENTS

S. TITLE DOCUMENT NO.

No.
A GENERAL
1 Planning, Scheduling, monitoring & Control System for Package 8-2744-1002
contract
2 Typical Inspection methodology and coordination procedure for 5-1842-0005
EPCC/ LSTK or Package Supplier
3 Specification for Quality Management System requirement from 6-78-0001
bidder
4 Specification for documentation requirement from contractors 6-78-0002
5 Specification for documentation requirements from suppliers 6-78-0003

B DATA SHEETS, FORMATS & EXPERIENCE RECORD

1 GENERAL CIVIL (Refer Note-1)
1.1 Technical data Sheet Cooling Tower EIL-1647-1852
1.2 Tower Sizing Data for Cooling Tower (By Fulkerson’s Method) for EIL-1647-1853
counter flow tower
1.3 Tower Sizing Data for Cooling Tower (By Kelly’s Method) for cross EIL-1647-1854
flow tower

2 ROTATING EQUIPMENT (Refer Note-2)

2.1 Typical Data Sheets
2.1.1 Data Sheet for Centrifugal Pump (Horizontal – General Purpose 16-45-DS-01
Process Service (1 Sheet)
2.1.2 Data Sheet for Centrifugal Pump (Horizontal -General Water 16-45-DS-02
Service / Large Capacity Water Service)(1Sheet)
2.1.3 Data Sheet for Centrifugal Pump (Vertical) (3 16-45-DS-03
Sheets)
2.1.4 Data Sheet for Controlled Volume Pumps (2 16-45-DS-04
Sheets)
2.2 Typical Experience Record Proforma (Refer Note-2)
2.2.1 Experience Record Proforma – Centrifugal Pump (Horizontal) 16-45-ER-01
(4 Sheets)
2.2.2 Experience Record Proforma – Centrifugal Pump (Vertical) 16-45-ER-02
(4 Sheets)
2.2.3 Experience Record Proforma – Controlled Volume Pump 16-45-ER-03
(3 Sheets)

3 PACKAGED EQUIPMENT 16-44-DS-01

3.1 Datasheet of E.O.T. Crane
3.2 Datasheet of H.O.T. Crane
3.3 Datasheet of Chain Pulley Block

C STANDARD SPECIFICATIONS

1
GENERAL CIVIL
1.1
Standard specification for Cooling Tower (For Freshwater) 6-65-0058
2 PIPING

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 202 of 207

S. TITLE DOCUMENT NO.

No.
2.1 Standard specification for erection of equipment & machinery 6-76-0001
2.2 Standard specification for colour coding of Piping Material 6-82-0003

3 SMMS
3.1 Standard Specification for corrosion protection tape coating for 6-79-0011
underground steel piping

4 INSTRUMENTATION
4.1 Standard Specification for Programmable Logic controller 6-52-0040

5 CONSTRUCTION
5.1 Standard Specification for Positive Material Identification (PMI) at 6-82-0002
Construction Sites
5.2 Standard Procedure for Boxing of Interface Joints Not subjected 5-7700-0120
to hydro static test at site
5.3 Standard Specification for HSE Management at Construction Sites 6-82-0001

D STANDARDS
1.0 GENERAL CIVIL
1.1. Abbreviations, legends and Eqpt. Symbols 7-65-0001
1.2. Cable crossings under road (PVC Pipes) 7-65-0006
1.3. Road curves and Crossing 7-65-0010
1.4. Pipe culvert for storm water drainage 7-65-0103
1.5. Detail of rungs for manholes, valve pits, tanks, etc. 7-65-0211
1.6. Standard miscellaneous details for manholes 7-65-0212
1.7. Conc. Bedding and encasement for pipes 7-65-0213
1.8. Gully trap chamber 7-65-0214
1.9. Inspection chamber 7-65-0215
1.10. Valve pit type-1 for dia. ≤ 3". 7-65-0220
1.11. Valve pit type – II for Ø4" to Ø6" valve 7-65-0221
1.12. Typical detail of bend pipe for manholes 7-65-0230
1.13. Unit drainage details (Rectangular ditch details) 7-65-0272
1.14. Details of neutralization pit 7-65-0310
1.15. RCC Pavement Details 7-65-0404
1.16. Typ. Detail of acid /alkali proof lining 7-65-0412

2.0 STRUCTURAL
2.1. Electroforged Grating Type-I &Type-II. 7-68-0697

3.0 ARCHITECTURAL
3.1. Skirting detail (with brick wall). 7-75-0002
3.2. Skirting detail (with R.C.C. column). 7-75-0003
3.3. Dado detail (with BK. Wall & RCC col.) 7-75-0004
3.4. Wooden flush door (with pressed steel frame.) 7-75-0011
3.5. Aluminium glazing details. 7-75-0014
3.6 Glazed aluminium window. 7-75-0015
3.7. Wooden hand rail (round type) 7-75-0035
3.8. Pipe hand rail with SQ upright type. 7-75-0036
3.9 Aluminium panel false ceiling (tray type). 7-75-0043
3.10. Orissa pan W.C. fixing detail. 7-75-0060

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 203 of 207

S. TITLE DOCUMENT NO.

No.
3.11. European type W.C. fixing detail. 7-75-0062
3.12. Urinal fixing detail. 7-75-0063
3.13. Wash basin fixing detail. 7-75-0064
3.14 Wooden panel door (toilet door). 7-75-0066
3.15. Roof drainage and water proofing. 7-75-0068
3.16. Steel door (pressed steel) single shutter. 7-75-0070
3.17. Steel door (pressed steel) double shutter. 7-75-0071

4.0 ELECTRICAL
4.1. Symbols - single line diagrams 7-51-0002
4.2. Symbols - wiring diagrams 7-51-0011
4.3. Symbols - plans (layout drawings) 7-51-0021
4.4. Typical earth electrode for earthing system 7-51-0101
4.5. Typical earth electrode in test pit 7-51-0102
4.6. Typical earth plate fixing details 7-51-0103
4.7. Typical arrangement for earthing for motors 7-51-0104
4.8. Typical earth connection for push button station 7-51-0106
4.9. Typical earth connection for street lighting pole 7-51-0107
4.10. Earthing of tanks, vessels and spheres 7-51-0108
4.11. Typical arrangement for earthing of overhead cable tray and 7-51-0109
electric motor
4.12. Typical earthing arrangement for process equipment 7-51-0111
4.13. Earthing/ bonding of pipes and pipe racks 7-51-0112
4.14. Equipment earthing schedule 7-51-0116
4.15. Typical details of directly buried earth electrode 7-51-0117
4.16. Typical installation of lighting fixture at ground level 7-51-0201
4.17. Typical installation of lighting fixture on platform 7-51-0202
4.18. Typical open area flood light mounted on wall or column 7-51-0203
4.19. Typical installation of street lighting fixture 7-51-0207
4.20. Typical marshalling box details for lighting poles 7-51-0208
4.21. Typical installation of fluorescent fixture mounting in exposed 7-51-0212
conduit wiring system
4.22 Typical installation of well glass lighting fixture 7-51-0217
4.23. Typical installation of bulkhead lighting fixture 7-51-0218
4.24. Typical installation of Div. 2/ FLP well glass lighting fixture 7-51-0221
4.25. Typical installation of flame proof lighting panel 7-51-0225
4.26. Typical installation of lighting/ power panel wall (surface) mounted 7-51-0226
Typical installation of lighting fixture mounting in concealed 7-51-0229
4.27.
conduit system
4.28. Typical installation of lighting/power panel flush mounted 7-51-0230
4.29. Marking of trenches for electric cables 7-51-0301
4.30. Typical section of cable trench in unpaved areas 7-51-0302
4.31. Typical section of lined cable trench in paved area 7-51-0303
4.32. Conduit or cable supports on concrete beam or column 7-51-0305
4.33. Installation of push button station on structural channel 7-51-0306
4.34. Installation of push button station on concrete/ steel column-indoor 7-51-0307
location
4.35. Typical installation for horizontal motor and push button station- 7-51-0312
(cables below ground)
4.36. Typical installation of cable for motor (cable in trench) 7-51-0313

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 204 of 207

S. TITLE DOCUMENT NO.

No.
4.37. Typical installation of cable for motor (cable in tray) 7-51-0314
4.38. Receptacle mounted on concrete column (cable in trench) 7-51-0315
4.39. Receptacle mounted on column-cable in tray below slab 7-51-0316
4.40. Typical installation of welding receptacle (mounted on steel 7-51-0318
column)
4.41. RCC duct above FGL 7-51-0321
4.42. ERC below grade level 7-51-0322
4.43. Arrangement for termination of cables laid in trays (for MV motors) 7-51-0323
4.44. Arrangement for termination of cables laid in trays (for HV/ MV 7-51-0324
motors)
4.45. Arrangement for termination of cables laid in trench (for MV 7-51-0325
motors)
4.46. Typical arrangement for laying of cables in cable trays 7-51-0327
4.47. Safety measures for electrical installations during construction 7-51-0332
4.48. Details for hot dip galvanized ladder type cable trays 7-51-0333
4.49. Typical installation details of electrical panels on floor cut-out 7-51-0334

5.0 INSTRUMENTATION
5.1. Instrument Connection on Vessel standpipes & tanks, 7-52-0001
5.2. Instrument Connection on piping 7-52-0002
5.3. Thermowell 7-52-0035
5.4. Thermocouple/ RTD assembly with Thermowell 7-52-0036
5.5. Orifice plates and flanges dimensional details 7-52-0041

6.0 STATIC EQUIPMENT

6.1. Vessel Tolerance 7-12-0001
6.2. Support for Horizontal Vessel 7-12-0002
6.3. Skirt Base Details 7-12-0004
6.4. Angle Leg Support 7-12-0006
6.5. Pipe Leg Support 7-12-0007
6.6. Bracket support for Vertical vessel 7-12-0008
6.7. Manhole with Hinge cover 7-12-0009
6.8. Manhole with davit 7-12-0010
6.9. Standard bolt hole orientation 7-12-0015
6.10. Sight glasses for pressure vessels 7-12-0017
6.11 Internal flanges 7-12-0018
6.12. Supports for internal feed pipe 7-12-0032
6.13. Earth connections 7-13-0001
6.14. Anchor chair 7-13-0002
6.15. Level indicator supports (for cone roof / floating roof tanks) 7-13-0006
6.16. Gauge hatch with cover (non-pressure tanks) 7-13-0007
6.17. Caged ladder for fixed roof tank 7-13-0010
6.18. Name plates (for tanks) 7-13-0012
6.19. Spiral stairway and hand railing for cone roof / floating roof tanks. 7-13-0013
6.20. Structural arrangement of cone roof - 2.5 m < dia < 6.0 m 7-68-0663
6.21. Structural arrangement of cone roof - 6.0 m < dia < 8.0 m 7-68-0664
6.22. Structural arrangement of cone roof - 8.0 m < dia < 10.0 m 7-68-0665
6.23. Roof structure for cone roof tanks joint details (dia < 40m). 7-68-0680
6.24. Roof structure for cone roof tanks central drum (detail B). 7-68-0681
6.25. Cone roof structure schematic joint details & central drum. 7-68-0682

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 205 of 207

S. TITLE DOCUMENT NO.

No.
6.26. Steel ladder joint details. 7-68-0509
6.27. Foundation for acid tanks. 7-67-004

7.0 PIPING
7.1. Stub in Standard 7-44-0032
7.2. Detail of Mitered Elbow 7-44-0033
7.3. Standard for spacers and blinds>26” 7-44-0162
7.4. Vents & Drains (On lines 1.5" and below) 7-44-0350
7.5. Vents & Drains (On lines 2.0" and above) 7-44-0351
7.6. Orientation of orifice taps 7-44-0352
7.7. Pressure Tapping 7-44-0354
7.8. Well Installation 7-44-0353
7.9. Utility Hose Station 7-44-0401
7.10. Steam Trap Assembly 7-44-0400
7.11. Drip leg for Steam Lines 7-44-0403
Notes:
1) Contractor to furnish duly filled formats along with the bid.
2) Contractor to furnish duly filled data sheets / experience record proforma during detailed
engineering

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 206 of 207

Annexure- I: Broad Scope Matrix

PACKAGE
Other’s
Sl. No. ITEM DESCRIPTION CONTRACTOR’S
Scope
SCOPE
1. Cooling Tower √
2. Cold Water Basin √
3. Channel √
4. Sump √
5. Cooling Water Recirculation Pumps and Pump √
House
6. Storm water Drain within package battery limit √
and interconnection with main drain
7. Approach Roads and Road crossings on √
approach roads
8. Micro grading √
9. RCC pavement within Battery Limit √
10. Cooling water Return Header within B/L √
including all instrumentation as per P&ID
11. Side stream filtration system √
12. Chemical Dosing system including acid dosing, √
Biocide & Formulation Dosing, polymeric
dispersion dosing, Chlorination system including
their Storage & handling
13. Soil Investigation √
14. CWTP building √
15. Substation with cable cellar & Switchgear Hall √
16. MCC room √
17. Motor Control Centres √
18. All MV motors along with respective Local √
control stations for motors.
19. Complete cable work, cable trench / above √
ground cable trays, supports, racks
20. Lighting system for the complete package √
21. Earthing & lightning protection system √
22. Installation of plant communication equipment √
(Communication
system as free issue)
23. Main incoming public address junction box √
(PAJB)
Installation of Fire alarm system equipment √
24.
Supply and installation of Fire alarm junction
25. box
Telephone wiring √
26.
All field-mounted instruments as shown in P&IDs √
27.
Local panels with all instruments and √
28. accessories duly mounted on them
Local gauge board/s with all instruments and √
29. accessories
PLC based control system √
30.
Junction boxes √
31.
Armoured cables (signal, alarm, control, √
32. thermocouple extension, RTD, power supply
Installation of HC & H2S detectors √
33. (Detectors as free

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved

 STANDARD SPECIFICATION STANDARD SPECIFICATION No.
FOR COOLING TOWER & CWTP
PACKAGE 6-65-0091 REV. 0
Page 207 of 207

issue)
All installation materials such as impulse tubes, √
34. pipes, valves, pipe & tube and fittings etc., for all
field instruments and instrument air supply
distribution
Cable glands and PVC sleeves √
35.
Canopies for field mounted electronic /electrical √
36. instruments and junction boxes
Sunshield/ Weather hood for local panels √
37.
Cable trays, perforated trays, angle trays for √
38. cable laying within the package battery limit
39. Cable Duct and RCC trenches for cable laying √
up to control room
40. Installation, Field Calibration/ Testing, Loop √
Checking
41. Centrifugal Pumps (horizontal/vertical/large √
capacity),
42. Controlled Volume Pump √
43. Rotary Pumps √
44. All driven equipment, its driver, couplings, √
coupling guards, common base plate, foundation
bolts, local instruments, local gauge board (as
required), local control panel (as required) and
other associated auxiliaries / accessories
45. Chain pulley Blocks, Mono Rail √
46. Air Conditioning system for control room , √
operator room
47. Complete Piping within the Battery Limit of the √
package including pipe supports
48. Painting on all Structural Steel surfaces √
confirming to environmental exposure conditions
49. Painting of all above ground piping and √
equipment
50. Painting of instruments, instruments supports √
and installation material/ impulse lines (as
applicable).
51. External and internal painting of vessels, tanks √
52. Painting of Buildings √
53. Installation of Corrosion Coupon and Corrosion √
Probe (Coupon and Probe
as free issue)
54. Complete Design, Engineering, procurement, √
fabrication, erection and construction of all Civil
& Structural, Electrical, Instrumentation and
Mechanical (including piping) and Environmental
Engineering works
55. Pre-Commissioning & Commissioning √
56. Performance Guarantee & Test √
57. Mandatory Spares √
58. Statutory Approval √

The scope matrix given above is for broad in nature. For details refer EIL specification 6-65-0091.

Format No. 8-00-0001-F1 Rev. 0 Copyright EIL – All rights reserved