HINDUSTAN PETROLEUM CORPORATION LIMITED,
E & P DEPT, 2nd FLOOR, Gresham Assurance bldg, Sir P.M.Road, Fort, MUMBAI-1
TENDER DOCUMENT
FOR
ELECTRIFICATION JOB
AT
BATHINDA IRD
Page 1 of 153
INDEX
Sr.No.
1.
2.
3.
4.
5.
6.
7.
8.
DESCRIPTION
TENDER COVER PAGE
INDEX
PROJECT DESCRIPTION AND SCOPE OF THE JOB
SCHEDULE OF QUANTITIES
TIME SCHEDULE
TECHNICAL SPECIFICATIONS
SPECIAL CONDITIONS OF CONTRACT
SAFETY, HEALTH & ENVIRONMENT
PAGES
FROM
TO
1
1
2
2
3
6
7
29
30
31
32
126
127
145
146
153
Page 2 of 153
PROJECT DESCRIPTION
AND
SCOPE OF THE JOB
Page 3 of 153
SCOPE OF THE JOB
PROJECT DESCRIPTION/SITE INFORMATION
The proposed electrification job is to be executed at Bathinda POL Installation, Bathinda in the state of
Punjab.
The location addresses is as below:
Hindustan Petroleum Corporation Limited
Bathinda IRD
Phoos Mandi Road - 492101
Punjab.
Ph: (0164)2430430
Project Incharge:Shri Gurmeet Singh :- 09417602067
The brief scope of the work involves but not limited to the following:1. Installation, Testing & Commissioning of 1500 KVA Transformer & DG Sets (500KVA- 2Nos.)
along with Synchronizing cum AMF Panel.
2. Design, engineering, fabrication, supply, erection, testing and commissioning of Double Poles, HPole, Isolation switch, CT & PT unit, Vaccuum Circuit Breaker and PCC Panel.
3. Design, engineering, fabrication, supply, erection, testing and commissioning of the Panels for the
New Pumps of MS and HSD, Lighting for Pump house and gantry.
4. Supply, erection, testing and commissioning of FLP fixtures.
5. Supply, laying, testing and commissioning of the HT & LT Cables.
6. Supply, installation, testing and commissioning of the Earthing system.
7. Obtaining approval from electrical inspectorate and local/ central authority for the entire system of
energization.
8. Executing other miscellaneous jobs such as civil works etc.
The complete requirements shall be executed with single point responsibility including preparation of
working drawings based on design, obtaining approvals from Statutory authorities for commissioning of
the electrical system.
Page 4 of 153
SITE CONDITION:
The job needs to be carried out in the Depot premises. , hot work/ cold work/ other work permission has
to be obtained for working on a daily basis. The explosive meter readings and check for presence of
flammable vapour shall be checked by contractor‟s supervisor along with HPCL‟s representative before
undertaking any work. Full time supervisor to be provided at work spot and job shall be carried out only
after complying with all safety norms of the depot. Also, during hot work necessary precautions have to
be taken to prevent any incidents due to presence of any petroleum vapours. Since the Terminal is in
operation A full Time Qualified Engineer who is technically competent and having sufficient Site
experience to be posted for supervising and carrying out all the Jobs as per the Scope and technical
specifications.
Before quoting for the said job the contractor is required to visit the site and make himself acquainted
with the scope of the job and the working condition and quote accordingly.
The tenders are required to go through the tender document thoroughly and carefully and offer their most
competitive rates for the job.
In case of any clarifications contractor may contact Shri B.S. Gopalkrishna, Manager-E&P, Engg &
Projects Deptt, 2nd Floor, Gresham House, Sir P. M. Road, Fort, Mumbai- 400001 on 022-22608531 &
Shri GURMEET SINGH Manager-E&P, HPCL IRD, Bathinda, Punjab- 492101 on
(0164)2430430/ 09417602067 regarding any queries.
The contractor shall arrange all equipment, tools, power and water required for execution, testing
& completion of the job.
All the safety precautions including supplying & providing localised fire screens for welding of
reinforcements etc shall be arranged by the Contractors as per the directions of Engineer in charge
at no extra cost to HPCL.
Following to be submitted by the Party to EIC for approval before commencement of the job:
1.
2.
3.
4.
5.
Design & Working Drawing of the Panels.
Layout of the cable route.
Layout of the earthing grid and plan.
Preparation of any other drawing / design required for execution of the work.
Electrical drawings for the approval of the Statutory Authority.
.
After the job is completed, 4 copies of all the above drawings (As built) shall be submitted along with CD
containing soft copy in Autocad latest version.
NOTES:
1. Any cables / piping encountered during electrification job during execution of the job, the same
shall be separated using Sand Bed and Tiles or to be re-routed, if necessary as directed by the
Engineer incharge at no extra cost to HPCL.
Page 5 of 153
2. On receipt of LOI/ PO/ FOI, contractor is required to prepare a detailed date wise schedule of
work/Bar Chart of the activities as per PO and submit the same to Engineer-In-Charge for
approval before commencement of activities.
3. The Contractor has to give progress report with photographs every fortnight in hard copy as
well as soft copy.
Scope also includes shifting of any scrap materials lying at the constructional area to the designated place
inside the depot premises at no extra cost. Job also includes site clearing from any debris, vegetation,
bushes and trees, etc and make the site free for construction at no extra cost.
The contractor shall arrange for all materials, equipment, tools, power and water required for execution &
completion of the job.
The bidders are required to go through the tender document thoroughly and carefully and offer their most
competitive rates for the job. They are also advised to visit the site before offering their quotation.
SITE VISIT
The bidder is advised to visit and examine the site of works at all locations and their surrounding and
obtain for himself on his own responsibility all information that may be necessary for preparing of the bid
and entering into the contract. The cost of visiting the sites shall be at bidder‟s own expenses. No extra
claim on account of non-familiarity of site conditions shall be entertained during execution of works.
Page 6 of 153
SCHEDULE OF QUANTITIES
Page 7 of 153
BATHINDA ELECTRIFICATION JOB
Sr.
No.
Item Description
Quantity
Unit
1
EXCAVATION
Earthwork in excavation for Foundations of buildings, pipe supports, equipment
foundation, drain ,pit, trenches etc. or any other place as directed, in Ordinary
soils including Soft rock / Disintegrated rock, in both Dry and Wet conditions,
including backfilling etc, in layers of 150mm at all heights and depths as per
Drawing and Specifications wherever required , in Foundation pits, under floors
and other places with excavated suitable surplus earth, including reclaiming
from spoil heaps kept elsewhere including dressing and leveling, watering and
mechanical compaction etc. Transporting surplus soil to unobjectionable place
within boundary limits and spreading in layers and as per Specifications and
direction of Engineer. The Measurement for payment shall be for the theoretical
volume only and it shall be the volume of the block of the excavation having
maximum bottom dimension of the foundation as per drawing and to actual
depth.
2350
CUM
2
SAND FILLING
Supplying and filling approved quality course sand as per IS 383 - 1970 in layers
of compacted thickness 200 mm each for as directed by EIC. Rate to include
arranging for approved quarries /borrow pits outside Depot premises, loading,
transportation, unloading, removal of debris, organic matter etc, spreading in
layers, watering and compacting each layer till desired compaction is achieved
and finishing to slopes and grades as per drawings specifications and instructions
of Engineer In Charge. Job also to include compaction completely. Rate to
include the execution of the job as per latest codal provisions, attached
Technical specifications and as directed by EIC.
100
CUM
3
PLAIN CEMENT CONCRETE 1:2:4
Supply and laying PCC 1:2:4, using 20 mm and downsize crushed aggregate
including providing shuttering for formwork, mixing, compacting by Vibrators,
curing etc complete for foundations etc. Cement shall conform to IS 8112 – 43
grade / 53 grade or IS 1489. Cement shall be Ultratech, ACC, L&T or approved
make. Rate to include the execution of the job as per latest codal provisions,
attached Technical specifications and as directed by EIC.
120
CUM
4
REINFORCED CEMENT CONCRETE M-25
Supply and laying RCC M-25, using 20 mm and downsize crushed aggregate
including providing shuttering for formwork, mixing, compacting by Vibrators,
curing etc complete for foundation etc. Cement shall conform to IS 8112 – 43
grade / 53 grade or IS 1489. Cement shall be Ultratech, ACC, L&T or approved
make. Rate to include the execution of the job as per latest codal provisions,
attached Technical specifications and as directed by EIC.
425
CUM
Page 8 of 153
5
STEEL REINFORCEMENT
Supply, fabrication, tying and laying in position TMT (Thermo Mechanically
Treated) steel reinforcement conforming to IS 1786, Fe-500 (latest edition)
manufactured by SAIL/TISCO/RINL .Job includes, cutting, cold bending, tying with
20 SWG black annealed binding wire and placing in position at all heights/line/
levels etc, complete in all respects as per standard specification. Laps, chairs and
spacer bars shall not be considered for measurement and payment purposes.
Rate to include execution of the job as per latest codal provisions, attached
Technical specifications and as directed by EIC.
27
TM
6
STRUCTURAL STEEL
25
TM
Supply, Fabrication & Erection of steel structure for base frames, supports for
switchgear, bus ducts, dummy panel, adaptor boxes and additional supports for
proper cable termination etc, cable and cable tray supports out of rolled MS
sections. Job to include painting with 2 coats enamel paint over 2 coats of zinc
phosphate primer as per instruction of EIC.
7
PRECAST CONCRETE SLAB
Providing & erecting in position precast concrete trench cover units to match
with the flooring of required sizes and thickness as directed at site using
reinforced cement concrete with M-25 design mix as per IS 456-2000 with 20
mm downgraded coarse aggregates including formwork to give fair and smooth
finish, casting, vibrating providing lifting arrangement, loading / unloading
transporting, load testing etc., complete but excluding cost of reinforcement
(which will be separately paid as per Reinforcement Item No. 229.0), all as per
specification and as directed by the engineer in charge. The cement content shall
be governed by design mix or soil characteristics as per soil investigation report
(report shall be forwarded to the successful bidder), whichever is higher. The
slab rate shall consists of sunken MS handles of 10 mm dia or as directed by
Engineer Incharge. Concrete to be used shall be ready mix concrete/ weigh
batcher only. RMC shall be from approved RMC Plants like ACC, L&T, Ultra Tech
etc. The scope of mix design is included in the scope of bidder and the same to
be vetted by reputed engineering institute like IIT, Kharagpur or any other
reputed Engineering Institutes/ Consultant duly approved by HPCL.
115
CUM
8
PAVER BLOCK
Paver Block-Supply and laying 80mm thick glazed interlocking blocks of approved
colors in approved design, brand and pattern as directed, of compressive
strength 400Kg/sq. cm. placing each against its neighbour on the un-compacted
sand, cutting the pieces to fill up edges next to the edge restrains. The paver
blocks should have chamfered top edges of not less than 4mm and shall be laid
with a min. Of 2mm gap which in turn shall be packed with sane and compacted
with plate/surface vibrator to the correct line, level and gradient and as directed
by EIC After laying compact with vibrator. Sweep dry fine sand over the surface,
making sure it fills all the gaps between the paver. Vibrate the area again to give
900
SM
Page 9 of 153
strong interlocking bond. Sweep off excess sand including all work complete as
per direction of engineer-in-charge. (interlocking blocks pattern to be approved
by Owner)
9
10
TRANSFORMER INSTALLATION & COMMISSIONING
Shifting from client's store & erection on foundations, assembling of all loose
supplied accessories testing for pre-commissioning checks with due coordination with the supplier & Commissioning Of TRANSFORMER of 1500KVA ,
11/0.433KV, Oil Natural Air Cooled, Distribution transformer. Job to be executed
as per attached technical specifications and as directed by Engineer Incharge
complete.
Inspection & Testing
Specification in Section 16.1.2 of IS 2026 with latest amendment. The routine
test shall be as follows.
a) Visual Inspection.
b) Insulation Resistance Test.
c) Fixing up of marshaling box
d) Megger
e) H.V test
f) Polarity Test.
g) Winding Resistance Test
h) Separate Source Voltage with stand.
i) Oil used in the transformer shall be tested as per Oil Tests Specification in IS:
335-1972 as modified to date.
D.G. SET INSTALLATION & COMMISSIONING
Shifting from client's store and erection on foundations, assembling of all loose
supplied accessories& Installation of Diesel Generator in coordination with the
DG vendor. Pre-commissioning of the DG Sets with due co-ordination with the
DG supplier and final commissioning of the same. Structural support supply &
fabrication shall be paid separately under respective item. Job to be executed as
per attached technical specifications and as directed by Engineer Incharge
complete.
500KVA, Speed 1500 RPM
a) Inspection & Testing
b) Governor response.
c) Voltage regulations and AVR Response.
d) Automatic Mains Failure cum Auto Start operation of Diesel Generating Set
and load transfer to D.G Bus.
1
EACH
2
EACH
e) The DG vendor to provide necessary assistance to the electrical vendor for
executing the following tests at site in the presence of the client’s representative
before energization.
Page 10 of 153
f) Checking the alignment by engine manufacturer’s representative and
obtaining approval.
g) Insulation resistance test on alternator, control panel and cabling / Bus bar
trunking.
h) Checking the engine safeties for satisfactory operation.
i) Checking vibration levels.
j) Testing of individual protective devices on engine and alternator and ensuring
that the wiring is carried out properly.
k) Full load running for 8 hours continuously. All the readings shall be logged to
evaluate the fuel consumption, lube oil pressure, water & oil temperature vis-àvis the electrical load.
l) The noise level at 1m from the enclosure and the temperature rise inside the
enclosure shall be measured.
m) The DG set shall be deemed to be commissioned after satisfactory
performance of all associated equipment.
n) Laying, wrapping up with insulation of the exhaust piping system
o) Installation of the exhaust & fuel system of the piping.
11
SYNCHRONISING PANEL
Erection, Testing & Commissioning of Synchronizing Panel with provision of Auto
Synchronization & Testing of Load Sharing and recording of all parameters. Job
to be executed as per attached technical specifications and as directed by
Engineer Incharge complete.
1
EACH
1
LS
HT SIDE
12
SUPPLY, INSTALLATION OF 11KV OUTDOOR STRUCTURE & EQUIPMENTS
Supply, Installation, Testing & Commissioning of 11KV Outdoor Structure and
equipments, all accessories and fixing material as per drawings and documents
of this SOW, as stated below including transportation upto site/ yard and
unloading.
11KV, 400A, 50Hz, 25kA for 1 sec, 3-pole, outdoor type, Gang operated
disconnector with operating handle from ground.
- 2 Each
11KV, 50Hz, outdoor type, drop out fuse with base unit.
- 6 Each
11KV, 50Hz, outdoor type, Strain Insulators.
- 9 Each
11KV, 50Hz, outdoor type, Pin (post) insulators.
12KV, 50Hz, 10kA, outdoor type, distribution class, lightning arrestor.
- 12 Each
– 3 Each
7/0. 144" ACSR conductor with terminations.
- 1 Lot
Outdoor structure for mounting of equipments.
- 1 Lot
10 SWG, 75 sqmm, 2 m high, chain link fence with supports and barbed wire, hot
dip galvanized.
- 1 Lot
2 x 1.5m wide x 1.8m high, chain link fence gate with tubular pipes, hot dip
galvanized.
- 1 Each
Cement gravel, G.I. pipes, paint, accessories and fixing material.
- 1 Lot
Page 11 of 153
11Mtr MS Round Pole
13
- 2 Each
VACUUM CIRCUIT BREAKER:- Supply & erection of 11 KV VCB 800A CT Ratio
100/1 PT Ratio 11KV/110V (Make :-Schneider/ L&T/ ABB/ Siemens). (BOQ As per
ANNEXURE-A).
1
EACH
16
Supply of 3C x 150 sqmm XLPE FRLS insulated 11 KV grade armoured cables
confirm to IS – 7098 Part - II with latest amendments as per Technical
Specifications attached and as advised by EIC. MTC for the cables also needs to
be provided. The approved makes of the cable are Polycab/ NICCO/ CCI/ Finolex/
RPG/ Havels/ equivalent approved makes.
100
METER
17
Laying of 3C x 150 sqmm HT cables rated for 11KV in readymade trench or
buried in ground, supported on structure with etc in miscellaneous locations pull
through pipes concrete including all the consumables like CI number tags every
25 mtr. Job to be executed as per attached technical specifications and as
directed by Engineer Incharge complete.
100
METER
18
HT CABLE INDOOR TYPE JOINT KIT:- Supply and termination of HT cable
termination kit (Indoor joints) for 3C x 150sq.mm. AL-XLPE cable It shall be heat
shrinkable type and of approved make. Job to be executed as per attached
technical specifications and as directed by Engineer Incharge complete.
2
EACH
19
HT CABLE OUTDOOR TYPE JOINT KIT:- Supply and termination of HT cable
termination kit (Outdoor joints) for 3C x 150sq.mm. AL-XLPE cable It shall be
heat shrinkable type and of approved make. Job to be executed as per attached
technical specifications and as directed by Engineer Incharge complete.
2
EACH
20
NFLP CABLE GLANDS:- Supply & Installation of Single Compression Non
Flameproof nickel plated cable glands of approved make & termination of cables
include supply of lugs of approved make. The job also includes labour
component for cutting, stripping of cable insulation, drilling of gland plate and
fixing the same. Job to be executed as per attached technical specifications and
as directed by Engineer Incharge complete.
4
EACH
14
15
LT PANELS
PMCC Panel (details attached as Annexure-B)
MCC Panel (details attached as Annexure-C)
HT CABLE
A
LT CABLE
SUPPLY OF LT CABLES: Supply of XLPE FRLS insulated 1.1 KV grade armoured
cables confirm to IS – 7098 Part - I with latest amendments as per Technical
Specifications attached and as advised by EIC. MTC for the cables also needs to
be provided. The approved makes of the cable are Polycab/ NICCO/ CCI/ Finolex/
Page 12 of 153
21
22
23
24
25
26
27
28
29
30
31
32
33
34
B
I
35
36
37
38
39
40
41
42
43
44
45
46
47
48
RPG/ Havels/ equivalent approved makes.
3C x 95 sqmm Al armored cable
3C x 120 sqmm Al armored cable
3C x 185 sqmm Al armored cable
3.5C x 25 sqmm Al armored cable
3.5C x 50 sqmm Al armored cable
3.5C x 70 sqmm Al armored cable
3.5C x 95 sqmm Al armored cable
3.5C x 150 sqmm Al armored cable
3.5C x 185 sqmm Al armored cable
3.5C x 300 sqmm Al armored cable
3.5C x 400 sqmm Al armored cable
3.5C x 500 sqmm Al armored cable
3C x 2.5 sqmm Cu armored cable
6C x 2.5 sqmm Cu armored cable
600
3650
4650
850
700
50
180
225
135
2800
2450
550
6200
11500
METER
METER
METER
METER
METER
METER
METER
METER
METER
METER
METER
METER
METER
METER
LAYING OF LT CABLES
LAYING OF CABLES BELOW GROUND:- Laying, Testing & Commissioning of LT
XLPE insulated PVC sheathed FRLS armoured cable with Aluminium conductor
1.1 KV grade conforming to IS 7098 Part I of following sizes as per attached
technical specifications. The job includes excavation up to a minimum depth of
750 mm and a minimum width of 300mm. Laying & compaction of 150mm sand
bed, laying of bare cable along with overlaying of 150mm sand bed, along with
laying of bricks in transverse directions. Rate also includes tagging of cable with
the Aluminium cable tag at an interval of 100m and at the change of direction.
Job to be executed as per attached technical specifications and as directed by
Engineer Incharge complete.
3C x 95 sqmm Al armored cable
3C x 120 sqmm Al armored cable
3C x 185 sqmm Al armored cable
3.5C x 25 sqmm Al armored cable
3.5C x 50 sqmm Al armored cable
3.5C x 70 sqmm Al armored cable
3.5C x 95 sqmm Al armored cable
3.5C x 150 sqmm Al armored cable
3.5C x 185 sqmm Al armored cable
3.5C x 300 sqmm Al armored cable
3.5C x 400 sqmm Al armored cable
3.5C x 500 sqmm Al armored cable
3C x 2.5 sqmm Cu armored cable
6C x 2.5 sqmm Cu armored cable
50
300
500
100
75
25
50
45
35
300
150
350
200
1500
METER
METER
METER
METER
METER
METER
METER
METER
METER
METER
METER
METER
METER
METER
Page 13 of 153
LAYING OF CABLES IN BUILD-UP TRENCH:- Laying, Testing &
II
49
50
51
52
53
54
55
56
57
58
59
60
61
62
Commissioning of LT XLPE insulated PVC sheathed FRLS armoured cable with
Aluminium conductor 1.1 KV grade conforming to IS 7098 Part I of following sizes
as per attached technical specifications. The job includes laying of cables in the
cable tray laid in the trench at different levels of cable trench with the support of
angles. Rate also includes tagging of cable with the Aluminium cable tag at an
interval of 100m and at the change of direction. Job to be executed as per
attached technical specifications and as directed by Engineer Incharge complete.
3C x 95 sqmm Al armored cable
3C x 120 sqmm Al armored cable
3C x 185 sqmm Al armored cable
3.5C x 25 sqmm Al armored cable
3.5C x 50 sqmm Al armored cable
3.5C x 70 sqmm Al armored cable
3.5C x 95 sqmm Al armored cable
3.5C x 150 sqmm Al armored cable
3.5C x 185 sqmm Al armored cable
3.5C x 300 sqmm Al armored cable
3.5C x 400 sqmm Al armored cable
3.5C x 500 sqmm Al armored cable
3C x 2.5 sqmm Cu armored cable
6C x 2.5 sqmm Cu armored cable
450
3200
4000
650
600
25
130
180
100
2500
2300
200
4200
8000
METER
METER
METER
METER
METER
METER
METER
METER
METER
METER
METER
METER
METER
METER
50
150
150
100
25
1800
2000
METER
METER
METER
METER
METER
METER
METER
ABOVEGROUND CABLES:- Laying, Testing & Commissioning of LT XLPE
III
63
64
65
66
67
68
69
insulated PVC sheathed FRLS armoured cable with Aluminium conductor 1.1 KV
grade conforming to IS 7098 Part I of following sizes as per attached technical
specifications. The job includes laying of cables in the cable tray along with
proper dressing at all heights. Vertical run shall be clamped by means of 16 SWG
GI wire whereas the horizontal run shall be tied by means of nylon chord. All
power cables shall be laid in a single run whereas control cables can have
maximum two runs. Rate also includes tagging of cable with the Aluminium cable
tag at an interval of 100m and at the points of turning. Job to be executed as per
attached technical specifications and as directed by Engineer Incharge complete.
3C x 95 sqmm Al armored cable
3C x 120 sqmm Al armored cable
3C x 185 sqmm Al armored cable
3.5C x 25 sqmm Al armored cable
3.5C x 50 sqmm Al armored cable
3C x 2.5 sqmm Cu armored cable
6C x 2.5 sqmm Cu armored cable
END TERMINATION
Page 14 of 153
A
70
71
72
73
74
75
76
77
78
79
80
81
82
83
B
84
85
86
87
88
89
90
91
92
93
94
95
96
97
NFLP CABLE GLANDS:- Supply & Installation of Double Compression Non
Flameproof nickel plated cable glands of approved make & termination of cables
include supply of lugs of approved make. The job also includes labour
component for cutting, stripping of cable insulation, drilling of gland plate and
fixing the same. Job to be executed as per attached technical specifications and
as directed by Engineer Incharge complete.
3C x 95 sqmm cable gland
3C x 120 sqmm cable gland
3C x 185 sqmm cable gland
3.5C x 25 sqmm cable gland
3.5C x 50 sqmm cable gland
3.5C x 70 sqmm cable gland
3.5C x 95 sqmm cable gland
3.5C x 150 sqmm cable gland
3.5C x 185 sqmm cable gland
3.5C x 300 sqmm cable gland
3.5C x 400 sqmm cable gland
3.5C x 500 sqmm cable gland
3C x 2.5 sqmm cable gland
6C x 2.5 sqmm cable gland
3
15
15
5
5
4
5
10
5
35
30
24
20
40
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
FLP CABLE GLANDS:- Supply & Installation of Double Compression Flameproof
nickel plated cable glands of approved make & termination of cables include
supply of lugs of approved make. Rate to include supply & installation of PVC
hoods of suitable size over the glands. The job also includes labour component
for cutting, stripping of cable insulation, drilling of gland plate and fixing the
same. Job to be executed as per attached technical specifications and as directed
by Engineer Incharge complete.
3C x 95 sqmm cable gland
3C x 120 sqmm cable gland
3C x 185 sqmm cable gland
3.5C x 25 sqmm cable gland
3.5C x 50 sqmm cable gland
3.5C x 70 sqmm cable gland
3.5C x 95 sqmm cable gland
3.5C x 150 sqmm cable gland
3.5C x 185 sqmm cable gland
3.5C x 300 sqmm cable gland
3.5C x 400 sqmm cable gland
3.5C x 500 sqmm cable gland
3C x 2.5 sqmm cable gland
6C x 2.5 sqmm cable gland
4
15
18
4
1
1
1
1
1
1
1
1
160
50
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
Page 15 of 153
98
99
100
101
102
103
104
105
106
107
108
109
110
111
STRAIGHT THROUGH JOINTS
Supply & Performing of Straight through joints including joint kits with heat
shrinkable or equivalent type joint kit for 1.1 KV XLPE Cables of following sizes.
Job to be executed as per attached technical specifications and as directed by
Engineer Incharge complete.
3C x 95 sqmm cable
3C x 120 sqmm cable
3C x 185 sqmm cable
3.5C x 25 sqmm cable
3.5C x 50 sqmm cable
3.5C x 70 sqmm cable
3.5C x 95 sqmm cable
3.5C x 150 sqmm cable
3.5C x 185 sqmm cable
3.5C x 300 sqmm cable
3.5C x 400 sqmm cable
3.5C x 500 sqmm cable
3C x 2.5 sqmm cable
6C x 2.5 sqmm cable
2
5
6
2
1
1
1
1
1
5
6
2
10
12
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
EACH
112
113
114
115
116
TESTING & COMMISSIONING OF PUMPS: Testing & commissioning of 415V 3
phase induction Motors of following ratings. Rate to include replacing of grease
if required, checking of rotation and other insulation tests, recoupling the motor
with pump and checking as per standard engineering practices. Job to be
executed as per attached technical specifications and as directed by Engineer
Incharge complete.
75 KW rating Motor
55 KW rating Motor
37 KW rating Motor
30 KW rating Motor
15 KW rating Motor
7
4
3
2
2
EACH
EACH
EACH
EACH
EACH
40
EACH
117
EARTHING SYSTEM
G.I. PIPE ELECTRODE:- Supply and erection of G.I. earth pipe electrode 65mm
diameter, atleast 3.0 mtr. below ground with 40Kg charcoal and salt with
alternate layers of charcoal and salt with 19mm dia GI pipe with funnel with a
wire mesh for watering 230 brick masonry chamber (300mm x 300mm x 300mm)
C.I. cover 300mm x 300mm (10 Kg) complete as per para 7.3 of I.S. 3043 with
necessary length of double G.I. earth wire no.6 SWG bolted with lug to the plate
and covered in 19 mm dia G.I. pipe 3.0 mtr. long complete connected to the
nearest switchgear with end socket as per directions and duly tested by earth
tester and recording the results. Excavation work is included in the scope of
contractor. Job to be executed as per attached technical specifications and as
directed by Engineer Incharge complete.
Page 16 of 153
118
Cu PLATE ELECTRODE:- Supply and erection of Copper. earth plate size
600X600X6.3 mm earth pit, atleast 3.0 mtr. below ground with 40Kg charcoal
and salt with alternate layers of charcoal and salt with 19mm dia GI pipe with
funnel with a wire mesh for watering and 230 brick masonry chamber (300mm x
300mm x 300mm) C.I. cover 300mm x 300mm (10 Kg) complete as per para 7.3
of I.S. 3043 with necessary length of double G.I. earth wire no.6 SWG bolted with
lug to the plate and covered in 12 mm dia G.I. pipe 3.0 mtr long complete
connected to the nearest switchgear with end socket as per directions and duly
tested by earth tester and recording the results. Excavation work is included in
the scope of contractor. Job to be executed as per attached technical
specifications and as directed by Engineer Incharge complete.
6
EACH
750
300
300
1000
1000
METER
METER
METER
METER
METER
100
METER
125
126
127
128
129
CABLE TRAY:- Supply & Installation of pre-fabricated perforated, hot dipped GI
cable tray with coupler plate, 90 deg. bends, tees, hardware etc. made out of
2.5mm thick sheet up to size 300 mm cable tray and 3mm thick sheet for tray of
above 300mm width. Length of cable tray shall be 2.5 m. The cable tray shall be
laid at all heights above the ground and as per the direction of Engineer
Incharge.
750mm perforated cable tray
450mm perforated cable tray
300mm perforated cable tray
100mm perforated cable tray
50mm perforated cable tray
500
300
500
200
450
METER
METER
METER
METER
METER
130
131
132
GI PIPES:- Supply and laying of following size of hot dipped GI class 'B' pipes in
required length fixed on in concrete or buried in trench/concrete for cable/GI
strip protection. End of pipes to be sealed. Job includes minor civil works and to
be carried out as per the instructions of EIC.
50mm GI Pipes
80mm GI Pipes
100mm GI Pipes
150
150
200
METER
METER
METER
119
120
121
122
123
124
GI STRIP:- Supply, Laying & Connecting of following size hot dipped GI strip along
the cable trench/ cable structure tray, wall structure etc including welding at
joints, anti-corrosive paint on welded portions. Clamping complete with GI
hardwares, labour etc as per instructions of EIC.
50mm x 6mm GI strip
25mm x 6mm GI strip
25mm x 3mm GI strip
10mm SWG hot dipped GI wire
1C x 2.5 sqmm Cu cable
Supply, Laying & Connecting of Cu strip of 50 x 6 mm for earthing including
welding at joints, anti-corrosive paint on welded portions.
Page 17 of 153
133
LIGHTING FIXTRUES
150W MH WELL GLASS FITTING:- Supply, installation and commissioning OF
Flameproof and Weatherproof Well Glass Fixture suitable for 150 W Metal
Halide Lamp in cast aluminium alloy LM6 construction ¾” ET entries, including
inbuilt control gear box, lamps and choke. The materials has to be certified by
CMRI, Dhanbad, CCOE etc for use in group flame zone I, IIA, & IIB as IS: 2148 1981. The fitting to be provided with FLP Junction Box complete with lamps. Rate
to include fixing of GI clamp, hardware etc as required and as specified by EIC.
Job to be executed as per attached technical specifications and as directed by
Engineer Incharge complete.
60
EACH
134
BULK HEAD FIXTURES:- Supply, installation and commissioning OF Flameproof
and Weatherproof IP 66 Bulk Head Fixture suitable for 150 W Metal Halide Lamp
in cast aluminium alloy LM6 construction ¾” ET entries, with ES27 holder, FLP
control gear box, lamps, choke. The materials has to be certified by CMRI,
Dhanbad, CCOE or approved agencies etc for use in group flame zone I, IIA, & IIB
as IS: 2148 - 1981. The fitting to be provided with FLP Junction Box complete
with Lamps, rate to include fixing of MS Clamps, hardwares etc as required and
as specified by E.I.C. Job to be executed as per attached technical specifications
and as directed by Engineer Incharge complete.
20
EACH
135
MS STREET LIGHT POLES:- Supply & Installation of 11.0 mtr long MS Tubular
swaged & welded type Street Light Pole Confirming to ISS – 2713 – 1969
complete with Base plate, MS pipe inserts for I/C & O/G cables, necessary
foundations min. length 1.8 M to be grouted below ground. The pole shall be
painted with Bitumen paint up to planting height. Pole shall be provided with 2
coats of epoxy based primer And 2 coats of finish paint of approved colour. Pole
shall be fitted with single arm bracket of 2.0M Long to fix St. Light fixture
complete with suitable CI Cable end Box with bottom type cable entry, Earth
boss, internal wiring from cable end box up to the light fixture, with all
Hardwares. Base plate shall be minimum 300 x 300 x 10 mm.
10
EACH
136
250W SON T PLUS LIGHT:- Supply & Installation of Bajaj type BGEST 250 SV IP 66
FFG street light fittings or equivalent make with 1 no. 250 W SON T plus HPSV
lamps or any other approved equivalent make.
10
EACH
137
16A SPN, 240V FLP ROTARY SWITCH:- Supply, installation and commissioning OF
Flameproof Weatherproof IP 66 Rotary Switch FLP junction box complete, rate to
include fixing of GI Clamps, hardware etc as required and specified by EIC.
10
EACH
138
FLP LDB:- Supply, installation and commissioning of FLP/WP IP-66 Lighting
Distribution Board a. Incomer 32A TPN SFU & b. Outgoing 6 Nos of 16A SPN
Switches with bottom type cable entry etc as required and specified by E.I.C. The
Incomer shall be suitable to cable of 3.5C x 95 sq.mm and should also have loop
in loop out arrangement along with metallic stopper. The outgoings shall be
provided with 16A FLP Rotary Switches. Certificates: Certified by CMRI, Dhanbad
for Group II A & II B, CCOE Nagpur and carry ISI mark on nameplate itself as per
4
EACH
Page 18 of 153
IS: 2148:1981.
139
FLP 4-WAY JB:- Supply, installation and commissioning OF FLP 4-way Junction
Box with Terminals with top & bottom type cable entries complete, rate to
include fixing of galvanized MS Clamps, hardwares etc as reqd. & specified EIC.
Certificates: Certified by CMRI, Dhanbad for Group II A & II B, CCOE Nagpur and
carry ISI mark on nameplate itself as per IS: 2148-1981.
8
EACH
3
2
EACH
EACH
142
FLP PUSH BUTTONS:- Supply, installation and commissioning OF Flameproof
Weatherproof IP 66 pressure die cast aluminium alloy LM 6 construction On/Off
Push Button Station with I/Lamp having 2 no. ¾” ET entries from bottom and
colour shade as per shade 631 of IS-5. Hardware Steel:- Stainless Steel Earthing:
1 no. Red Mushroom stay put type press and turn to lock and reverse turn to
release with pad locking arrangement but without lock & key. Element: 10 A 1
NO + 1NC contact element of approved make. Indicating Lamp: 1 no Red
indicating lamp of approved make. Certificates: Certified by CMRI, Dhanbad for
Group II A & II B, CCOE Nagpur and carry ISI mark on nameplate itself as per IS:
2148:1981.
60
EACH
143
CHAIN LINK FENCING:- Supplying, stretching and straining chain link fencing,
1.8m high, made with 10SWG galvanised steel chain link 50mm mesh, 3mm dia
Galvanised steel guard wire at top & bottom, fixing to angle posts of 65x65x6 @
3.0m c/c and lateral supports with angle 75x75x6 @ change of direction or at
15m c/c including 6mm Galvanised steel rods and galvanised steel J hooks &
providing 2 MS flats 50mm x 5mm thick bolted to the vertical post, 50 mm NB
(medium) pipe to be clamped at top & bottom along the length of the fencing to
the vertical post including excavation, PCC M10 for fixing angle post, two coats
of synthetic enamel paint over coat of primer, all complete as per drawings,
specifications and as directed by the Engineer. The job also includes providing 1
No. Gate of 3m width and 1 Gate of 1.5m width.(Note: The supply of all the
above items is included in the scope and payment will be made on Running
meter basis). Job to be executed as per attached technical specifications and as
directed by Engineer Incharge complete.
100
METER
144
BLUE METAL FOR TRANSFORMER:- Supplying & laying blue metal in layers of 20
mm down size coarse aggregate of uniform size/graded for transformer yard.
40
CUM
140
141
FLP SOCKET WITH PLUG:- Supply, installation and commissioning OF Flameproof
Weatherproof IP 66 Switch Socket with Plug Top. Plug top must be interlocking
with the switch in ON position and cannot be detached unless it is rotated to OFF
position. The cable entry shall be at the bottom suitable for following ratings as
per the advice of EIC. Certificates: Certified by CMRI, Dhanbad for Group II A & II
B, CCOE Nagpur and carry ISI mark on nameplate itself as per IS: 2148:1981.
63A TPN+E with Plug top.
32A TPN+E with Plug top.
Page 19 of 153
145
ELECTRICAL SIREN:- Installing & commissioning of HPCL Supplied Electrically
operated siren of 3 KM range vertical or horizontally mounted, operated with
starter, provision to manually operate through Push Button or thru PLC
command as per the instruction of EIC.
1
EACH
146
HAND OPERATED SIREN:- Installing & commissioning of Hand operated siren of
1 KM range vertical or horizontally mounted, as per the instruction of EIC.
2
EACH
147
FLP TELEPHONE:- Supply of ZONE 1, GAS GROUP IIA/IIB, IP-66 Electronic Push
Button Telephone, Intrinsically safe circuit, with hand set and push button dialer.
1 No.3/4 ET cable entry, with 1 No.3/4ET FLP Brass Ni. plated cable gland, w/o
blanking plug and M.S. Canopy. Approved make- Flame proof controls/ approved
equivalents. Finish: Epoxy Blue Colour/approved equivalent colour. The
materials has to be certified by CMRI, Dhanbad, CCOE etc for use in group flame
zone I, IIA, & IIB as per IS:2148 - 1981.
2
EACH
148
FLP FANS:- Supply & Installation of free standing pedestal type fan with
adjustable rod of 24” dia with safety guard. The same shall be having IP 66
degree of protection and shall flameproof & weatherproof type suitable for
ZONE 1, GAS GROUP IIA/IIB. The materials has to be certified by CMRI, Dhanbad,
CCOE etc for use in group flame zone I, IIA, & IIB as IS: 2148 - 1981.
1
EACH
149
CHEQUERED PLATE:- Supply, fabricate and cover the cable trench in MCC Rooms
using 5 mm thick MS chequered plates as directed at site. Rate to include
providing and fixing of lifting hooks in all the plates and painting with 2 coat of
enamel paint of approved shade over 2 coat of zinc phosphate primer as per the
instructions of EIC.
25
SQUARE
METER
20
20
20
METER
METER
METER
RCC HUME PIPE:- Supplying and laying RCC hume pipes of NP3 class at
designated places or as directed by EIC. Job to include collars/joints jointed with
stiff mixture of CM 1:2 proportion, curing, aligning and joining etc. to correct
line, level, slope and gradient complete. Job also to include excavation ( a min. of
300 more in all directions), 200mm thick sand bedding, followed by 150mm thick
PCC 1:2:4(with 20mm down aggregate),laying of hume pipe and backfilling the
trench with approved quality sand to a depth of 150mm and then placing
murrum & compacting using a surface vibrator and completing the top of the
finished surface below the level of bitumen carpet with 100 mm thick RCC 1:2:4
with provision of reinforcement of 8mm 200 c/c including backfilling at all
depths and job to be executed as per attached technical specification and
directions
of
EIC
complete.
Note: Party to quote for the item including the entire scope of the above job as
one job and no separate payment will be made.
150
151
152
500 mm NB Hume Pipe
350 mm NB Hume Pipe
200 mm NB Hume Pipe
Page 20 of 153
MISCELLANEOUS ITEMS:
153
Supply and fix Rubber Mat confirming to IS - 15652 and the same to be laid in
Meter Room suitable for HT Panel as per the directions of EIC.
10
SM
154
Supply and fix Rubber Mat confirming to IS - 15652 and the same to be laid in
MCC and Control Rooms suitable for LT Panel as per the directions of EIC.
25
SM
155
Supply of 11 KV Rubber Gloves for electrical operation works.
1
PAIR
156
Supply and fix shock treatment chart with glass frame as per directions of EIC.
2
EACH
157
Supply if First Aid Box with accessories.
1
EACH
158
Supply and fix Exit sign Board suitable for 230V supply with battery back - up.
2
EACH
159
Supply & fixing 20 W tubular emergency light fixtures of approved make suitable
with 4 hours back up battery.
4
EACH
50
50
50
50
EACH
EACH
EACH
EACH
160
161
162
163
PAINTING & STENCILLING:- Righting of following sizes letters, numbers by
painting, radium stickers on panels, transformers as per directive of EngineersIn-Charge. Rate shall be inclusive of paints, radium paper, all tools - tackles, manpower etc complete for the job.
Signwriting 1” size
Signwriting 2” size
Radium Stickers 1” size
Radium Stickers 2” size
164
CABLE MARKER:- Supply and Installation of Cable Markers for showing the route
of cable laying within the Depot premises.
100
EACH
165
STATUTORY APPROVALS:- Preparation of Drawing, obtaining Approval of the LT
work / modification Works carried out for the proposed facilities, from the
Office of the Electrical Inspectorate Office and all applicable agencies. The job
shall include obtaining approval for the entire executed job of LT/ HT and also
the required approvals for the commissioning of DG set/ Transformer/ MCC
Panels etc and any other approval associated with this job not mentioned above
but required for successful commissioning of the entire job. Job includes
liasoning, arrangements for site visits by Electrical Authority concerned like PSEB,
Electrical Inspectorate etc. Obtainance of clearance to commission facilities
complete as per direction of EIC. Job includes energization from PSEB HT side
of line and the enhancement of the Contract Demand of the Energy from PSEB.
Liasoning thereof to ensure commissioning of the entire Depot.
Note:- All Statutory Fees shall be paid by HPCL. However liasoning shall be
1
LS
Page 21 of 153
made by the party with the Electrical Authorities.
166
MODIFICATIONS IN EXISTING PANEL
The job includes tapping off the input for the existing Panels of Depot, Pipeline
and Siding from the new PMCC Panel. The job also includes carrying out any
required modification in the existing panels for the charging of the existing
Panels and the commissioning of the entire Electrical facility. The job needs to be
executed with all the required safety and to be followed in strict adherence to
electrical standards and guidelines. The job to be done as per the instructions of
Engineer Incharge.
167
SHIFTING OF EXISTING DG SETS
The job includes dismantling of the existing DG sets (200KVA & 100 KVA) from
the existing location along with all the accessories and shifting the same to the
new location as directed by the Engineer Incharge. Both the DG sets needs to be
installed, tested and commissioned at the new location keeping in view all the
safety precautions and in line with the CPCB guidelines. Further any damage
caused during dismantling shall be borne by the vendor.
LADDER TYPE CABLE TRAY:- Supply & Installation of pre-fabricated ladder type,
hot dipped GI cable tray with coupler plate, 90 deg. bends, tees, hardware etc.
made out of 2.5mm thick sheet up to size 300 mm cable tray and 3mm thick
sheet for tray of above 300mm width. Length of cable tray shall be 2.5 m. The
cable tray shall be laid on the RCC trench and shall be supported on the angles at
different levels as per the direction of Engineer Incharge.
168
750mm ladder type cable tray
1500
METER
169
450mm ladder type cable tray
700
METER
NOTE:- Following points to be noted:The bidder is advised to visit the site and understand the complete scope of the job
before bidding in the tender.
Any procurement of the material to be done only after the approval from the Engineer
Incharge
Item No. 12 & 13 to be executed based on the requirement at the site and the approval
from the Engineer Incharge. The same may or may not be executed.
Item No. 166 & 167 is kept in the tender for any required modification in the Panel. This
item may or may not be executed / may be removed from the scope of the tender as per
the requirement.
Page 22 of 153
VCB 630A, BATHINDA
Sr.
No.
FAULT LEVEL
System Voltage Level
RATING
QUANTITY
PAINT SHADE
Degree of Protection
A
A1
ANNEXURE- A
DESCRIPTION OF ITEMS
Cable In - Cable Out
Unit Panel
:- 25kA for 3 sec
:- 11 KV
:::- Alu-Zinc / RAL 7032
:- IP 4X
630 A
1
MOVING PORTION:Indoor type metal clad, totally enclosed & fully interlocked draw out type Vacuum Circuit
Breaker as per IEC 62271-100/ 200/ IS 3118. Single break trip free breaker with SPMX
mechanism, mounted on a truck carriage, complete with self-contained operated fully
interlocked rack in & rack out mechanism ON & OFF Indicator with hand trip device, spring
release coil, shunt trip coil & auxiliary switch of 6 NO + 6 NC.
1
800 A, 25 KA for 3 sec VCB (Cassette/ Trolley Mounted)
A2
Sheet Steel/ Alu-Zinc Enclosure + Aluminium Connections +Side Entry
Cable Box
B
CT (APPROVED MAKE) & PT DETAILS :
B1
2 Core CT with accuracy Class 5P 10 for protection & Class 1.0 for
metering, 15VA, STR 25KA for 1 sec, 100A/1A + 1A
3
B2
3-phase PT with ratio 11000/V3/ 110/V3; 100VA Class 1.0, OVF 1.9
for 30 sec for metering backed by HT fuses and LT MCB.
1
C
C1
C2
BREAKER PANEL INDICATION LAMPS
Breaker On/ Off/Trip/ Trip Circuit Healthy/ Spring Charge etc.
R-Ph. / Y-Ph. / B-Ph.
5
3
D
D1
D2
D3
D4
D5
D6
D7
D8
D9
SWITCHES AND OTHER ACCESSORIES :
DC ON/OFF Switch
AC ON/OFF Switch
Heater with heater switch & thermostat
Cubicle illumination lamp
15A, 230V, 3 pin plug & socket
Local Remote Switch
T-N-C Switch
Mech. ON-OFF push button
Hooter/ Alarm
1
1
1
1
1
1
1
1
1
1
Page 23 of 153
E
E1
E2
E3
METERS :
Ammeter with selector switch
Voltmeter with selector switch
MFM with RS485 port (in MODBUS)
F
RELAYS :
IDMT O/C & E/F protection relay (ER make MIT 103/ C&S make IRIPro-V / Schneider make MiCOM P111L) without communication.
F1
1
1
1
1
F2
Trip Circuit Supervisor relay type - VAX 31 (Alstom/ Equivalent make)
1
F3
Auxiliary relay type VAA33 for Transformer Fault Indication (Alstom/
Equivalent makes)
1
F4
Master Trip relay type - VAJH13 (86) (Alstom/ Equivalent make)
1
Page 24 of 153
S.No.
1
1
2
3
4
2
1
2
3
4
3
1
4
1
2
3
4
5
6
7
8
9
10
11
12
5
1
2
3
4
5
6
7
8
9
10
11
12
6
1
7
1
8
1
2
MAIN PMCC PANEL, BATHINDA
DESCRIPTION OF ITEM
POWER INCOMER
2500A 4P ACB EDO Type with SR 18G Release
Under Voltage Release
TNC Switch
Aux. Contactor with Add on Block
DG INCOMER
2000A 4P ACB EDO Type with SR 18G Release
Under Voltage Release
TNC Switch
Aux. Contactor with Add on Block
INTERLOCKING
Electrical interlocking between Power & DG Incomer
ANNEXURE : B
Unit
QTY.
Nos.
Nos.
Nos.
Nos.
1
1
1
2
Nos.
Nos.
Nos.
Nos.
1
1
1
2
Nos.
1
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
2
1
1
2
6
6
6
2
4
4
2
2
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
1
1
1
1
1
2
2
2
1
1
1
1
Set
1
Set
1
Set
Set
1
1
METERING & CONTROL
Volt Meter 0-500V Digital with VSS
Ampere Meter 0-2500A Digital with ASS
Ampere Meter 0-2000A Digital with ASS
Multi Function Meter with 2 D/O High/Low Voltage Protection
CT 2500/5A,15VA
CT 2000/5A, 15VA
Control MCB 6A SP 10KA
Neutral Link 40A
Phase & Off Indication Light Red
Phase & Trip Indication Light Amber
Phase Indication Light Blue
On Indication Light Green
OUTGOING FEEDERS
1600A 4P ACB EDO Type with Thermal Release
800A 4P ACB EDO Type with Thermal Release
630A 4P MCCB 50KA 'DN'
Spreader Link
Door Operating Handle
400A 4P MCCB 50KA 'DN'
Spreader Link
Door Operating Handle
250A 4P MCCB 50KA 'DN'
Spreader Link
Door Operating Handle
Cubical Space
CUBICAL PANEL
Cubical Panel made out from 16/14 SWG CRCA sheet steel duly power coated
in Siemens grey colour size of panel 3900 mm (W) X 2200 mm (H) X 1000 mm
(D) Floor Mounted (Back Open)
BUS BAR
Bus Bar 2400A TPN AL
MISC. ITEMS
Wiring & Fixing material
Hardware & legends
Page 25 of 153
MCC PANEL, BATHINDA
S.No.
1
1
2
1
2
3
4
5
6
7
8
9
10
3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
4
1
5
1
6
1
2
DESCRIPTION OF ITEM
INCOMMER
1600A 4P ACB EDO Type with Thermal Release
METERING & CONTROL
Volt Meter 0-500V Digital with VSS
Ampere Meter 0-1600A Digital with ASS
KWH Meter Digital (LG + 1119)
CT 1600/5A, 15VA
Control MCB 6A SP 10KA
Neutral Link 40A
Phase & Off Indication Light Red
Phase Indication Light Amber
Phase Indication Light Blue
On Indication Light Green
OUTGOING FEEDERS
800A 4P ACB MDO Type with Thermal Release
400A 4P MCCB 50KA 'DN'
Spreader Link
Door Operating Handle
250A 4P MCCB 50KA 'DN'
Spreader Link
Door Operating Handle
63A 4P MCCB 36KA 'DN' - 0 (For Lighting)
Spreader Link
Door Operating Handle
63A 4P MCB 10KA (For Lighting)
32A 4P MCB 10KA (For Lighting)
Star Delta Starter 100 HP (75 KW)
Star Delta Starter 75 HP (55 KW)
Star Delta Starter 50 HP (37 KW)
DOL Starter 40 HP (30 KW)
DOL Starter 20 HP (15 KW)
Space for Star Delta Starter 75 HP (55 KW)
CUBICAL PANEL
Cubical Panel made out from 16/14 SWG CRCA sheet steel duly power coated
in Siemens grey colour size of panel 8850 mm (W) X 2100 mm (H) X 1000 mm
(D) Floor Mounted (Back Open)
BUS BAR
Bus Bar 1600A TPN AL
MISC. ITEMS
Wiring & fixing material
Hardware & legends
ANNEXURE : C
Unit
QTY.
Nos.
1
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
1
1
1
3
3
1
2
1
1
2
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
2
2
2
2
2
2
2
3
3
3
2
2
8
5
4
3
2
4
Set
1
Set
1
Set
Set
1
1
Page 26 of 153
S.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
STARTER DETAILS, BATHINDA
20 HP DOL STARTER (15 KW)
Description Of Item
63A TP MCCB 36KA 'DN' - 2
Spreader Link
Door Operating Handle
70A TP Contactor MNX 70
Over Load Relay 24 - 40A
Control MCB 6A SP 10KA
63A Fuse Base
63A Fuse Link
On & Off Ind. Light Red & Green
Start & Stop Push Button
Single Phase Preventor
10 KVAR Capacitor Bank MPP Type
Capacitor duty power contactor suitable for 10 KVAR Capacitor MPX 12
Power Terminal Block Bus Bar Type
Remote On/Off Push ButtonT. B. 5 mm2
Amperemeter 0-60A Digital with ASS
CT 60/5A
Wiring & fixing Material
S.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
S.No.
1
2
3
4
5
6
ANNEXURE : D
Unit
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Set
Qty.
1
1
1
1
1
1
3
3
2
2
1
1
1
6
3
1
3
1
40 HP DOL STARTER ( 30 KW)
Description Of Item
100A TP MCCB 36KA 'DN'
Spreader Link
Door Operating Handle
110 TP Contactor MNX 110
Over Load Relay 45 - 75A
Control MCB 6A SP 10KA
63A Fuse Base
63A Fuse Link
On & Off Ind. Light Red & Green
Start & Stop Push Button
Single Phase Preventor
20 KVAR Capacitor Bank MPP Type
Capacitor duty power contactor suitable for 25 KVAR Capacitor MPX 25
Power Terminal Block Bus Bar Type
Remote On/Off Push ButtonT. B. 5 mm2
Amperemeter 0-100A Digital with ASS
CT 100/5A
Wiring, Bus Bar & fixing Material
Unit
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Set
Qty.
1
1
1
1
1
1
3
3
2
2
1
1
1
6
3
1
3
1
50 HP STAR DELTA STARTER (37 KW)
Description Of Item
125A TP MCCB 36KA 'DN'
Spreader Link
Door Operating Handle
70 TP Contactor MNX 70
Over Load Relay 30 - 50A
Electronic Star- Delta timer 0-60 sec
Unit
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Qty.
1
1
1
3
1
1
Page 27 of 153
7
8
9
10
11
12
13
14
15
16
17
18
19
Control MCB 6A SP 10KA
63A Fuse Base
63A Fuse Link
On & Off Ind. Light Red & Green
Start & Stop Push Button
Single Phase Preventor
20 KVAR Capacitor Bank MPP Type
Capacitor duty power contactor suitable for 25 KVAR Capacitor MPX 25
Power Terminal Block Bus Bar Type
Remote On/Off Push ButtonT. B. 5 mm2
Amperemeter 0-150A Digital with ASS
CT 150/5A
Wiring, Bus Bar & fixing Material
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Set
1
3
3
2
2
1
1
1
6
3
1
3
1
S.No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
75 HP STAR DELTA STARTER (55 KW)
Description Of Item
200A TP MCCB 36KA 'DN'
Spreader Link
Door Operating Handle
95A TP Contactor MNX 95
Over Load Relay 45 - 75A
Electronic Star- Delta timer 0-60 sec
Control MCB 6A SP 10KA
125A Fuse Base
125A Fuse Link
On & Off Ind. Light Red & Green
Start & Stop Push Button
Single Phase Preventor
20 KVAR + 20 KVAR Capacitor Bank MPP Type
Capacitor duty power contactor suitable for 50 KVAR Capacitor MPX 50
Power Terminal Block Bus Bar Type
Remote On/Off Push ButtonT. B. 5 mm2
Amperemeter 0-200A Digital with ASS
CT 200/5A
Wiring, Bus Bar & fixing Material
Unit
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Set
Qty.
1
1
1
3
1
1
1
3
3
2
2
1
1
1
6
3
1
3
1
S.No.
1
2
3
4
5
6
7
8
9
10
11
100 HP STAR DELTA STARTER (75 KW)
Description Of Item
250A TP MCCB 36KA 'DN'
Spreader Link
Door Operating Handle
110A TP Contactor MNX 110
Over Load Relay 66 - 110A
Electronic Star- Delta timer 0-60 sec
Control MCB 6A SP 10KA
125A Fuse Base
125A Fuse Link
On & Off Ind. Light Red & Green
Start & Stop Push Button
Unit
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Qty.
1
1
1
3
1
1
1
3
3
2
2
Page 28 of 153
12
13
14
15
16
17
18
19
Single Phase Preventor
25 KVAR + 25 KVAR Capacitor Bank MPP Type
Capacitor duty power contactor suitable for 60 KVAR Capacitor MPX 60
Power Terminal Block Bus Bar Type
Remote On/Off Push ButtonT. B. 5 mm2
Amperemeter 0-250A Digital with ASS
CT 250/5A
Wiring, Bus Bar & fixing Material
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Set
1
1
1
6
3
1
3
1
Page 29 of 153
TIME SCHEDULE
Page 30 of 153
ELECTRIFICATION JOB
AT
BATHINDA IRD
PART
LOCATION
COMPLETION PERIOD
FROM DATE OF
BATHINDA IRD
ISSUE OF
FOI /LOI/ PO
4(FOUR) MONTHS
NOTE:
1) Time for completion shall be reckoned from the date of issue of Fax/
Letter of Intent/Purchase Order by HPCL.
2) Time for completion shall include the time required for Design, vetting,
QAP/ITP approval, mobilization, supply, inspection, demobilization,
carrying out the works as per requirements of Contract Document and
instructions of HPCL Engineer-in-Charge.
3) The job scope is as defined in tender.
Page 31 of 153
TECHNICAL SPECIFICATIONS
Page 32 of 153
TECHNICAL SPECIFICATIONS FOR ELECTRIFICATION JOBS
STANDARDS
Materials and equipment to be supplied by the contractor for this work shall be in accordance with
relevant IS specifications. The following standards shall be applicable to various instruments.
1.
2.
IS: 2516
IS: 4047
3.
4.
5.
6.
7.
IS: 1818
IS: 2607
IS: 2208
IS: 3072
IS: 3106
8.
IS: 4237
9.
IS: 375
10.
11.
12.
IS: 2705
IS: 1248
IS: 2419
Specification for AC Circuit Breakers
Specification for Heavy duty air break switches and fuse for voltage not
exceeding 1000 V.
Specification for AC Isolators and earthing switches.
Air Break Isolators for voltages not exceeding 1000V
HRC Cartridge fuses links up to 650V.
Code practice for installation and maintenance of Switchgear.
Code of practice for selection, installation and maintenance of fuses (Voltages
not exceeding 650V)
General requirements for switchgear and control gear for voltages not exceeding
1000V.
Marking and arrangement for switchgear busbars, main connection and auxiliary
wiring.
Current transformers.
Direct acting electrical indicating instruments.
Dimensions of electrical indicating instruments.
Erection of equipment and material whether supplied by owner or contractor shall be in accordance with
the best engineering practice, conforming to respective provisions of IS codes. Site testing shall conform
to relevant IS code.
In addition the work shall conform to the following:
i) Indian Electricity rules and Acts.
ii) Fire insurance regulations.
iii) Requirements of Electrical Inspector.
iv) Requirements of State Electricity Boards.
v) Requirements of Factory Inspector
vi) Requirements of State/Central/Local Authorities
vii) Requirements of Chief Controller of Explosives Nagpur.
Note: A Copy of the above mentioned codes/manual to be provided by the vendor at the site at no
extra cost.
SPECIFICATION FOR TESTING AND COMMISSIONING OF MOTORS:
Power cables of the specified size shall be laid under ground from the MCC room to the motors, and
emerge through a pipe of suitable diameter with bends laid up to motor base in the pump house flooring.
Glands at the terminal box shall be of double compression type GP brass glands. No sealing compound
shall be used in the terminal box.
All electrical and mechanical checks shall be made in accordance with IS: 900.
Page 33 of 153
Ventilation and cooling system of the motors shall be checked and corrected if necessary.
Phase sequence of the motors shall be checked. Direction of rotation of the motors shall be checked.
When no load working is found satisfactory load shall be connected with all necessary adjustment of
settings for testing for further 1 hour. Contractor shall make all arrangements for de-coupling and recoupling of the pump sets with feeler gauge at no extra cost. Contractor shall be present during
commissioning of the pump sets.
Motor operation with push button stations shall be checked for correct operation.
SPECIFICATIONS FOR FLAME PROOF PUSH BUTTON STATIONS:
Each motor shall be provided with two FPBS. Each FPBS shall be provided with one indicating lamps of
neon type fixed with screwed type CP brass glands, for ON positions. The push buttons shall have the
following specifications:
Enclosure
Degree of protection
No. of earthing points
Painting
Rating of contracts
Push Buttons
Cable entry
Indicator Lamps
Shall conform to
:
:
:
:
:
:
:
:
:
Cast aluminum LM-6
IP - 66
2
Epoxy
415V, 50 Hz
1NO + 1NC
From Button
1 No. for on Position.
IS-2148
Only flame proof double compression glands shall be used for terminating the control cables of the motor.
Unused entries shall be closed by flame proof plugs.
The control cables shall be of 6C X 1.5 sq mm. Size and wired to get on/off controls of the motor from
places mentioned above.
The FPBS shall be fixed on a frame made out of ISA 50X50X6 angle iron frame welded to the steel
column of the gantry. On each column a frame of sufficient size to accommodate 2 Nos. of the FPBS
shall be provided. The cables and the earthing wire shall be neatly clamped to the columns by means of
MS clamps and shall be straight with no bends. The cable shall gradually enter the GI pipe and lead to
the MCC. FPBS shall be fixed to the frame by nuts and bolts.
SPECIFICATION FOR CABLES:
General
Scope
This specification covers the basic requirements for design, manufacture, inspection and testing at
vendor‟s works, of XLPE insulated cables upto 1.1KV for power, control and lighting purpose to be used
in the Oil Terminal Project of M/s Hindustan Petroleum Corporation Ltd. (HPCL), at Mandir Hasaud –
Raipur.
Page 34 of 153
Codes and standards
The design, construction, manufacture and performance of XLPE insulated cables shall comply with all
currently applicable statutes, regulations and safety codes of the locality where cables will be installed.
The cables shall conform to the applicable Indian, IEC and British Standards.
The relevant Indian standards are: IS: 613 (1984)
Copper rods and bars for electrical purposes
IS:1885-(Part32) (1993)
Electro Technical vocabulary - electric cables
IS: 2633 (1986)
Method of testing uniformity of coating on zinc coated articles.
IS:3961-(Part4) (1968)
Recommended current ratings for Polyethylene insulated cables.
IS: 3975 (1988)
Mild steel wire, formed wires and tapes for armouring of cables.
IS: 5831 (1984)
Specification for PVC insulation and sheath of electric cables.
IS: 6474 (1984)
Specification for Polyethylene insulation and sheath of electric
cables.
IS:7098-(PartI) (1988)
Specification for cross-linked Polyethylene insulated, PVC sheathed
cables.
(For working voltages upto and including 1100 volts)
IS: 8130 (1984)
Conductors for insulated electric cables and flexible cords.
IS: 10418 (1982)
Drums for electric cables.
IS: 10462
(1983)
(Part
1) Fictitious calculation method for determination of dimensions of
protective coverings of cables
IS: 10810 (Pt 58)
Methods of test for cables : Part 58 Oxygen Index test
IS: 10810 (Pt 61)
Methods of test for cables : Part 61 Flame retardant test
IS: 10810 (Pt 62)
Methods of test for cables : Part 62 Flame retardant test for bunched
cables
IEC:60540& 60540A
Test methods for insulation & sheaths of electric cables
IEC: 230 (1966)
Impulse tests on cables and their accessories
IEC: 60332 (3 parts)
Tests on electric cables under fire conditions
Page 35 of 153
IEC: 811 (5 parts)
Test methods for insulating and sheathing materials of electric cables.
IEC: 840 (1988)
Tests for power cables with extruded insulation for rated voltages
above 30KV upto 150KV
ASTM: D2863
Standard method for test for flammability of plastics using oxygen
index method
IECAS-61-402 NEMA- Thermoplastic insulated wire & cable for transmission & distribution
WC5
of electrical energy
IECAS-66-524 NEMA- Cross linked thermosetting poly ethylene insulated wire & cable for
WC5
transmission & distribution of electrical energy
IEC: 840 (1988)
Tests for power cables with extruded insulation for rated voltages
above 30KV up to 150KV
The cables & accessories shall also confirm to the provisions of the Indian Electricity Rules and other
statutory regulations in force in the country.
In case of any contradiction between various referred standards/ specifications/ data sheets and statutory
regulations, the following order of priority shall be given:
-
Statutory regulations
-
Data sheets
-
Unit Specifications
-
This Specification
-
Codes & Standards
General construction and material of construction
The cables shall be suitable for laying on trays, trenches, ducts and conduits and for underground-buried
installation with uncontrolled backfill and possibility of flooding by water & chemicals.
Outer sheath of all PVC insulated cables shall be black in color and minimum value of the oxygen index
shall be 29 at 27+/-2 0 C .In addition suitable chemicals shall be added in to the PVC compound of the
outer sheath to protect the cable against rodent & termite attack.
Sequential marking of the length of the cable in the meters shall be provided at every one meter. The
embossing or engraving shall be legible or indelible.
The overall diameter of the cables shall be strictly as per the values declared by the manufacturer in the
technical information subject to a maximum tolerance of +/- 2mm up to overall diameter up to 60mm and
+/- 3mm for above 60mm.
Page 36 of 153
XLPE insulated FRLS cables
All power and control cables shall be heavy-duty type, 1100V grade, with Copper/Aluminum Conductor,
XLPE insulated, PVC inner sheathed, armoured and overall FRLS PVC sheathed. All cables covered in
this specification shall be FRLS unless otherwise specified in the data sheet. The outer sheath of XLPE
cables shall possess flame propagation properties meeting requirements as per IS-10810 (Part-62)
category AF. Exact type of the cable shall be as specified in the cable quantity list.
Conductor
The conductor shall be composed of plain aluminum or high conductivity annealed copper wires
complying with relevant Indian standards. The conductors of size above 6mm2 shall be stranded.
Insulation
The insulation shall be of cross linked polyethylene (XLPE) compound with anti oxidant stabilisers and
shall conform to IS-7098, Part-1. (As applicable)
Filler and inner sheath
(1)
The filler and inner sheath shall be of the following:
(a)
Unvulcanized rubber, or
(b)
Thermoplastic materials
(2)
Unvulcanized rubber or thermoplastic material used shall not be harder than PVC used
for insulation and PVC used for outer sheath. The material chosen shall be compatible
with temperature ratings of the cable and shall have no harmful effect on any other
component of the cable.
(3)
The inner sheath shall be applied by extrusion method such that it fits closely on the laidup cores and shall be possible to remove without damaging the insulation.
(4)
Single core cables shall have no inner sheath.
Armouring
(1)
(2)
Armouring shall be one of the following: (a)
Galvanized round steel wire
(b)
Galvanized steel strip
(c)
Any metallic non-magnetic wire/strip.
Where the cable diameter below armour does not exceed 13mm, the armour shall consist
of galvanized round steel wires. Where the diameter below armouring is greater than
Page 37 of 153
13mm, the armour shall consist of either galvanized round steel wires or galvanized steel
strips.
(3)
The joints in armour wires or strips shall be made by brazing or welding and any surface
irregularities shall be removed.
Outer sheath
(1) The outer sheath shall be poly-vinyl chloride (PVC) compound conforming to the requirements of
Type ST1/ST2 compound as per IS: 5831 and shall be of FRLS type only.
(2) Outer sheath of all PVC cables shall be black in colour and the minimum value of oxygen index
shall be 29 at 27 2 deg. C. In addition suitable chemicals shall be added to the PVC compound
of the outer sheath to protect the cable against rodent and termite attack.
(3) The outer sheath shall be applied by extrusion over the armouring.
Dimension / thickness of materials
The thickness of insulation, inner sheath, outer sheath and dimension of wire/strips used for
armouring shall be as per relevant standards.
Core identification
Cores of cable shall be identified by colour coding of PVC insulation by adopting the following scheme.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
1 core :
Red, black, yellow, blue or natural
2 core :
Red and black
3 core :
Red, yellow and blue
4 core :
Red, yellow, blue and black
5 core :
Red, yellow, blue, black and gray
6 core and above : The core identification shall be done by printing numbers or by
providing colored strips all along cores. The insulation of cores
shall be of the same colour and numbered sequentially. The
numbers shall be printed in Hindu-Arabic numerals on the outer
surface of cores. The numbers shall be repeated at regular
intervals along the core and the spacing between consecutive
numbers shall not exceed 50mm.
For reduced neutral conductors, the insulation colour shall be black.
Identification of Cables
The cables shall be clearly and permanently marked with following information throughout the length.
(1) Voltage grade.
(2) Manufacturer‟s name or trade mark.
(3) Year of manufacture.
Cross sectional area of conductor and no of cores.
Page 38 of 153
Cable Drums
(1)
Cables shall be supplied in non-returnable wooden drums of heavy construction. The wood
used for construction of the drum shall be properly seasoned, free from defects and wooden
preservatives shall be applied to the entire drum. All ferrous parts shall be treated with a
suitable rust preventive finish or coating to avoid rusting during transit or storage.
(2)
The vendor shall indicate in the offer, the maximum length of cable, which can be
accommodated on one drum. The actual length supplied on each drum shall be within
tolerance limit of +5%. The drum length shall be as per the cable quantity list.
(3)
The cables shall be wound on drums of suitable barrel diameter, securely battened, with the
take-off and fully protected against mechanical damage. The cut ends of cable shall be sealed
by means of non-hygroscopic sealing material to avoid ingress of water during transit or
storage. Also, PVC /Rubber end caps shall be supplied free of cost for each drum with a
minimum of eight per thousand metre length.
(4)
The following information shall be stencilled on each drum.
(a)
Name of manufacturer, brand name or trademark.
(b)
Nominal cross sectional area of conductor
(c)
Number of cores.
(d)
Type of cable and voltage grade.
(e)
Cable code
(f)
Length of cable on the drum.
(g)
Number of lengths on drum (if more than one).
(h)
Drum number.
(i)
Direction of rotation of drum (by means of an arrow).
(j)
Reference standard
(k)
Approx. gross weight.
(l)
Job number.
(m)
Country of manufacture
(n)
Year of manufacture.
A tolerance of +/- 3% shall be permissible for each drum. However, overall tolerance for each size of
cable shall be limited to +/ - 2%. Offer with short / non-standard lengths are liable for rejection. If nonstandard drum lengths are specified in the data sheet, then same shall be supplied.
Cable quantity
The bidder shall quote unit rates for all types of cables as indicated in the Job Schedule List.
Inspection and tests
Note :- Manufacturer’s test certificate to be provided comprising of the following tests result for all
the cables supplied:(1)
All routine tests, acceptance tests, type tests & additional type tests for improved fire
performance shall be carried out as listed in IS-7098 (Part-2).
(2)
The test for resistance to Ultraviolet radiation: This test shall be carried out as per DIN 53387
or ASTM-G-53 on outer sheath. The retention value of tensile strength & ultimate elongation
Page 39 of 153
value after the test shall be minimum 60% of the tensile strength and elongation value before
the test. The test certificates with respect to this test (not older than 1 year) from recognized
testing laboratory to be furnished for review by PMC before dispatch clearance of cables. In
case test certificates are not available, test is to be conducted by vendor at his own cost in any
recognized test laboratory or in-house testing laboratory, before dispatch clearance of cables.
Sampling for this test is to be carried out one for each order, provided the outer sheath
remains the same.
(3)
Acceptance tests as per IS-1554 Part-1 and IS-7098 Part-2 and the following special tests to
be performed on the cables as per the sampling plan. This tests are to be witnessed by PMC/
Owner before the dispatch of cables: a) Accelerated Water absorption test for insulation as
per NEMA –WC-5 (For PVC insulated cables) and as per NEMA WC-7 (For XLPE insulated
cables). Test certificates with respect to this test (not older than one year) from recognized
testing laboratory to be furnished for review by PMC before dispatch, clearance of cables. In
case test certificates are not available, test is to be conducted by vendor at his own cost in any
recognized test laboratory or in-house testing laboratory, before dispatch clearance of cables.
Sampling for this test is to carried out one for each order.
(4)
Dielectric Retention test: The dielectric strength of the cable insulation tested in accordance
with NEMA WC-5 at 75 ± 1o C shall not be less than 50% original dielectric strength. Test
certificates with respect to this test (not older than one year) from recognized testing
laboratory to be furnished for review by PMC before dispatch, clearance of cables. In case
test certificates are not available, test is to be conducted by vendor at his own cost in any
recognized test laboratory or in-house testing laboratory, before dispatch clearance of cables.
Sampling for this test is to carried out one for each order.
(5)
Oxygen Index Test: The test shall be carried out as per ASTM D2863 or applicable Indian
Standard specifications. Sampling to be done for every offered lot / size as per sampling plan.
(6)
Flammability Test: The test shall be carried out on finished cable as per IS-10810 (part 61 &
62). Sampling for this test is to be carried out one for each order, provided the outer sheath
remains the same. The acceptance criteria for tests conducted shall be as under:
Part-61: The cable meets the specifications if there is no visible damage on the test specimen
within 300 mm from its upper end.
Part-62: The maximum extent of charred portion measured on the test sample should not
have reached a height exceeding 2.5m above the bottom edge of the burner at the front of the
ladder.
(7)
Test for rodent & termite repulsion property: The vendor shall furnish details to analyze the
property by chemical method. Sampling to be done for every offered lot / size as per the
sampling plan.
Information required with the bid
Vendor shall furnish technical particulars / description and performance details of all cables, current
carrying capacities and derating factors, for all conditions of cable laying.
Page 40 of 153
CABLE LAYING:
1
General
Cable installation shall include power and control cables. These shall be laid in
trenches/ cable trays as detailed in the cable layout drawings. Cable routing given on the
cable layout drawings shall be checked in the field so as to avoid interference with structures,
heat sources, drains, piping, air-conditioning duct etc. Any change in routing shall be done to
suit the field conditions wherever deemed necessary, after obtaining approval of Engineer-incharge.
1.1
Deleted
1.2
The lengths indicated in the cables schedule is only approximate. The contractor shall
ascertain the exact, length of cable for a particular feeder by measuring at site. All cable
routes shall be carefully measured .Before the start of cable laying, the contractor shall
prepare cable drum schedule and get that approved by Engineer-in -charge to minimize/avoid
straight through joints and then the cables cut to the required lengths, leaving sufficient
lengths for the terminations of the cable at both ends. The various cable lengths cut from the
cable reels shall be carefully selected to prevent undue wastage of cables. Extra loop length
shall be given for feeder cables where required as per the directions of Engineer-in-charge to
meet contingencies.
Cables shall be laid in directly buried trench or in RCC trench (underground trench) or in cable
tray along pipe sleepers or in over head trays as shown on cable layout drawings.
Overhead trays shall be installed 2700 nun (minimum) above grade level. At road crossings
overhead trays shall be installed at 7000 mm (minimum) above grade level or cables shall be
routed cable tray culvert/ Electrical road crossings as per layout drawings.
Sufficient care shall be taken while laying cables to avoid formation of twist, sharp bend etc. in
order to avoid mechanical injuries to cables. Rollers shall be used for pulling of cables
Cable installation shall provide minimum cable bending radii as recommended by cable
manufacturer.
1.3
Cables shall be neatly arranged in the trenches / trays in such a manner that criss-crossing is
avoided and final take off to the motor / switchgear is facilitated. Arrangement of cables
within the trenches / trays shall be in line with cable layout drawings. Cable routing between
cable trench and equipment/motors shall be taken through GI pipe sleeves of adequate size.
Pipe sleeves shall. be laid at an angle of maximum 45 to the trench wall. Bending radius of
pipes shall not be less than 8D. It is to be ensured that both the ends of GI pipe sleeves shall be
sealed with approved weather proof sealing plastic compound after cabling. In places where it is
not possible, cables shall be laid in smaller branch trenches.
1.4
All cables shall be identified close to their termination point by cable tag numbers as per cable
schedule. Cable tag numbers shall be punched on aluminum straps (2mm thick, 20 mm wide and
of enough length) securely fastened to the cable and wrapped around it. Each underground cable
shall be provided with cable tags of lead securely fastened every 30 m of its underground length
with at least one tag at each end before the cable enters/leaves the ground. In unpaved areas,
cable trenches shall be identified by means of cable markers as per installation drawing. These
cable markers shall be placed at location of changes in the direction of cables and at
intervals of not more than 30 in and also at cable straight through joint locations.
1.5
All temporary ends of cables must be protected against dirt and moisture to prevent damage to
Page 41 of 153
the insulation. For this purpose, ends of cables shall be taped with an approved PVC end cap or
rubber insulating tape.
1.6
Each row of cables shall be laid in place and before covering with sand. All wall
openings/pipe sleeves shall be effectively sealed after installation of cables to avoid seepage of
water inside building/lined trench. Every cable shall be given an insulation test in presence of
Engineer-in-charge/Owner before filling the cable trench with sand Any cable which is found
defective shall be replaced
1.7
Where cables pass through foundation walls, the necessary openings shall be provided in
advance for the same by another agency. However, should it become necessary to cut holes in
existing structures for example floor slab etc., the electrical contractor shall determine their
location and obtain approval of the Engineer-in-charge before carrying out the same.
1.8
Cables for road crossings shall be taken through ERC (Electrical Road Crossing) as shown in
the cable layout drawings. At road crossing and other places where cables enter pipe sleeves
adequate bed of sand shall be given so that the cables do not slack and get damaged by pipe ends.
1.9
Wherever cable trench crosses storm water, waste water channel/drain, cables shall be taken
through PVC/RCC pipes. Where cables are required to cross drains of depth more than 1200 mm,
cables shall be taken over the drain on cable trays supported suitably using ISMC 150/200
sections.
1.10
Ends of cables leaving trench shall be coiled & capped and provided with protective cover till
such time the final termination to the equipment is completed.
2
Cables laid direct in ground
Cables shall be laid underground in excavated cable trenches where specified in cable layout
drawings. Trenches shall be of sufficient depth and width for accommodation of all cables.
Cables shall be properly spaced and arranged with a view of heat dissipation and
economy of design. Maximum number of cable layers in trench shall be preferably limited to
5 layers.
Minimum depth of cable trench shall be 750 mm for low voltage. The depth and the width of
the trench shall vary depending upon the number of layers of cables as per EIL installation
Standards
Cables shall be laid in buried trenches at depth as shown in the cable layout drawings. It is
to be insured by the contractor that the bottom of buried trenches shall be cleared of all rocks,
stones and sharp objects before cables are placed. The trench bottom shall be filled
with a layer of sand. This sand shall be leveled and cables laid over it. These cables shall be
covered with 150 mm of sand on top of the largest diameter cable and sand shall be
lightly compacted. A flat protective covering of 75 min thick second class red bricks shall
then be laid and the remainder of the trench shall then be back -filled with soil, rammed and
leveled.
3
Cables laid in concrete trench
Cables shall be laid in 3 or 4 tiers in concrete trench as shown on layout drawings. Concrete
cables trenches shall be filled with sand in hazardous area to avoid accumulation of hazardous
gases and oil. RCC covers of trenches shall be effectively sealed to avoid ingress of chemical
Page 42 of 153
and oil in process area. Removal of concrete covers where required for the purpose of cable
laying and reinstating them in their proper position after cables are laid shall be done by
electrical contractor.
All wall openings/pipe sleeves shall be effectively sealed after installation of cables to avoid
seepage of water
4
Above ground cables
4.1
Cables installed above grade shall be run in cable trays, clamped on walls, ceiling or
structures and shall be run parallel or at right angles to beams, walls or columns. Cable
routing shall be planned to be away from heat sources such as hot piping, gas, water, oil
drainage piping, air-conditioning duct etc. Each cable tray shall contain only one layer of
cables as far as possible for power cables. However control cables may be laid in double layer
in the cable trays.
4.2
Individual cable or small group of cables (up to 3 to 4 cables) which run along structures
/ walls etc. shall be clamped by means of 16 SWG GI saddles on 25 x 6 mm saddle bars.
Alternatively small group of cables can be taken through 100/150 mm slotted channel tray /
ISMC 100. Cables shall be supported so as to prevent sagging. In general, distance between
supports shall be approximately 300 mm for cables up to 25 mm diameter and maximum 450
mm for cables larger than 25 mm dia. to prevent the sagging of cables.
4.3
Cable laid on supporting angle in cable trenches, structures, columns and vertical run of cable
trays shall be suitably clamped by means of G.I. saddles / clamps, whereas cables in
horizontal run of cable trays shall be tied by means of nylon cords. Distance between
supporting angles shall not exceed 600 mm.
4.4
All cable trays (other than galvanized trays) and supporting steel structures shall be painted
before laying of cables. The under surfaces shall be properly degreased, derusted, descaled
and cleaned. The painting shall be done with one coat of red oxide zinc chromate primer.
Final painting shall be done with two coats of approved bituminous aluminum paint unless
otherwise specified.
4.4
All cable trays (other than galvanized trays) and supporting steel structures shall be painted
before laying of cables. The under surfaces shall be properly degreased, derusted, descaled
and cleaned. The painting shall be done with one coat of red oxide zinc chromate primer.
Final painting shall be done with two coats of approved bituminous aluminum paint unless
otherwise specified.
4.5
Where cables rise from trench to motor, lighting panel, control station, junction box etc., they
shall be taken in (31 pipe for mechanical protection up to a minimum of 300 mm above grade.
Cable ends shall be carefully pulled through conduit to prevent damage to cable.
4.6
All G.I. Pipes shall be laid as per layout drawings and site conditions. Before fabrication of
various profiles of' pipes by hydraulically operated bending machine (which is to be arranged by
the contractor) all the burrs from the pipes shall be removed. GI Pipes having bends shall be
buried in soil / concrete in such a way that the bend shall be totally concealed. For G.I. pipes
buried in soil, bitumen coating shall be applied on the buried lengths, Installation of G.I. pipes
shall be undertaken well before paving is completed and necessary co ordination with paving
agency shall be the responsibility of Electrical Contractor.
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Following guide shall be used for sizing of G.I. pipe.
a)
b)
c)
d)
4.7
1 cable in a pipe
- 53% of pipe cross-sectional area occupied by cables.
2 cables in a pipe
- 31 % of pipe cross-sectional area occupied by cables.
3 cables in a pipe
- 43% of pipe cross-sectional area occupied by cables.
4 and above cables in a pipe - 40% of pipe cross-sectional area occupied by cables.
After the cables are installed and all testing is complete, conduit ends above grade shall be
plugged with a suitable weatherproof plastic compound/bitumen/suitable sealing compound.
Alternatively rubber bushes shall be employed for the purpose of sealing.
TERMINATIONS
5.1
All PVC cables up to 1100V grade shall be terminated at the equipment by means of
compression type cables glands suitable for the cable size. They shall have a screwed nipple with
conduit electrical threads and check nut. The cables shall be identified close to their terminations
points at both the ends of cable ( cable numbers shall be punched on aluminum straps 2 mm thick
and securely fastened to the cable, wrapped around it ) and also along the route at recommended
intervals, by cable tag numbers.
All cable entries for outdoor termination shall be preferably through bottom. Outdoor cable
termination through top of equipment shall not be permitted.
5.2
Power cables cores wherever color coding is not available sha ll be identified with red,
yellow and blue PVC tapes. Where copper to aluminum connections are made, necessary
bimetallic washers shall be used.
5.3
In case of control cables, all cores shall be identified at both ends by their terminal numbers by
means of PVC ferrules suitable for core size. Wire numbers shall be as per schematic/
wiring/inter-connection diagram. All unused spare cores of control cables shall be neatly
bunched and ferruled with cable tag at both ends, for future use.
For trip circuit identification additional red ferrules shall be used only in the particular cores of
control cables at the termination points in the Switchgear/ Control panels and Control
Switches.
5.4
Contractor shall drill holes for fixing glands wherever necessary. Gland plate shall be of nonmagnetic material/ aluminum sheet in case of single core cables. All unused cable entries on
equipment/panels shall be plugged/ sealed.
5.5
The cable shall be terminated at electrical equipment/switchboards through glands of proper
size. The individual cores shall then be dressed and taken along the cables ways or shall be fixed
to the panels with polyethylene straps. The cable glanding shall be done as per
manufacturer‟s instructions. Cable armor shall not be exposed after termination is complete. In
case of termination of cables at the bottom of a panel over a cable trench having no access from
the bottom close fit holes shall be drilled in the gland plate for all the cables in one line, and then
gland plate shall be split in two parts along the centre line of holes. After fixing bottom plate,
uncovered cable holes/gaps shall be sealed with cold setting compound.
5.6
Crimping of lugs to cable leads shall be done by hand crimping / hydraulically operated tool as
per requirement. Insulation of the leads shall be removed before crimping. Conductor surface shall
be cleaned and shall not be left open. Suitable conducting jelly shall be applied on the conductor
lead. Lugs shall enclose all strands of cable core. Cutting of strands shall not be allowed.
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5.7
The contractor shall bring to the notice of Engineer-in-charge any mismatch in cable glands,
lugs provided with the equipment vis-a-vis to the cable size indicated in cable schedule for taking
corrective action.
5.8
The cable joints in power and control cables shall be avoided as far as possible. In case a joint is
unavoidable, the following shall be insured:
The number of joints shall be restricted to minimum as far as possible.
The location of joints shall be identified with permanent markers.
No joints shall be allowed in hazardous areas without the approval of Engineer-in charge.
The jointing and termination of medium voltage power cables shall be carried out by trained
personnel only. Jointing and termination of high voltage cables shall be done by skilled and
experienced jointer duly approved by Engineer-in-charge. Only type tested termination kits of
approved make shall be used.
5.9
No unauthorized repairs, modifications shall be carried out on the hazardous area equipment
terminal boxes and junction boxes. Damaged enclosures of hazardous area equipment shall be
brought to the notice of Engineer-in-charge by contractor. After termination is complete, all the
bolts, nuts, hard ware‟s of terminal box shall be properly placed in its po sition and
tightened.
5.10
Where required, cable sealing boxes intended to be used with the apparatus shall be filled with
solid setting type bituminous compound unless otherwise specified.
TESTING AND COMMISSIONING
6.1
Field testing and commissioning of electrical installation shall be carried out as per specification.
6.2
Before energizing, the insulation resistance of every circuit shall be measured from phase to phase,
phase to neutral and from phase/neutral to earth.
6.3
Where splices or terminations are required in circuits rated above 650 volts, insulation
resistance of each length of cable shall be measured before splicing and or / terminating. After
completion of splices and /or terminations measurements shall be repeated.
6.4
The insulation resistance of directly buried cables shall be measured before cable trenches are
backfilled. Measurements shall be repeated after back filling.
For cables up to 1.1 kV grade 1000 V Megger and for H.V.
Cables 2.5 kV / 5 kV Megger shall be used.
6.5 D.C. High Voltage test shall be conducted on cables given below after installation.
All 1100 volts grade cables in which straight through joints have been made.
All cables above 1100 V grade.
The D.C. High Voltage test shall be performed as detailed below in the presence of the Engineer-InPage 45 of 153
charge or his authorized representative only.
Cables shall be installed in final position with the entire straight through joints complete. During
the high voltage test, all other electrical equipment related to the cable installation, such as
switches, instrument transformers, bus bars, etc., must be earthed and adequate clearance shall be
maintained from the other equipment and framework to prevent flash over.
In each test, the metallic sheath/screen/armor shall be connected to earth.
6.6 All checks and tests shall be made as per standard test performs available with site engineer.
All test readings shall be recorded and submitted to HPCL in triplicate sets.
6.7. Cable schedule, cable layout drawings, Interconnection drawings shall be marked by contractor for 'AS
BUILT STATUS' and two sets of copies shall be submitted to HPCL.
CABLE MARKERS:
Contractor shall supply and fix CI cable markers at every 15mts distance and also at every change of
direction. Cable markers shall be as per IS specifications.
CABLE TRAYS (Contractor supply)
Cable trays shall be fabricated out of 10 SWG GI perforated sheets. The cables shall be secured to the
trays at every 1 m with painted MS hooks. The width of the trays shall be sufficient width to
accommodate all cables with 50mm clear spacing. This shall be supplied and installed by the contractor.
GANTRY AND PUMP HOUSE:
For gantry flame proof well glass fittings shall be provided one in each bay and one above each of the
checking platform. Two Nos. flame proof rotary switches shall be provided to control these circuits. For
pump house FLP well glass fittings shall be provided one in each bay and one FLP rotary switch be
provided for every 3 Nos. of the fittings. The switches shall be provided at 1.6mt ht. from the floor level
in both the structures.
SPECIFICATIONS FOR EARTHING SYSTEM:
MATERIALS FOR EARTHING:
Earthing system shall comprise of GI strips and GI plates, GI wires of proper size as specified, GI
Electrodes, salt, charcoal, G1 clamps, bolts, etc. All earthing pits shall be of pipe electrode type
mentioned in IS 3043 Latest edition with all GI parts.
The earthing conductor shall be laid at 500 mm depth inside the ground. When cable trenches are
provided the conductor shall be clamped to the walls of the trench.
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All the joints under ground shall be welded and protected from rusting by treating with Barium chromate.
Such welded surfaces shall be protected by applying Zinc chromate red oxide and aluminium paint.
Finally they shall be treated with Bitumen paint.
Equipment and machinery like motors, control panel, oil circuit breaker and transformer shall be earthed
individually. Exposed parts of the earthing conductor shall be treated with Bitumen Paint.
MAKE:
Cables offered shall be from reputed manufacturer. Vendor to specify manufacturer‟s name in the
technical bid. It will be mandatory to supply the same make cable if accepted by us during technical
evaluation.
DRAWING AND DATA:
The vendor shall furnish technical particulars of cables, type, make and BIS certificate with their offer in
duplicate failing which the offer is liable to be rejected.
NOTE: Any deviation from the above specifications shall be brought out clearly by the vendor on
separate sheet.
Both the specifications and job schedule shall be duly filled, signed and returned to HPCL without which
offers are liable to be rejects.
SPECIFICATION FOR ERECTION AND COMMISSIONING OF PANELS
MAIN MCC PANEL:
Following pre-commissioning checks and tests shall be carried out on Main MCC panel:
Control wiring, busbar and other live parts of the circuit shall be meggered by 1000V for Resistance
values.
If interior of the equipment is moist or gives lower Resistance value, then entire equipment shall be dried
up as per instruction of Engineer-in-charge.
All protective alarm or other relays shall be checked for the working if required by secondary injection
method and test certificate shall be given.
All the fuses of the main and control circuit shall be checked for rating and continuity. All indicating
lamps shall be working. The doors shall be closing properly and gaskets shall not peel off. The tripping
and closing mechanism shall work properly. Various clearances shall be maintained as per rules. Metallic
parts of the equipment shall be properly earthed. Interlocking arrangement of transformer OCB and DG
shall be checked for proper working. If any of the above is not satisfactory, it shall be reported to the
Engineer-in-charge for necessary corrective action.
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LIST OF ACCEPTABLE MAKES OF MATERIAL/COMPONENTS
The following are the acceptable makes of materials & components to be used in the installation:1) ACB
L&T /GE/SIEMENS /SCHENIEDER
2) FUSE SWITCH
L&T /GE/SIEMENS /SCHENIEDER
3) HRC FUSES
L&T /GE/SIEMENS /SCHENIEDER
4) CONTACTORS
L&T /GE/SIEMENS /SCHENIEDER
5) THERMAL O/L RELAYS
L&T /C&S /GE/SIEMENS /SCHENIEDER
6) CONTROL SWITCHES
KAYCEE /SALZER
7) PUSH BUTTONS
TEKNIC /VAISHNO /SCI
8) INDICATING LAMPS
TEKNIC /VAISHNO /FTC /L&T
9) TIMERS
EAPL /L&T /TEKNICA /SIEMENS
10) INDIATING METERS DIGITAL AE/RISHABH /INDOTECH
11) TERMINALS
CONNECTWELL /ELMEX /TOSHA
12) MCB‟S
MDS/INDO-KOPP /GE /L&T
13) PROTECTIVE RELAY
AVKC /GE /EASUN
14) MCCB
ABB /L&T /SIEMENS /SCHNIEDER
15) 4 POLE CHANGEOVER
HAVELLS /HPL-SOCOMCE
16) CT
AE/INSEL/ C&S/ GILBERT & MAXWELL/ AREVA/ KAPPA
ELECTRICALS/ PRAGATI ELECTRICALS/ SILKAANS
17) SPP
MINILEC /L&T
18) CABLE GLANDS
BRACO/ COMET/ COMOS/
SWITCH
19) FLP FITTINGS
FLAMEPROOF EQUIPMENTS/ BALIGA/ SUDHIR
(Wellglass & Floodlight Fittings SWITCHGEARS/ SHYAAM SWITCHGEARS/ ACTIVAA
Push Buttons, Telephone etc.)
TECHNO-CONTROLS PVT. LTD./ FLEXPRO/ FCG
20) LIGHTINGS
BAJAJ ELECTRICALS/ SURYA ROSHINI/ PHILLIPS/
WIPRO/ GE
21) STRAIGHT THRU JOINTS
M-SEAL/ 3-M/ RAYCHEM
22) CABLES
CCI/ HAVELS/ POLYCAB/ RPG/ KEI/ FINOLEX
23) ATS/ MANUAL CHANGEOVER HAVELLS/ SIEMENS/ L&T/ SCHNEIDER/ ABB
24) BUSBAR
HINDALCO/ EQUIVALENT APPROVED MAKE
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Specific Requirements:
All components shall be rated for in-panel (i.e. with the components inside the
panel) continuous current carrying capacity with end temperatures as defined in
this tender document and shall be rated for specified short circuit rating for 1 sec.
All bus bars and jumpers of outgoing feeders shall be rated 20% higher than the
incomer or outgoing switch.
The switchboard shall be rated for specified MVA level or fault current for 1 sec.
Links shall be used for connecting the FDS and the vertical bus bar. Short circuit
capacity of this link shall be as the vertical bus bar.
All MCB‟s supplied shall be rated for 240/415 V, IP20, DIN rail mountable, and
with pad lock support, Biconnect upper & lower terminals, Safety shutter at cable
terminals & Suitable for clip on accessories.
Minimum compartment size for the contactor feeder shall be 200 mm.
Maximum height of operating handle/ switch shall exceed 1900 mm and the
minimum height shall be below 300 mm.
A minimum of 10% spare shall be provided in each terminal block, without
affecting the size of the module.
Control bus shall be provided and the power for same shall be derived from the
incomer or Control transformers wherever applicable.
Earthing of doors shall be done with flexible braided copper up till the earth bus
bar in the respective module.
The earth bus shall run into every module and the size of the bus bar shall be
furnished.
Proper space and arrangement should be available in cable alley to clamp and
segregate the power and control cables.
The rear door shall be of 400 mm width and shall vertical-split type for rear access.
This is done to ensure minimum rear clearance.


Following details shall be provided along with offer;
Comprehensive characteristics of the O/L relay.
Minimum clearance required on all the three sides of the panels.
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
Rating of space heater provided for panel and its adequacy.
For multiplication of breaker contacts, latched in type relays (VAJC of Alstom
make or equivalent) shall only be used. Alternatively, only breaker auxiliary
contacts shall be used wherever required.
Protection relays shall be numerical type, communicable, with protocol for
communication as IEC –5-103. Vendor shall therefore specifically mention the
relays offered in their quotation. No other makes/ models of relays shall be
accepted. Prior to the ordering of the relay, vendor shall take approval from HPCL
regarding the ordering information details. Other than the relays mentioned above,
any other relays required for achieving the operation of the switchboard shall be
supplied by the vendor without any extra cost.
The MCCB breaking capacity shall have Icu = 100% of Ics for the entire range.
Coil of the contactor shall be suitable for operation on 240V, 1 PH, AC supply and
shall work satisfactorily between 65 to 110% of rated value.
CT‟s shall have minimum ratings of 10VA and metering equipments shall have
sufficient ISF‟s.
Separate cores shall be used for metering through analogue meters / load
managers. When metering is done through relays, protection core shall have
additionally the metering class accuracy built into.
Maximum height of the Board, including the height of the base channel, shall not
be more that 2450 mm
The maximum height of the operating handle/ switches shall not exceed 1900 mm
and the minimum height not below 300 mm.
Unused modules in the panel shall be fully equipped with hinged door, power and
control terminals for starter modules and cradle for future use.
Outgoing ACB‟s can be mounted in a maximum of two tier execution while the
incoming/ bus coupler ACB‟s shall be single tier execution only. The metering
and protection equipments associated with a particular breaker shall be mounted on
the same panel front.
The in-panel current carrying capacity of main phase bus bars shall be 20 %
more than incomer breaker rating.
The in-panel current rating of the neutral busbars shall be the same as that of
respective phase busbars.
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The minimum earth bus size shall be 25 x 3 mm copper and shall be of adequate
cross-section to withstand the specified fault level.
Double front M.C.C. shall have two nos. earth busbars, one for each front.
Minimum size of bus bars for starter/ feeder power connections above 100 Amp
rating shall be 20 x 6 mm Aluminium.
Minimum size of bus bars for control bus bars shall be 25 x 3 mm Aluminium.
Busbars shall be of high conductivity electrolytic aluminium ( E91E)/ copper.
Unloading and stacking of the panels at our premises.
TECHNICAL SPECIFICATION
MV SWITCHGEARS & PANEL BOARD :The panel shall be manufactured as per the following specification.
deviation from
In case of any
the mentioned, vendor shall bring into notice the same along with its offer. In absence
of such deviation, it will be presumed that equipment offered is exactly similar to the
specification.
The following Standards shall be refered :5
Colors for Ready Mixed Paints
375
Specification for Marking & Gen Arrangement of Swgr, Busbars, Main
Connection & Aux. Wiring
398
Specification for Hard Drawn Stranded Aluminum & Steel Cored Aluminum
Conductors for
Overhead Power Transmission Purpose
513
Cold Rolled Low Carbon Steel Sheet & Strips
722
Specification for A. C. Electricity Meters. (Integrity Meters)
1248
Specification for Direct Acting Electrical Instruments.
1822
AC Motor Starters of Voltages not exceeding 1000 V
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1841
Specification for EC grade Aluminum Rod Produced by Rolling
1897
Specification for Copper Strips for Electrical Purposes
1901
Visual Indicator Lamps.
2147
Degree of Protection provided by Enclosure for Low Voltage Switchgear
2208
Specification for HRC Fuse Links up to 650 Volts
2516
A.C. Circuit Breaker Requirement for Voltages not Exceeding 1000 V (Part - I,
Sec - I + Part - II, Sec-II)
2705
Specification for Current Transformers.
2834
Specification for Capacitors for Power System
2959
AC Contactors for voltages not exceeding 1000 V
3202
Code of Practice for Climate Proofing of Electrical Equipment
3231
Electrical Relays for Power System Protection.
3247
Switchgear General Requirements
3427
Metal Enclosed Switchgear & Control gear
4064
Specs for Heavy Duty Air Break Switches Fuses for Voltages not exceeding
1000 V.
4237
General Requirement for Switchgears & Control gear for Voltage not exceeding
1000 V
6875
Control Switches / Push Buttons
8623
Factory Built Assemblies of Switchgears & Control Gear.
8828
Miniature Circuit Breaker
Indian Electricity Acts & Rules :All codes & standards means the latest, wherever not specified.
The manufacturing shall generally follow the Indian Standard codes of practice or the
relevant British
Standard Codes of Practice in the absence of corresponding Indian Standard.
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REQUIREMENTS OF SWITCHBOARD:
A. General:
All switchboards shall comply with the requirements of IS 8623 applicable for Factory
Built Assemblies. Refer to “Data Sheet of required switchboard” & “SLD” , if any,
for rating of feeders, individual components, service designation & total number of
each type of feeders required on the switchboard completely assembled in one line up .
B. SWITCHGEAR MODULES
Feeders are classified into three main categories viz. Air circuit breakers, switch
dis-connector fuse/ MCCB feeders and motor starter feeders.
MCCB : Fuse less starters with minimum 18 control terminals..
All combination motor starter feeders shall meet requirements of type-II coordination as per IS:13947.
All identical modules shall be interchangeable.
Internal control wiring of all modules of each type shall be identical for all ratings.
C. COMPONENTS:
I.
Circuit Breaker :1. General Construction :
Air Circuit breakers shall be Air break, double break, quick make/ break, fully
draw out type, electrically operated, with or without overload and short circuit
releases as indicated in enclosed single line diagram. ACB shall be modular in
construction and conforming to the latest IS specification IS – 13947 (2) & or
IEC60947. It shall comprise three/ four separate identical single pole units operated
through a common shaft by the operating mechanism.
Exact ratings and no. of poles shall be as indicated in SLD. Circuit breaker for
generator incomer and of substations catering primarily to unbalanced loads shall
be with four poles with the 4th pole 100% rated.
Main poles of the breakers shall operate simultaneously. There shall be no
objectionable rebound and the mechanism shall not require any critical adjustment.
It shall be strong, rigid, positive and fast in operation.
Air Circuit breaker along with its operating mechanism shall be mounted on a
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wheeled carriage moving on guides or any other suitable mechanism, designed to
align correctly and allow easy movements. All Air circuit breaker trucks of the
same rating shall be interchangeable.
The racking handle, manual charging handle and mechanical close / open push
button shall be in the front and shall be an integral part of ACB.
All circuit breakers of same rating shall be identical in all respects and shall be
interchangeable.
Releases are not required to be provided with breakers where relays are used.
Arc extinguishing devices shall be easily removable for routine inspection of fixed
contact assemblies.
Circuit breaker for bus couplers shall be identical to the incoming/outgoing
breaker.
There shall be distinct overall door for the breaker compartment and it should be
lockable.
2. Electrical
ACB shall be suitable for operational voltage 415 V AC and insulation voltage
of 690 V AC + 10%, 50Hz supply system and shall be suitable for impulse
withstand of 12 kV.
ACB shall be suitable for isolation according to IEC 60 947-2
The ACB at its rated current shall be suitable for operation in extremely
tropical humid climate at 50 Deg C ambient temp. The ACB shall have no
derating upto 55 C service temperature. In case the ACB needs derating,
manufacturer shall declare the derated current carrying capacity at 55 C service
temperature.
ACB shall have a service breaking capacity rating (Ics) of 65KA for rated
current upto 1600A, 80 KA for rated current from 2000- 3200 A & 100 kA for
4000 to 6300 Amp .
ACB shall have minimum short circuit breaking capacity of Icw =70 kA for 1 sec.
& Ics = 100% of Icu.
The ACB shall be fitted with an under voltage release of 240 or 415 V ac with
built-in time delay to avoid nuisance tripping.
Circuit breakers shall be suitable for switching duty of motors.
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ACB can be reverse fed without compromising on the performance.
ACB shall be provided with following,
 Universal motor rated for both 240 V A.C & 110 V DC for charging the breaker
closing spring.
 Closing coil rated for satisfactory operation from 80% to 110% of rated voltage
of 110 V DC.
 Tripping coil rated for satisfactory operation from 50% to 110% of rated
voltage of 110 V DC.
 Limit switches with 2 NO and 2 NC contacts for cutting off the power supply to
spring charging motor and closing coil circuit.
Each circuit breaker shall have necessary auxiliary contacts for indication,
protection, interlocking supervision, metering and other purposes. Min. 8 „NO‟ + 8
„NC‟ breaker operated potential-free changeover contacts rated for 10 amps at 240
V AC and 1.0 amp (inductive breaking) at 110V DC shall be provided for owner‟s
exclusive use. All spare contacts shall be wired upto the terminal blocks. If these
are not available, keep type relay shall be used to multiply contacts of the breakers.
The shunt trip of the circuit breaker shall be wired through an advanced „NO‟
contact, which shall make before the main contact close. Auxiliary contacts and
limit switches shall be in dust tight enclosures.
3. Draw Out Mechanism
There shall be 4 distinct and separate position on the draw out frame viz.
„Service‟, „Test‟, „Fully withdrawn‟ and „maintenance‟ positions for the
breakers. In the „Test‟ position the circuit breaker shall be capable of being
tested for operation without energizing the power circuits, i.e. the control
circuits shall remain undisturbed while the power contracts shall be
disconnected. Separate limit switches each having a minimum of 4 „NO‟
contacts shall be provided for both „Service‟ and „Test‟ positions of the circuit
breakers.
It shall be possible to padlock the draw out ACB in the connected, test
and disconnected position of the guide frame.
Main plug-in contacts of the guide frame shall not have joints to avoid the heat
generation & possibility of loose contacts inside the cubicles. Jaw contacts of
the plug-in main contacts shall be detachable from the guide frame to ease the
maintenance. If required, it shall be possible to provide rated current coding
between circuit breaker and guide frame.
Connection of the control circuit between the fixed portion of the cubicle and
the breaker carriage shall be by means of a plug and socket having adequate
number of pins. The plug and socket shall be so designed that it shall be
possible to insert the plug into the socket in one position only, thereby
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eliminating the possibility of faulty insertion and wiring connections. The plug,
after insertion, shall be secured in position by spring clamps, which need
considerable force to operate. The length of the plug cord shall be such that the
plug can be inserted into the socket only when the breaker is in the „Service‟
and „Test‟ positions but it shall be necessary to withdraw the plug from the
socket before the breaker truck can be pulled out into the “Fully Withdrawn”
position.
Isolating plugs and sockets for power as well as control circuits shall be of
robust design and fully self-aligning. Plugs and sockets for power circuits shall
be silver faced and shall be shrouded with PVC or any other insulating material
shrouds.
Each circuit breaker panel shall be provided with integral earthing switch for
cable earthing. An integral earthing system or separate earthing carriage shall
also be provided, which can be inserted to facilitate earthing of cables after
withdrawing the circuit breaker.
Circuit breaker cubicles shall be provided with safety shutters operated
automatically by the movement of the circuit breaker carriage, to shroud the
stationary isolated bus side contacts and the cable side main disconnecting
contacts of the circuit breakers, when the circuit breaker is withdrawn.
Padlocking facilities shall be provided for locking the shutters positively in the
closed position. It shall, however be possible to open the shutters intentionally
against spring pressure for testing purposes. Shutters shall be made of permalli/
hylam with minimum 10 mm thickness and shall be painted red in color.
The breaker feeder trolley shall remain inside the cubicle even in the drawout
position.
4. Indications:
Following shall be indicated electrically through cluster type LED color lamps.
BREAKER „CLOSE‟
- RED
BREAKER „OPEN‟
-GREEN
BREAKER „AUTO TRIP‟
-AMBER
READY TO CLOSE
- YELLOW
TRIP CIRCUIT HEALTHY
- WHITE
Mechanical indicator coupled to the operating mechanism shall be provided to
positively show the following It shall be located in a position where it will be
visible to the operator standing on the front of the switchgear with cubicle door
closed.
BREAKER STATUS : Open and Closed.
BREAKER POSITION : SERVICE , TEST & Isolated
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SPRING CHARGE CONDITION
READY TO CLOSE when all trip & off conditions are eliminated .
Breaker “Service” and “Test” positions shall be indicated by separate indicating
lamps on the cubicle door, in case mechanical indication of “service” and
“Test” positions are not available on the cubicle door.
Physical contact wear indicator shall be provided to indicate the erosion of the
contacts. Inspection of the contact shall be possible only with the circuit breaker
in ON condition.
Operation counter reading at least up to 999 figures.
5. Breaker Operating Mechanism :-
Circuit breaker shall be closed by a motor operated spring charged stored energy
mechanism and shall open through a shunt tripping device operated by a suitable
voltage from battery or rectifier. Spring operated mechanism, shall be complete
with motor, opening spring, closing spring with limit switch for automatic charging
and all necessary accessories to make the mechanism a complete operating unit.
The spring charging motor shall be universal type operable on both AC and DC.
Operating mechanism shall be shall be suitable for remote operation and designed
to give trouble free service over extended periods and shall be trip free.
The ACB shall have trip free mechanism which prevents the
mechanism from interfering with the tripping or opening action.
operating
The closing/ tripping circuits shall be self-opening on completion of their
respective functions irrespective of the position of the functions or the position of
the control switch.
As long as power is available to the spring charging motor, a continuous sequence
of closing and opening operations shall be possible. After failure of power supply
to the motor, at least one open-close-open operation of the circuit breaker shall be
possible.
Breaker duty shall be O-3min-CO-3min-CO except for switchgear line up having
motor feeders with stage wise, re-acceleration feature in which case the duty shall
be O-0.3sec.-CO-3min-CO.
Arrangement shall be provided for slow closing and slow opening of circuit breaker
for maintenance purpose.
Breaker operation shall be independent of the motor, which shall be used solely for
compressing the closing spring. Closing action of the circuit breaker shall compress
the opening spring ready for tripping.
Closing operation shall be completed once the closing impulse is given and the first
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device in the control scheme has responded even though the control switch/PB is
released provided no counter trip impulse is present.
When closing springs are discharged, after closing a breaker, closing springs shall
automatically be charged for the next operation without waiting for tripping of
circuit breaker. In case the limit switch fails to cut out the spring charging motor
when the springs are fully charged, the motor shall be automatically decoupled and
annunciation for this shall be provided.
Motor shall be such that it requires only about 30 sec. for fully charging the closing
spring. Motors shall be rated for 240V AC & 110 V DC and shall operate
satisfactorily at all values of voltage between 80% to 110% of rated voltage.
The circuit breaker shall have facility to charge the spring manually and close the
breaker in the event of failure of motor/ control supply to motor. The motor shall be
automatically, delinked (mechanically) once the manual charging handle is
inserted. Closing time of circuit breakers with manual operating mechanism shall
be independent of the speed of the operating handle.
Operating mechanism shall be non-pumping electrically and mechanically under
every method of closing (except on manual closing of breaker during maintenance).
Electrical antipumping feature shall be obtained by means of an auxiliary relay.
Use of contactor to achieve this feature is not acceptable. The anti pumping
features shall be maintained even when the bus voltage disappears during fault.
Operating Mechanism shall be such that failure of any auxiliary spring shall not
cause unintended operation of breaker or prevent intended tripping operation and
will not cause tripping or closing operation of the power operated closing devices.
When the circuit breaker is already closed, failure of any auxiliary spring shall not
cause damage to the circuit breaker or endanger the operator and closing of circuit
breakers shall be prevented unless the spring is fully charged.
A shunt trip shall operate correctly under all operating conditions of the circuit
breaker upto the rated breaking capacity of the circuit breaker and all values of
supply voltage between 50% and 110% of rated voltage.
All breakers shall be trip free and shall be provided with a release to trip the
breakers instantaneously if closed on to a fault.
Mechanical trip push buttons shall be provided for manual operation of the breaker
and shall be brought out to the front of the cubicle door.
Mechanically operated „closing‟ device shall be provided for all breakers except
circuit breakers controlling motor feeders. Access to mechanical closing device
shall be only after opening the cubicle door. The close/trip control switch shall be
interlocked to trip before close.
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The tripping time of C.B. shall not exceed 5 cycles (100 Msec.). The circuit breaker
closing time shall be approximately 5-7 cycles. The closing and tripping time of
the breaker shall be independent of the speed of the operating handle.
6. Breaker Operating Mechanism Control :-
Operating Mechanism shall normally be operated by remote electrical control or
through the relay when the breaker is in “Service” position.
Provisions shall be made for local electrical control or through the relay when the
breaker is in “Test” position by a control switch on the switchgear cubicle door.
Also, “Local/Remote” selector switch lockable in “Local” position shall be
provided on the cubicle door.
Castell key lock if asked for shall be provided on the ACB itself. Facility
shall be provided to remove the castell key only when ACB is in OFF condition &
it is ensured that contacts are separated such that suitable for isolation.
7. Breaker Safety Interlocks & Features :-
Mechanical /Electrical interlocks shall be provided to prevent mal-operation and in
particular to ensure:
a) The breaker can be operated only if it is in the defined “Full in” or “service” and
“test” position inside the panel. It shall be not be possible to operate the breaker
in intermediate positions while inserting or withdrawing circuit breaker. It shall
not be possible to operate breaker in service position unless its primary contacts
are fully engaged.
b) The breaker cannot be closed until closing spring is under fully charged
condition.
c) Withdrawal or engagement of a circuit breaker shall only be possible if it is in
the open position.
d) Any attempt to withdraw the breaker in the closed position shall trip the breaker.
e) Compartment door of a breaker shall not open unless the associated breaker is in
open position. However, it shall be possible to defeat this interlock for inspection
purposes.
f) “Plugging in” a breaker is possible only if earthing isolator is open.
g) Closing of earthing isolator is possible only when breaker is fully withdrawn.
h) Scraping earthing contact shall be provided for effective earthing of breaker
trolley.
i) Pulling out of auxiliary circuit plug is not possible when breaker is in service
position.
j) Pushing in breaker to service position is not possible with auxiliary circuit plug
not in position.
k) Test to isolated position of circuit breaker can be achieved only when the control
plug is removed.
l) Isolated to test position of circuit breaker can be achieved only after inserting
control plug.
m) Automatic safety shutters shall be provided to completely cover the female
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n)
o)
p)
q)
primary contacts, when breaker is withdrawn from service position.
To padlock safety shutters and guide rails in the absence of the circuit breaker.
To padlock Mechanical 'ON' push-button
Access to the accessory of the circuit breaker (like Motor, Shunt etc) shall be
prevented with the ACB in ON condition. However defeat interlock shall also be
provided.
Withdrawal portion of the circuit breaker shall be removable from the guide
frame only when it is ensured that breakers is in OFF condition & the contacts
are separated suitable for isolation.
In the operating positions of the breaker, the circuit breaker shall be securely locked. It
can be withdrawn or inserted only with appropriate operations of the interlocking
levers. This operating lever shall facilitate to overcome the contact pressure of the main
disconnecting contacts while pushing in or drawing out.
All ACB‟s shall be with Safety Shutter, Door Interlock, castle-key interlock, Door
Seali Sealing Frame.
8. Protection :
The ACB shall be equipped with an integral self powered microprocessor based
current release, which works on true R.M.S values for ensuring accurate
protection. This release shall provide Overload, Short Circuit and Earth fault protection
and shall be EMI/EMC compliant.
The release should be modular in construction in terms of up-gradation or retrofitting
of the vital components like LED scrolling display, rating plug & Ground fault, w/o
removing the release from the circuit breakers. Display when added shall be able to
visualize the parameters when observed while standing, even if the breaker is mounted
at the ground level. Display shall be rotatable at 180° to the axis & angled 15° to the
vertical axis.
For communication capable feature, without upgrading the entire release, it shall be
possible to add the communication module. The release shall necessarily support open
bus system like IEC. Communication capable release shall signal the temperature
inside the breakers & the temperature inside the panels.
Release shall be provided with the rating plug to enable the circuit breaker to use at the
lower currents without hanging the current transformer. Protection parameters under
such scenario shall be proportional to the current detected by the rating plug.
Release shall an option to provide the safety lock to prevent the resetting of the release.
Standard release shall have the provision for remote diagnostic, configuration or
protection parameters settings, maintenance management via ethernet or internet.
Integral Test facility to test healthiness of release and the ACB shall be
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provided on the over-current release. Test facility shall check the internal wiring &
tripping solenoid of the circuit breaker. It shall be possible to conduct the test condition
in ON condition with the option of trip.
Trip indicators shall be provided to display the exact nature of fault (i.e. O/L,
S/C, E/F) that caused tripping of circuit breakers by way of LED indication. The
memory of cause of fault retention shall be minimum 48 hours. The circuit breaker
shall necessarily be with mechanical re-closing lockout.
Release shall also have the LED indication when Release is active, communication is
active & Alarm.
It shall be possible to change the release setting on load.
9. Setting range of protection release :
1.
Overload protection Switchable from I²t to I4t characteristic for optimal adaptation to
upstream fuses.
Setting Range from IR = 0.4 to 1 In
Time Lag Class tr setttable : 2 – 30 seconds
Long time delay setting ( 6x IR) for I²t: tr = 2 - 30 s & I4t: tr = 1 - 5 s
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Short time delayed short circuit protection Isd shall be adjustable from 1.25 to 12 of the
overload setting in 8 different steps & adjustable time setting for fault discrimination
from 0.02 -0.1 - 0.2 -0.3- 0.4 sec. Short time delay shall be switchable ON /OFF &
switchable from standard to I2t characteristics curve for optimal selectivity adaptation
to downstream fuse.
Instantaneous short circuit protection Ii shall have adjustable current setting from
150 % to 1200% of In or can be set equal to the Icu. Instantaneous protection shall
have standard phase failure protections for motor protection with the delay time of 20
msec.
Earth fault protection Ig if specified will have adjustable current setting as
follows. Earth fault module shall be modular & should be retrofitable as required.
Size I and II: OFF, 100A to 1200 A.
Size III: OFF, 400A to 1200A and adjustable time setting from 100 - 500msec for
trip / alarm..
Neutral protection shall be provided as standard protection in both 3 & 4 pole versions.
Neutral setting shall be upto 100 % in 4 pole & 200% in 3pole ACB. Neutral protection
shall have the time lag class same as phase.
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II.
Moulded Case Circuit Breakers (MCCBs):
1. Construction:
MCCB shall conform to the latest IS specification IS – 13947 (2)
MCCB shall comprise of a switching mechanism, arc extinguishing device and a
trippi tripping unit in a compact moulded case and cover. The insulating case and
cover shall be made of high strength, heat resistant and flame retardant thermo setting
insulating materials.
MCCBs shall be provided with Non-Welding silver alloy main contacts and arcing
contacts with arc chutes.
Arc extinguishing device shall be made out of a series of design plates mounted in
parallel between insulating supports and shall be highly effective in positively drawing
out the arc, confining it, dividing it and finally extinguishing the arc in less than 20
msecs.
MCCB shall be 3 pole / 4 pole as indicated in drgs. In case of 4 pole MCCB, the 4th
pole shall be 100% rated.
MCCBs shall be provided with spring assisted, double break, quick make/break
manually operated, trip free mechanism. The position of the handle shall clearly
indicate “tripped, “ON” & “OFF” positions.
It shall be possible to fit accessories on the MCCB such as aux contact, trip indication
contact, rotary handle, under voltage coil or shunt trip coil, etc.
MCCB shall be manually operated with Rotary Handle which shall have built-in door
interlock, defeat & padlocking facility. The rotary handle shall be same as that for SDF
or MPCB for better aesthetics. „ON‟ and „OFF‟ position of the operating handle of
MCCB shall be displayed and the operating handle shall be mounted on the door of the
compartment housing MCCB.
All MCCB shall be suitable for remote tripping operation and the tripping device shall
be suitable for the specified control supply voltage.
If specified in the data sheet, the MCCBs shall be provided with solenoid/ Motorised
closing mechanism to make them suitable for remote closing operation. The closing
solenoid/ motor shall be suitable for specified control supply voltage.
MCCB shall be provided with minimum 2 NO+ 2NC auxiliary contacts.
2. Electrical
The MCCB shall be suitable for operating voltage of 415 V AC and insulation voltage
of 690 V ac system voltage.
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The MCCB shall be suitable for impulse withstand of 8 kV.
The MCCB shall have short circuit breaking capacity Icu of 35 kA rms unless
otherwise specified. The MCCB breaking capacity shall have Icu = 100% of Ics for the
entire range.
The MCCB shall have no derating upto 50 C service temperature. In case the MCCB
needs derating, manufacturer shall declare the derated current carrying capacity at 50 C
service temperature.
The MCCB shall be current limiting type and shall have line-load inter changeability
without any loss of capacity.
The MCCBs above 100 A, shall have adjustable and properly calibrated overload and
short circuit settings.
3.Trip Unit:
The MCCBs upto 800A shall be provided with Thermo-magnetic tripping device.
Incomer MCCBs shall be provided with microprocessor based release.
MCCB shall provide inverse time current characteristics for overload protection, and
should trip if any one phase is overloaded. And shall be provided with a device for
instantaneous protection against short circuit.
In case of Micro-processor based Release, the protections shall be as follows:
L –Adj. Overload with inverse time characteristic = 0.4 to 1.0 In (rated current)
S – Time Delayed Short Circuit ( Id = 1.5 to 10 Ir; td = 0 to 0.5sec)
Ii
- Inst S/C Current with instantaneous characteristics = 11In & 4) G - Ground fault
protection.
In case of Thermal Magnetic protection, following is required.
L – Adj. Overload - 0.8 to 1.0 In
Ii – Adj S/C protection – 5 to 10 In
It shall be possible to change the trip unit from thermo-magnetic to microprocessor
based and vice-versa.
III.
Miniature circuit breakers :
MCB shall be heat resistant, molded type, conforming to IS8828/ IEC 60898 and rated
for 240/415 V.
MCB shall have a minimum breaking capacity of 10KA RMS symmetrical and shall be
limiting class 3.
MCB shall offer inverse-time over loads and instantaneous characteristics against short
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circuit currents. The tripping characteristics shall either be C/D class. The tripping
mechanism shall be trip free.
MCB‟s shall be single, double, triple, four poles.
It shall be possible to fit accessories such as aux contact, trip indication contact, shunt trip coil,
etc.
They Shall meet a degree of protection of minimum IP 20 and shall be clip on type din
rail mountable.
MCB shall have pad lock support, Biconnect upper & lower terminals, safety shutter on
cable terminals. The incoming and outgoing of the MCBs shall be accessible only after
opening.
The ON and OFF positions shall be clearly marked. The MCBs shall be suitable for
operating in ambient of 50 C without de-rating.
MCB‟s shall be Quick make, quick break and with non welding silver alloy contacts
suitable for manual and automatic operation.
MCB‟s shall have Common operating handle and integral tripping for multiple MCB‟s.
The 4 pole, 3 pole and 2 pole MCB knobs shall be trucked with adequately
strengthened tandem pin.
MCB‟s shall have Pressure clamp terminals for cables upto 4 mm sq. and bolted lugs
for higher rating.
It shall have a trip free mechanism ensuring that contact cannot be held closed against
fault. Also, there shall be simultaneous isolation on all poles even if a fault is only a
single pole.
IV.
Earth Leakage Circuit Breakers: Not Applicable
V.
Switch-Disconnector Fuse :
All SDF‟s or switches shall be heavy duty/ motor duty, air break type suitable for
load break duty with quick make/ brake manual operating mechanism conforming to
IS – 13947 (3) and rated for 660 V AC system.
The SDF shall be 3 pole with bolted type removable copper links of adequate size
for neutral. In case required, facility shall be available to have switched neutral.
The switch-disconnector fuse units shall operate on “QUAD break” mechanism and
roller contact system for longer life.
Continuous current rating of SDF‟s shall be atleast 15% higher than the full load
current of motor/ feeder at the minimum operating voltage.
Rating of duty switches for a particular starter module shall be as indicated in the
switchboard data sheet.
SDF‟s of motor starters shall have AC 23 rating corresponding to full load current
of the Motor. Motor duty switches of smaller ratings meeting the requirements of AC
23 duty as per IS:13947, may be accepted in place of specified heavy duty switch
rating for particular starter module only if, motor duty switches have been tested and
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certified for use with the large size of fuse link specified in the switchboard data sheet
for the same starter module. Also the AC 23 rating of the switches used shall not be
less than the rating of the HRC fuses in the feeder.
The switch fuse feeders shall be provided with SDF‟s of AC 22 utilization
category.
The operating handle shall be mounted on the front door of the compartment having
the switch, with the position of the switch clearly indicated on the cubicle door. A user
friendly handle coupling arrangement (conforming to IS 8623 – 1993) shall be
provided with a self restorable door inter lock and padlocking facility for both ON &
OFF positions.
The cubicle door shall be interlocked with the switch mechanism so that the door
cannot be opened unless the switch is in the OFF position. It shall, however, be
possible to release this interlock if so desired for testing purposes.
It shall be possible to fit accessories on the SDF such as aux contact, castle-key
interlock, etc.
In the event of an independent control circuit supply to the coils of the contactors,
the main switch shall be provided with necessary auxiliary contacts to disconnect this
control supply as well, when the switch is turned to OFF position for isolating the main
supply.
All live parts of the switch shall be shrouded with suitable insulating barriers so as
to prevent accidental contact with the live parts after opening the cubicle front door.
Wherever solid links are used for connections between switches and fuses, such links
shall be fitted with insulating sleeves.
VI.
Fuses:
Fuses shall be HRC cartridge link type with non -deteriorating characteristics and shall
be rectangular in construction as per DIN standard. Screw type “DZ” or Diazed fuses
and Rewirable fuses are not acceptable.
The HRC fuse shall be of operating class gG with current limiting characteristics.
HRC fuse shall be suitable for insulation voltage of 690V ac system voltage and
conform to IS – 13703.
The HRC fuse shall have breaking capacity of 120 kA.
The HRC fuse shall have trip indication flag / pop.
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Power Fuses shall be pressure fitted type and shall preferably have ribs on the contact
blades to ensure good line contact.
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 removing any equipment or disconnecting any wiring.
VII. Contactors :
The contactors shall be air break type, equipped with three main contacts and
minimum 2 NO +2NC auxiliary changeover contacts. Where the requirement of
auxiliary contacts exceeds the limit of manufacturer‟s standard range, suitable
auxiliary contactor with necessary number of contacts shall be provided alongwith
the main contactor.
Auxiliary contact rating shall be 6A for 240 V.A.C. and 1.5A for 110 V.D.C.
The main contacts shall have AC3 ratings .
Unless specified otherwise, the coil of the contactor shall be suitable for operation
on 240V,1 PH, AC supply and shall work satisfactorily between 65 to 110% of
rated value.
Auxiliary contactors shall generally be used for interlocking and multiplying
contacts.
VIII. Thermal Overload Relay :
Bimetal relays shall be provided for protecting the motor from thermal overload.
Bimetal relays shall be positive acting, ambient temperature compensated type with
adjustable setting range.
Bimetal relays shall have built-in-single phasing prevention feature, which operate
even with 50% rated current at the time of single phasing.
Heavy duty starters shall be provided with different tripping class Overload relays,
which shall be suitable for motor starting time of 15-60 seconds. Saturable type
current transformer operated overload relays are not acceptable.
Bimetal overload relays shall be separately mounted type with connecting links
rated for the maximum rating of the contactor in a starter module.
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.
Bimetal overload relays of various current ranges required for motors likely to be
connected to a contactor must be identical in dimension for interchangeability. 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.
Overload relay shall be provided with potential free 2 NO + 2 NC changeover
auxiliary contacts.
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Stop push button of the starter and hand reset device shall be separate from each
other.
IX.
Current Transformers :
Current transformers shall generally confirm to IS:2075 and rated for operation on
415V 50 Hz system.
CT‟s shall be made of class F wound type with the secondary terminals housed in a
terminal box and marked indelibly. Also polarity shall be marked.
CT‟s shall be mounted on the switchgear stationary part / Bus-Bar either in incoming
side or outgoing side of circuit breaker as specified.
The CT ratio and ratings shall be as indicated in the switchboard data sheet. However,
vendor shall ensure that VA output and ALF of the CTs are adequate for the relays and
meters connected on its secondary terminals. Current transformers shall have sufficient
capacity to operate with the burden imposed by the devices shown on drawings within
their accuracy classification.
For general guidance, the protective current transformers shall have an accuracy class
“5P”, and an accuracy limit factor of 20. Low reactance C.Ts shall be used for
protection. Current transformers for instruments shall have an accuracy class 1.0 or 0.5
as per requirement and instrument security factor less than 5.0. However, accuracy
class of 3.0 is acceptable for CT‟s meant for remote ammeters. If a metering load is fed
from a protection C.T, suitable 1/1 or 5/5 ratio saturably interposing C.Ts shall be used.
However, CT‟s for restricted earth fault and differential protection shall be of class
“PS”. And CT‟s shall have a minimum ratings of 10VA.
Separate cores shall be used for metering through analogue meters / load managers.
When metering is done through relays, protection core shall have additionally the
metering class accuracy built into.
CT‟s shall be capable of withstanding dynamic and thermal stresses originated by short
circuit fault current for three second. If specified separate CT‟s are provided for
metering for electricity boards, then provision shall be made for sealing this CT.
Unless otherwise required for proper relaying, one side of current transformer
secondary shall be grounded in the compartment with the meters or relays which they
serve and each current transformer group shall be grounded with a separate identified
lead which may be disconnected for testing. The neutral side of CT shall normally be
earthed through a link.
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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
1.
2.
3.
X.
Potential Tranformers:
The PT‟s wherever specified shall be epoxy class F cast resin type with the secondary
terminals housed in a terminal box and marked indelibly. The burden and ratio and
class of accuracy shall be as given in the specific requirements. However, voltage
transformers shall have sufficient capacity to operate with the burden imposed by the
devices shown on the drawing with their accuracy classification.
The voltage transformers shall have an accuracy class 1.0 or 0.5 from 10% to 120% of
normal voltage.
The primary rated voltage shall be equal to the rated voltage Vn of the system or if the
voltage transformers is connected between phase and neutral then shall be rated to
VN/ 3. If not otherwise specified, secondary voltage shall be 110 V or 110/ 3V.
For directional relays either a 3-phase 5 limb V.T or three single phase V.Ts with
tertiary windings shall be provided.
All PT‟s shall be drawout type and it shall be possible to remove voltage transformer
from the circuit breaker whenever required. For Incomer feeders PT may be of fixed
type since the same are connected on the incoming cable side.
The draw out mechanism shall disconnect the busbars and the V.T, and primary and
secondary terminals shall be earthed. The primary connection shall be disconnected
before V.T or its primary fuses become accessible. Automatic shutter shall be provided
to shroud the busbar when PT is withdrawn. Connections between the busbars and PT
shall be completely shrouded.
HRC fuse protection shall be provided on primary side. Miniature circuit breakers with
auxiliary contacts will be preferred on the secondary side.
Plug in type test terminal blocks should be provided for each PT circuit.
Unless otherwise specified for proper relaying one side of potential transformer
secondary shall be grounded at the transformer and the ground connection shall be
identified and removable for testing.
XI.
Indicating And Metering Instruments:
Instruments shall be provided as specified in Data Sheet/SLD. All auxiliary equipment
such as shunts, transducers C.Ts, V.Ts that are required shall be included in the supply
of switchboard.
All indicating instruments and meters shall be capable of carrying continuously their
full load currents and full voltage across their pressure coils. They shall not be
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damaged by the passes of fault currents or the existence of over pressure on the primary
side of their instrument transformers, for the maximum permitted duration of fault
conditions which may occur during normal operation.
4.
5.
6.
7.
8.
9.
1.
Make of all indicating instruments shall be as specified and shall be square pattern
moving iron of 96/144mm size having 90 Deg scale suitable for flush mounting.
All instruments and meters shall be back connected.
Meters shall be provided with zero adjusting device for external operation.
1. Ammeters, Voltmeters, Power Meters :
2.
3.
4.
5.
6.
7.
8.
9.
10.
These shall be of moving iron type with accuracy class of 1.0 as per IS:1248.
The range shall be as indicated in Data Sheet/SLD. Ammeter for motors shall have
nonlinear suppressed scale to read starting current. The motor full load current reading
shall be at one-third scale. For other feeders full load current reading shall be at centre
of scale.
Voltmeter shall be suitable for direct line connection.
K.W, KWH, KVARH meter shall be suitable to measure unbalanced loads on a 3phase 4-wire system with minimum accuracy class of 2.5
Power meters shall be of registering type and shall be flush mounted type. They shall
be provided with test terminal blocks.
2. Load Managers :
1.
2.
3.
4.
5.
It shall be suitable for operation on 50 Hz, 3-phase 4-wire system with Accuracy Class1.0 or 0.5. , PT- ** kV/ 3 //110/ 3, CTR- as per requirement.
It should be flush mounted, preferably in a drawout case.
Features : kW, kVA, kVAR, kWH, kVAH, kVARH (lag), kVARH (lead), MD kW,
MD kVA, PF, Freq., V rms, I rms and with RS-232/ 485 port (import export).
3. Frequency Meters :
These shall be digital type square pattern 144 mm x 144 mm size suitable for flush
mounting and shall operated off a V.T secondary voltage of 110 volts. The standard
range shall be 45-50-55 Hz.
4. Power Factor Meters :
The power factor meter shall also be square pattern 144 mm x 144 mm size suitable for
flush mounting. The meter shall operate off 110 volts secondary voltage. The C.T
secondary current shall be as shown on the relevant drawing. The standard range shall
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be 0.5-1.0-0.5.
XII. Relays :
A marking strip shall be provided in front of each terminal block and a diagram
plate at the back of each case to identify connection.
All relays shall be mounted in front of the panel in instrument chamber. The current
and voltage coils shall be rated as specified on the relevant approved schematic
drawings.
Relay covers shall be of non-ignitable materials and anti fungus treatment shall be
provided for all relays.
Relay contacts shall withstand repeated operation and shall make or break the
maximum currents in their circuits without deterioration. All spare contacts shall
also be wired up to the external terminals.
Relay coils (in case of electromechanical relays)/ circuits (in case of numerical
relays) shall carry their normal currents indefinitely and such currents as can occur
under fault conditions. Relay mechanisms shall not be affected by vibration or
magnetic fields, which may occur in normal operation.
Relays on which the function of a contact may be changed from „NO‟ to „NC‟ and
vise-versa by simply changing the contact arrangement / by software selection are
preferred.
Relay contacts shall be self / hand reset type as indicated in attachment-II.
All relays shall have built in flags/ indications to indicate relay operation. It shall be
possible to reset the flags without opening the relays case.
1.
Auxiliary relays/contactors :
Auxiliary relays/contactors shall generally be used for interlocking and multiplying
contacts. Auxiliary contacts shall be capable of carrying the maximum current. In any
case their rating must not be less than 5A for 240 V a.c at a power factor between 0.3
and 1, and 2 A for 110 V.d.c (inductive load). All auxiliary relays shall be supplied in
non-drawout cases.
2. Tripping Relays :
All tripping relays shall be lockout type with hand reset contacts and shall be suitable
to operate on the specified d.c voltage. These relays shall have self-coil cut-off contacts
and shall be provided with hand reset operation indicators. Indicators shall be capable
of being reset without opening the relay case. Tripping relays will be acceptable in
non-drawout cases. The number of contacts shall be as shown on the approved
schematic drawings.
Master tripping relay ( lock-out relays ) shall be of the hand reset type and shall have at
least 2 „NO‟ + 2 „NC‟ spare contacts, in addition to those required by the protection
and tripping scheme.
3.
Protective Relays :
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All protective relays as mentioned in the data sheet shall be numerical type,
communicable on IEC open protocol, back connected, drawout/ non-drawout type,
suitable for flush mounting and fitted with dust tight covers. Trip circuits shall be
automatically broken and current transformer secondary circuits shorted, when a
drawout type relay is withdrawn from its case.
All protective relays shall be with built in test facility. The protective relay cases shall
have provision for insertion of test plug at the front for “testing and calibration”
purposes. It shall be possible to test the relays without disconnecting the wiring and
without withdrawing the relays. The insertion of the test plug shall automatically short
circuit the CTS and permit extension of external power supply to the relay.
The plug-in type of relays will not be acceptable.
Each protective relays shall be provided with minimum 2 nos. potential free contacts of
required configuration.
Each tripping relay shall be lockout type with hand reset/ self rest coil cut-of contact.
The tripping relay shall be suitable for satisfactory operation from 50% to 110% of the
specified control supply voltage.
XIII. Auxiliary equipments:
1. Indicating Lamps :
Indicating lamps shall be provided on each panel as specified below;
Breaker ON
Breaker OFF
Breaker Auto Trip
Trip Ckt Healthy
-
Red Lamp
Green Lamp
Amber Lamp
White Lamp
DC Fail
-
Blue Lamp
The indicating lamps shall be Cluster LED type having low wattage, long life and shall be
suitable for the voltage indicated on the specific requirements. The lamps shall be
easily replaceable from front. Lamps shall be supplied complete with the necessary
current limiting resistor duly tested for its rating. Lamps shall be provided with
translucent and heat resistant lamp covers to diffuse light.
2. Push Buttons :
Push buttons shall be rated for continuous current rating of 10A at 240V a.c., 0.25
pf or 2A at 110 V d.c (inductive load).
Push buttons elements shall be spring return type. Stop push button shall be of
stayput type.
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All push buttons shall have 2 NO + 2 NC momentary contacts.
Push buttons colours shall be as follows :
Stop/Open/Emergency - Red
Start/Close
- Green
Trip circuit “Healthy” - Black
Reset/Test
- Yellow/ White
Red push buttons shall be on the left side and green push buttons on the right side.
3. Control and Selector Switches :
All control switches shall be rotary, back connected type having a cam-operated
contact mechanism with phosphor bronze contacts.
Unless otherwise stated, all Circuit Breaker Control Switch shall be Trip – NeutralClose Switch with spring return to neutral from both ON and OFF positions and
lockable in neutral position. The switch shall be provided with pistol grip type handle.
They shall be arranged to close the breaker by being turned clockwise. The trip, neutral
and close positions shall be clearly indicated. The movement shall be such that the
switch cannot be operated inadvertently and that it is mechanically interlocked to trip
before close. The operating switch shall be located on the centerline at about 1.5
meters from the floor level. Number of ways, locking system, lost motion device etc., if
required shall be shown on the relevant schematic drawings. Two spare ways shall be
provided on these switches.
All selector switches shall be provided with knob type handle.
Ammeter selector switches shall have make before break feature on its contacts.
The selector switch shall generally have 4 positions for reading 3 phase currents and
fourth position for OFF.
Voltmeter selector switch shall have 4 positions. Three shall be used to measure
phase to phase voltage and fourth shall be OFF position.
Remote/ Trip/ off selector switch for the motor feeders shall be lockable in OFF
position.
imer :
4. Timer:
For re-acceleration duty, timers unless otherwise stated, shall be electronic type and
shall have stepless continuously adjustable time setting of 0-60 secs. The time settings,
where specified, shall be accurately set before dispatch of the switchboard.
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Timers for auto-transfer schemes shall be of static type with timing ranges suitable
for the scheme employed.
The contacts shall be rated for 6A for 240 V.A.C.
D. Construction:
I. General:The switchboards shall be totally metal enclosed, compartmentalized, modular
type, fully draw out, free standing, floor mounting, suitable for indoor installation.
However, the incomer and bus tie feeders with load break switches, control supply
transformer modules, DB‟s, ASB‟s wherever specified in attachment-II may be in fixed
execution.
The switchboard shall be assembled out of standard prefabricated sheet steel units/
standard vertical sections of uniform height, joined together to form a rigid, free
standing, completely enclosed composite board of continuous line up to uniform
height, depth & especially front line-up. Each vertical section shall comprise the
following compartments.
 A metal enclosed horizontal main bus bar compartment running horizontally at
top.
 A metal enclosed busbar compartment running vertically (at rear or in center
of the section) along the height of the section and housing the vertical bus
bars serving all feeder modules in this section.
 A metal enclosed horizontal auxiliary bus bar compartment running
horizontally at top for control, interlock, and indication and metering wiring.
 Individual with-drawable feeder modules in multitier mode.

Cable termination compartment.
The switchboards shall conform to constructional requirements as per IS 13947.
Each unit of the switchgear shall have necessary internal sheet metal barrier to form
separate compartments for bus bars, instruments & relays, feeders and cable
connection etc. Each compartment shall be constructed and designed, to confine the
damage caused by an internal fault to that compartment. To achieve this
compartment segregation and /or suitable arc propagation barrier shall be provided.
Independent pressure release valves shall preferably be provided if required for
different compartments.
The switchboard shall be dust & vermin proof with enclosure protection not less
that IP52 as per IS- 2147 except for bus bar compartment. An equivalent degree of
protection as per any relevant international standard shall also be accepted. If
necessary, openings for natural ventilation shall be provided. These shall be
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louvered with GI wire mesh. Wire mesh for bus bar compartment shall be such as
to protect against objects of 1 mm and above.
Metal sheets shall be provided between two adjacent vertical panels running upto
full useful height of the switchboard.
The switchboard shall be fabricated using suitable mild steel structural sections or
using pressed and shaped cold rolled sheet steel of adequate thickness. The sheet
steel used for panel shall be of minimum 2mm for load bearing members, 1.6mm
for non- load bearing members. The thickness of base channel shall be minimum
3mm. Wherever required, stiffeners shall be provided to increase stiffness of large
size doors and covers.
Maximum height of the Board, including the height of the base channel, shall not
be more that 2450mm
The switchboard shall be provided with integral base frame for each vertical panel.
The switchboard integral base frame shall be suitable for directly bolting with the
help of foundation bolts and shall also be suitable for tack welding to the HPCL‟s
floor embedded channels.
Suitable removable type lifting hooks and/ or jacking pads shall be provided on
each panel or shipping section for ease of lifting of switchboard. On removing the
eye-bolts no holes offering access to panel shall be permitted.
All hardware shall be corrosion resistant. All joints, and connections of the panel
members shall be made by zinc passivated high quality steel bolts, nuts and
washers, secured against loosening. Star washers shall be used to ensure effective
continuity.
It shall be possible to extend the switchgear in either direction for future
expansions. Ends of bus bars shall be suitably drilled for this purpose. Panels at
extreme ends shall have openings, which shall be covered with plates screwed to
the panel. Details of drilled holes in bus bar and openings in panels provided for
future extension shall be clearly shown in drawings.
The switchboard shall have adequate strength to withstand all stress likely to be
encountered in the event of an electrical fault, shipping, handling, installation, and
operation, without distortion or damage.
The switchboard shall be constructed in shipping sections of one vertical panel. The
switchboard shall be as completely assembled as possible within shipping and handling
limitations, wired and ready for installation in accordance with this specifications.
All metering and protection equipment associated with a particular circuit shall be
housed in separate and independent compartment earmarked for that particular circuit
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and in the fixed portion of the vertical panel in case of breaker panels. Access to all
operating devices shall be from the front of the switchboard.
All auxiliary devices for control, indication, measurement and protection such as
push buttons, control and selector switches, indicating lamps, Ammeters, Voltmeters,
KWH meters and protective relays shall be mounted on the front side of the respective
compartments only. However, mounting of some of these devices on the trolley may
be accepted provided necessary blanking plates are provided to cover the opening left
in the panel door when trolley is withdrawn out of panel. The design shall be such that
unless required for maintenance/ inspection purposes, all power on/off or start/stop and
relay reset operations shall be performed without opening the panel door.
All barriers shall be of fire retardant, non-inflammable & non hygroscopic
materials such as FRBP/FR-2 only. Hylam is not acceptable.
All openings, covers and doors shall be provided with double lip neoprene Gaskets.
All doors shall be of lift – off type with pad locking facility. Doors should not be an
integral part of the drawout module.
Panels shall be suitable for bottom entry of cables unless otherwise specified.
All modules shall have cable termination facility in cable alley without duplicated
terminals and it should be possible to terminate / disconnect cables without removing
the modules.
II. PCC/PMCC/MCC/MOVDB/MLDB/CPDB PANELS :
PCC/ MCC shall be of single/double front execution.
The design of feeder trolleys shall not change for single front or double front
execution. Separate vertical bus bars shall be provided for each front. Identical feeder
modules in both the fronts shall be interchangeable.
The outgoing feeder trolleys shall be fully drawout and shall be with-drawable
without having to unbolt or unscrew any power and control connection to the
equipment mounted on the drawout trolley. Both power and control connection shall be
drawout type.
The trolley shall be withdraw-able by means of crank and screw arrangement or
any alternate mechanism like guided rollers etc. Plug in operation shall be independent
of manual force. For drawout type feeders of size equal to or greater than half the
useful height of panel, positive clamping arrangement shall be provided on the top
portion of the trolley in additional to clamping arrangement at the bottom, to ensure all
round positive pressure on the power drawout contacts once the trolley is plugged in.
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Power drawout contacts shall preferably be located towards the bottom portion of
each trolley. The trolley shall be lockable in fully plugged in position and devices shall
be provided to ensure positive plugging in. In test position, power contacts shall be
totally isolated and a device shall be provided for indication of test postion.
Various compartment sizes in a vertical MCC panel shall be multiples of a basic
dimension. However, the minimum module size shall be 200mm for switch fuse feeder
and 240mm for contactor feeders. Vertical bus bars shall be pre-drilled at regular
intervals (wherever necessary as per design requirement) for complete flexibility for
changes in sizes of modules.
The maximum height of the operating handle/ switches shall not exceed 1900mm
and the minimum height not below 300 mm.
Unused modules in the panel shall be fully equipped with hinged door, power and
control terminals for starter modules and cradle for future use.
All switch drives other than rotary switches, shall be lockable in both „ON‟ and
„OFF‟ positions. The switches/ moulded case circuit breakers shall be interlocked with
the compartment door to prevent opening of the door when the switch/moulded case
circuit breaker is in „ON‟ position and to prevent switching on when the door is open.
A defeat mechanism for this interlock shall also be provided.
Each MCC panel shall have a separate cable alley. The width of this cable alley
shall be sufficient to accommodate all the cables and shall have free access for cable
terminations and in any case shall not be less than 200mm. Cable alleys shall be
provided with suitable doors. Sheet steel barriers shall be provided between individual
compartments and cable alley. This barrier shall be provided to safely carryout
maintenance work on cable connections to any one circuit in the cable alley with the
busbars and the adjacent circuits live.
III. CIRCUIT BREAKERS PANELS :
Circuit breaker panels shall be single front execution only with distinct bus bar,
breaker and cable compartments. The design of each compartment shall be such as
to prevent movement of vermin from a particular circuit breaker compartment to
any other portion of the panel when the breaker is withdrawn and compartment
door is closed.
In order to minimize accidental access and avoid accidents due to falling tools, all
the outgoing links shall be shrouded. Blanking plates shall be provided for circuit
breaker compartments, which would be used after installation to cover the opening
in the event of withdrawing the breaker outside the compartment.
Outgoing ACB‟s can be mounted in a maximum of two tier execution while the
incoming/ bus coupler ACB‟s shall be single tier execution only. The metering and
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protection equipments associated with a particular breaker shall preferably be
mounted on the same panel front. Access to all operating devices shall be from the
front of the switchboard.
1. Circuit Breaker Compartment
The circuit breaker compartment shall be fully drawout, that is, bus side and
outgoing power and control connections shall be made through drawout contacts.
Suitable guides shall be provided to facilitate easy withdrawal of the circuit breaker.
All incidental feeder compartments shall be interchangeable.
There shall be three positions for the drawout trolley viz :

“Full in” or “Service” position –In this position both power and control circuits shall
be connected. This shall be the normal operating position of the circuit breaker.

“Test” position- The power contacts shall be disconnected in this position but the
control connections shall not be disturbed, it shall be possible to close and trip the
breakers in this position.

“Full out” Position- both power and control circuits shall be disconnected in this
position and breaker removed from the cubicle.
The circuit breaker shall be lockable in “service” and “test” positions. Safety
shutters shall be provided when the breakers is in withdrawn/drawout position.
The earth connection must remain connected in “Test” position. Earthing of the
unit shall be done with a “pin” or with scrapping earth connections. The earth
connection shall make before the main power/ control contacts make and break
after the power/ control contacts are disconnected. Earthing connection through
a plug and socket connection shall not be acceptable.
Any unused circuit breaker compartment shall be fully equipped and provided
with compartment door, vertical busbars and control terminals/wiring etc. such
that the same could be used for housing outgoing breakers in future without any
modifications to the panel.
The current transformers shall be mounted on the fixed portion of the
compartment. However, current transformers associated with built-in-releases
may be mounted on the breaker trolley.
All terminals except wiping/ sliding type control terminals shall be shrouded
with plastic covers to prevent accidental contact. For direct termination- Clip
on shrouded type terminals shall be provided.
Breaker shall not be mounted directly under the busbars. Preferably a barrier of
suitable material shall be provided between the arcing device and the busbars.
Special care shall be taken to cool the ionised air.
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2. Separate Cubicle Compartment
Separate compartment totally enclosed from all sides shall be provided for cable
termination, on the rear side. Access to cables shall be from the rear side after opening
the cabling compartment door. The incoming/ outgoing cable termination shall be
staggered for each circuit and barriers of sheet steel or insulating material shall be
provided between termination of two circuits such that maintenance on one circuit
could be carried out while the other circuit is live. Suitable clamping arrangement shall
be provided for cables and cable termination. Termination blocks shall not be used for
supporting the cables.
Provision shall be made for terminating each outgoing cable with a separate bolted
connection. Number of cables per termination shall be minimum two numbers unless
otherwise specified. In case the total number of cables entering a particular panel can
not be accommodated in the cabling compartment an extension panel shall be added to
the cabling compartment for accommodating extra cables. The enclosure design of
cabling compartment shall be such as to prevent the movement of vermin from this
compartment to any other part of the switchboard.
The incoming and outgoing cables shall have bottom entry unless otherwise
specified.
IV.
Auxiliary service Boards: (N.A.)
V. Accessibility/ Safety/Interchangeability :
Checking and removal of components shall be possible without disturbing adjacent
equipment.
All equipments shall be easily accessible and it shall be possible to set all
measuring relays independently without de-energising the switchboard.
In the TEST position it shall be possible to replace the fuses, contactor coils,
inspect switch, contactor operation etc. It should be possible to selectively program the
control terminals for SERVICE or TEST application and bypass / include field inter
locks suitably. It should be possible to program at least 30% of control terminals.
Adequate barriers shall permit personnel to work safely within an empty
compartment with the bus bars energised. Compartment for cable connection shall
allow cable pulling; termination and connection work with the subject cubicle only
being de-energized.
Unused CT secondary terminals must be short-circuited.
All terminals shall be shrouded with plastic covers to prevent accidental contact.
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Front/ rear access shall be available to all components in each cubicle, which
requires adjustment, maintenance or replacement, except in case of double front panels.
Rear access shall be available to all cable boxes of circuit breaker vertical section.
Rear side of these cable chambers shall be provided with additional removable
expanded wire guards/mesh with voltage danger notice board, to allow visual
inspection of busbars/CT and cable terminations and avoid accidental touch when rear
cover is removed.
Terminal strips for outgoing control cables connection should be accessible to
facilitate working and testing with breaker in test/service condition and while the
switchboard is energised.
Both the vertical and horizontal bus bars shall be provided with anti-tracking
barriers as an integral part of bus bar zone.
In the cabling chamber shrouds shall be provided on the side of vertical bus bars.
The switchboard shall be designed to ensure maximum safety during operation,
inspection, connection of cables, relocation of outgoing circuits and maintenance, with
the busbar system energized and without taking any special precautions. Means shall
be provided to prevent shorting of power and/or control terminals due to accidental
dropping of maintenance tools etc. inside switchboard.
Blanking plates shall be provided for all sizes of modules to cover the openings in
the event of withdrawing the feeder modules.
All identical equipment and corresponding parts shall be fully interchangeable
without any need for resorting to structural modification.
As a safety feature spring loaded safety shutters shall be provided for shrouding the
main incomer contact after the feeder / ACB module is with-drawn to ISOLATED
position in switchboards.
VI. DRAWOUT CONTACTS
All power contacts(both on busbar side and cable side) shall be fully drawout, self
aligning, plug-in design which get automatically disconnected when the drawout
module is withdrawn from the service position. Removable type male and female
contacts shall be provided.
The main power contacts shall be spring loaded type for maintaining constant
pressure.
The drawout contacts shall be only between copper / copper alloy / aluminium
faces all of which are silver plated.
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Control circuit contact shall have a minimum 15A AC / DC continuous rating
rated.
Power Circuit contact rating shall be as per the continuous current in attachment-II
and shall be the in-panel rating.
VII.
Busbars:
The main and vertical busbars (droppers) shall be a TPN system suitable for 415V,
3 phase, 4W, 50Hz system. The main and vertical busbars shall be housed in separate
fully enclosed chambers to prevent direct contact with the buses energised when
switchboard is under operation. All phase and neutral bars shall be housed in a
common chamber.
The main bus bars feeding the switchboard shall comprise of 3 phase & neutral
bus-bars extending horizontally at the top through all units of the switchgear line up.
Interconnection between the main bus bars and individual units shall be made by using
vertical bus bars of adequate rating. These interconnections and the vertical bus bars
shall be compartmentalized, and fully shrouded using sheet metal.
The supply of neutral shall be through a neutral busbar and stab-in contact in all
units wherever required. External looping through a separate contact is not permitted.
Auxiliary Bus Bars: Auxiliary bus bars each of minimum size 28 sq.mm copper
shall be provided for following applications. Exact number of bus bars shall depend on
various control, metering and auxiliary power distribution requirements specified in
material requisition.

240 A.C. control supply for space heater for Panel and motor.

Control supply for breaker tripping, closing and indication circuits.

Control supply for breaker spring charging motors, motor starter control and indication
circuit.

AC potential supply for KWH meters.
For distribution of power from bus to individual feeder modules, the vertical bus
bars shall branch off from the main bus. Two entirely different sets of vertical busbars
for front and back portion shall be provided for double front panel.
Tee-off connectors shall be used for distributing auxiliary supply to each vertical
panel.
Main horizontal busbars and auxiliary buses shall be of uniform cross-section
throughout the length. Similarly, vertical busbars shall be of uniform cross-section
throughout the height of the switchboard. Tapered busbar arrangements are not
acceptable.
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The in-panel current carrying capacity of main phase bus bars shall be 20 %
more than incomer breaker rating.
The in-panel current rating of the neutral busbars shall be half/full that of the
respective phase busbar.
The in-panel current carrying capacity of the vertical phase bus bars shall be 20
% more than the connected load to be catered in each vertical panel. However, size of
vertical busbars shall not be less than 50x 10mm Aluminium per phase.
Minimum size of bus bars for starter/ feeder power connections above 100 Amp
rating shall be 20 x 6 mm Aluminium/equivalent CU.
Minimum size of bus bars for control bus bars shall be 25 x 3 mm
Aluminium/equivalent CU.
Current density of copper busbar shall not be more than 1000 A/sq. in.
Thermal design of the busbars shall be based on installation of the switchgear in
poorly ventilated conditions. The cooling air volume shall take into account only the
bus enclosure. The maximum operating temperature of busbars at max. design
temperature shall not exceed the final end temperature (hot spot temperature including
the joints) 95 deg C under normal operating conditions and 200 deg C for short circuit
conditions. And the same shall be capable to withstand the full fault level without any
deformation. The current rating referred in the data sheets are for design ambient
temperature at site conditions and for being inside the cubicle at fully loaded condition
ie. In-panel rating. The vendor shall suitably derate the nominal rating to suit the above
condition. Successful vendor shall furnish the calculations for busbar sizing.
All joints surfaces at aluminium to copper joints shall be silver/ tin plated,
alternatively cup-al washers (bimetallic washers) may be used.
Busbars shall be of high conductivity electrolytic aluminium (E91E)/ copper .
Independent insulating supports for each phase busbar (vertical as well as
horizontal) shall be provided. Busbars shall be supported on insulators made of nonhygroscopic, non-inflammable, non-carbonizing material (like SMC,DMC epoxy
bonded fiberglass) resistant to acids and alkalis and shall have non-hygroscopic
characteristics with tracking index equal to or greater than 800 as per IEC 112.
Supports shall be adequately sized and braced to withstand the electrodynamic forces
developed during specified short circuit level without permanent deformation.
Successful vendor shall submit calculation for withstand capacity of busbar supports.
Both horizontal and vertical bus bars, bus joints and supports shall dynamically
brazed, thermally sized for being capable of withstanding dynamic and thermal stresses
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of the specified short circuit currents for 3 second. The short circuit capacity of the
neutral bus bars shall be in line with IS : 13947. Dynamic stresses shall be calculated
on the basis of the specified peak short circuit currents.
All bus bars shall be insulated with heat shrunk PVC sleeves of 1100V grade. Red,
yellow and blue colour shall be used for phase bus bars and black colour shall be used
for neutral bus bars. The sleeves used shall be capable of withstanding the
temperatures attained by busbars during normal operation and short circuits. Joints
shall be shrouded suitably.
Only zinc passivated high tensile strength steel bolts, nuts and washers shall be
used for all bus bar joints and supports.
Removable neutral links shall be provided on feeders to permit isolation of the
neutral busbar.
The support design shall be such that creepage distance between phases shall be
higher than those
specified in IS-4237. Necessary anti tracking barriers shall be
built-in in the design of the support. The clearance shall be at least 35 mm between
phases and phase to earth in the main busbar zone and 28 mm in vertical busbar
(droppers) zone. However clearances at components shall be as per individual
standards.
Both main and vertical busbars shall be housed in a separate metallic chamber
segregated from rest of the panel and shall be accessible for inspection with special
tools only.
Rubber grommets shall be used for all wire entries to make the entries dust and
vermin proof.
Isolating links/ fish plates shall be provided between two auxiliary bus sections.
The connection between the busbars and the terminals of the circuit breakers shall
be suitably shrouded.
VIII.
Cubicle Module Accessories And Wiring :Switchboard shall be supplied completely wired internally to equipments and
terminal blocks and ready for external cable connections at the terminal blocks. The
vendor shall carry out all control wiring within a cubicle and also inter-cubicle wiring
between cubicles of same switchgear. Interpanel wiring within each shipping section
shall also be vendor‟s responsibility. For wiring between shipping sections, vendor
shall provide terminal blocks on adjoining shipping sections and supply suitable jumper
wires duly ferruled and numbered for respective panel termination. Interconnection
schedule for wiring carried out between shipping sections shall be provided by vendor.
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Wiring shall run in enclosed plastic channel and shall leave at least 25% spare
space for future use. The interpanel wiring shall be taken through PVC sleeves or
suitable grommets and protected by beadings.
Neatly bunched flexible stranded copper conductor wires shall be used for
connection between moving parts. The same shall be soldered at the ends before
connections are made.
All control signaling, power, protection and metering wiring shall be by BIS
approved PVC insulated, 1100 V grade, copper stranded conductor wires of minimum
1.5 sqmm section provided the control fuse rating is 10 amps or less. For 16 amps
control fuse circuit 2.5 sqmm copper conductor shall be used.. For CT secondary
circuit, copper stranded conductor wires of minimum 2.5 sqmm shall be used.
Minimum size of power wiring shall be 4 sq.m. copper.
Each wire shall be terminated on a separate terminal. Terminal strips for connecting
incoming control cables shall be Elmex/ Technoplast/Wago make plug in type of
adequate size and shall be located conveniently and separated by barriers from power
circuits for easy accessibility and ease of connection without danger of contact with
live part. Sufficient terminals shall be provided on each terminal strip to ensure that not
more than one outgoing wire is connected per terminal. And at least 20% spare
terminals shall be provided in each terminal strip.
Wires shall not be joined or tied between terminal points.
Rubber grommets shall be provided at all such locations, so that metal parts should
not come in contact with any control wire/cables.
All spare contacts of equipments including ACB, relays, contractors shall be
terminated to terminal block.
Conductors shall be terminated with adequately sized compression type lugs for
connection to equipment terminal and strips. And proper PVC sleeving shall be
provided at each termination. Stranded conductors shall be soldered at the ends before
lugging.
All power terminals shall be of stud type. Clamp type terminal for direct conductor
termination shall be acceptable for wires unto 10 sqmm size and bolted type terminals
with crimping type copper lugs shall be provided for all outgoing cable connections
larger than 10 sqmm.
Each wire shall be identified at both the ends by, numbered ferrules provided at
each end, all in accordance with the connection diagram. All ferrules shall be made of
non-deteriorating materials and of yellow colour with black lettering.. The ferrules
shall be firmly located on each wire so that they cannot move or turn freely on the wire.
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All mounted equipment shall have tags of self-sticking PVC tapes at the rear. In
addition, identification numbers shall be painted on the panel wall, to give permanent
identification mark. Mounting of relays for a particular breaker panel shall be limited to
that particular panel only.
All auxiliary equipment terminals shall be made with pressure type terminals. All
spare contacts of aux. relays, timers etc. shall be wired up to the terminals.
C.T. terminal shall be with shorting and earthing facility. Phase identification for
CT secondary wires shall be done using coloured PVC sleeves.
Different voltage terminals, C.T. terminals, potential free terminals, power and
control terminals shall be segregated.
Duplication of a terminal block, wherever necessary shall be achieved by solid
bonding link.
Control cables entry shall be from the bottom. It shall be possible to have the
control cable entry from both the left and right side corners at the front portion of the
switchgear without cutting any standard part of the switchgear. Cable lugs and requisite
cable glands for these cables are not included in the scope of supply of the switchboard.
Supporting facilities shall be provided for clamping the control cables. All control
cables shall be of 2.5 sq.mm ywy, construction.
Multi pin plug provided should have scraping earth terminal.
E. Control Supply :
Breaker tripping and closing devices shall operate on 110 V DC/ 240AC unless
otherwise specified in the data sheet. The exact detail will be finalized during detailed
engg.
The control power supply shall be arranged as follows.

External 240V AC control supply shall be provided for auxiliary power and heater
circuits to any one panel of the switchboard.

Any other intermediate voltage required in the panel, shall be derived by vendor by
providing suitable control transformer- resistor.
Vendor to loop both these supply to all the panels in case of multibreaker panels
forming one unit. Each panel shall also have control supply switch and HRC fuses or
MCBs for isolation.
Vendor shall provide suitable control switch and fuse at the point of receiving control
supply.
F. Inspection chamber:
The instrument / control chamber shall incorporate the protection, control and
indicating devices like indication lamps, switches, meters, relays etc.
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This chamber shall be totally segregated from rest of the panel and shall be
provided with a separate door which can be opened when circuit breaker is ON.
Wherever equipments are mounted on the door, the wiring shall be with flexible
wires. The wires shall be neatly bunched and clamped and shall be sufficiently long so
that the door can be opened without causing unnecessary stress on the terminations at
the instruments.
G. Power Connection :
The incoming and outgoing power connection shall be through XLPE / PVC,
Aluminium/ Copper cables as indicated in the data sheet / drgs. The various cable
sizes and number of cables shall be as indicated in the material requisition. The power
cable shall enter the switchboard from the bottom bottom/top as specified.
Cable glands, lugs and the requisite bushes for sealing power cable entries shall be
excluded from the scope of supply of the switchboard.
Provisions shall be made for terminating each outgoing cable with separate bolted
connections. All terminals shall be properly sized for cable cores.
“Cupal” washers shall essentially be used for copper to aluminium joints.
The switchboard shall be supplied complete with supports for clamping outgoing
and incoming cables. Terminal blocks shall not be used to support cables.
Ample space and support arrangement shall be provided in the cubicles at the rear
of the switchboard to accommodate these cables. The head room available between
cable gland plate and terminal lug shall not be less than 750 mm for incomers and
major outgoing feeders/motors. The cable sockets shall be at such angle that the cable
tails may be brought up for termination with minimum bending and setting.
In case cable termination cannot be accommodated inside the panel, a suitable box
for mounting at bottom/rear of panel shall be supplied by vendor. Earth strip shall also
be brought to this box. In lieu of this dummy panel can also be provided.
Vertical cable alley covering the entire height with hinged door shall be provided
for cable connection. The minimum width of cable alley shall be 300mm.
Non-magnetic cable gland plates shall be provided for termination of single core
cables.
H. Earthing :The switchboard shall be constructed to ensure satisfactory electrical continuity
Page 85 of 153
between all metal parts not intended to be alive and the earth terminals of the board.
The earth bus shall be uniform & continuous and shall run the full extent of each board.
The minimum earth bus size shall be 50x6 sq.mm copper and shall be of adequate
cross-section to withstand the specified fault level with necessary termination
arrangement at both ends. It shall be bolted to the frame-work of each unit. Double
front M.C.C. shall have two nos. earth busbars, one for each front.
A separate Cu vertical earth bar shall be provided in all sections for earthing of
individual functional units.
All cubicles shall be connected to this earth busbar. All doors and movable parts shall
be earthed using flexible braided copper connections to the fixed frame of the
switchboard.
All with-drawable chassis shall be earthed through spring loaded silver plated copper
scrapping earth contact which make-before & break-after the power contacts are
engaged / disengaged. A suitable vertical earth bus shall be provided for each front of
the panel for this purpose.
The earth bus shall be easily accessible in each cable compartment either directly or
through a branch extension to ground the cable armor and shields. In each of the
vertical sections the earth bus bar shall be provided with minimum of two (over and
above the no. of feeders in each vertical sections) earthing bolts of 10 mm dia with nuts
to make termination of fourth core/ armor of cable.
Mating surfaces of all bolted parts shall be specially zinc passivated to ensure
continuity between them.
Provision shall be made to connect the earthing busbar to the plant-earthing grid at two
ends for which two nos. of earth terminals shall be provided on each switchboard, at
the back near the floor.
Positive earthing of circuit breaker truck/ frame shall be maintained when it is in the
connected position and in all other positions whilst the auxiliary circuits are not totally
disconnected.
Earthing by mere touching of metal-to-metal is not considered to be satisfactory
earthing. Hinged doors and movable parts shall be earthed through flexible copper
earthing braid.
All the non-conducting metal parts of the circuit breaker truck shall be bonded together
and shall make perfect electrical connections to earth through substantial sliding
contacts, at service and test positions. Such sliding contacts shall be arranged to make
before power plug-in and interrupt after draw out.
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All non-current carrying metallic parts of the mounted equipment shall be earthed.
I. Space Heaters :
The cubicles shall be provided with space heaters to prevent moisture condensation and
maintain cubicle temperature 50C above the ambient. The space heaters with porcelain
connectors shall be located at the bottom of each section of the switchboard, and shall
be supplied from 240V AC aux. Bus for space heater and controlled through a double
pole MCB and thermostat. The thermostat shall preferably be located in the
metering/relay chamber.
J. Name Plate :
Nameplate shall be provided on each panel as per schematic drawings for each
equipment (like switch, indicating lamp, meter, relay, auxiliary contactors, terminal
strips and other devices) mounted on the switchboard for easy identification.
Identification with stickers is not acceptable. Special warning labels shall be provided
on manual switching of interlocked circuit breaker, earthing switches, PT panels,
removable covers and doors giving access to live bus. Special warning label shall be
provided inside the switchboard also, wherever considered necessary. Identification
tags shall be provided inside the panels matching with those shown on the circuit
diagram.
A nameplate with the switchgear designation shall be put at the top of the central panel
of the switchgear on both front and rear side. A separate feeder nameplates giving
feeder details and panel number shall be provided at front as well as rear.
The nameplates for feeder compartments shall be in two parts. One part shall have
necessary details pertaining to the switchboards. The other parts shall be removable
and shall contain all details regarding the drives/ equipment controlled by the particular
module.
Each cubicle shall be labelled in the front and rear of the cubicle.
Caution/warning name plate labels stating live terminals/ busbars shall be provided on
all removable covers or doors giving access to cables or busbars.
K. Base-Frame:
The panels shall be suitable to be installed on a base frame. Amply dimensioned oblong
holes shall be provided on the bottom of all units for their assembly on the base frame,
which in turn shall have threaded holes. In addition, the panels shall have an additional
base channel at the bottom with smooth surface. The base frame shall be of IS Sections.
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L. Painting :
All metal surfaces shall be thoroughly cleaned, degreased, pickled and phosphatised to
remove mill scale, rust, grease and dirt. The under surface shall be prepared using the
seven tank process. And thereafter under surface shall be prepared by applying a coat
of phosphate paint and a coat of yellow zinc chromate primer. The under surface shall
be made free from all imperfections before undertaking the finishing coat. Fabricated
structures shall be pickled and then rinsed to remove any trace of acid.
After preparation of the under surface, all metal surfaces (both internal and external
surfaces) shall be applied with two coats of epoxy based primer. Subsequently the
work shall be powder coated with two coats of epoxy based final paint as per colour
shade No. 631 of IS:5, unless otherwise specified. Final coat shall be of air-drying
synthetic enamel paint. The finished panels shall be dried in stoving ovens in dust-free
atmosphere. Panel finish shall be free from imperfections like pinholes, orange peels,
runoff paint, etc. The final finish on the inside surface shall be glossy and the external
surface should be semi-glossy.
All unpainted parts shall be zinc passivated or suitably treated to prevent rust
formation. If these parts are moving elements, then these shall be greased.
Drawings :
The manufacturer shall develop his own general arrangement and schematic drawing
adding necessary auxiliary devices, accessories, components etc. peculiar to supplied
equipment, which are required for safe, convenient, efficient and proper operation of
the LT switchgear.
The number of circuit breaker panels and equipment/accessories schedule for each
breaker panel shall be as indicated in the material requisition given in the specific
requirement of tender document.
Manufacturer shall submit for HPCL‟s approval the single line diagrams, general
arrangement drawings, flooring and mounting detail drawings and schematic diagrams.
Approval of GA drawings is required before the fabrication of cubicles is started.
Approval, of schematic drawings is required before the manufacturer proceeds with the
cubicle wiring.
The approval of HPCL of any of the manufacturers drawings shall not relieve the
manufacturer of his responsibility for supplying equipment confirming with the
relevant specifications and standards or for any mistakes, errors or omissions in
manufacturers drawings.
Once manufacturers schematic diagrams have been finally approved by HPCL, the
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manufacturer shall prepare wiring connection diagrams for each cubicle.
These diagrams shall show any wiring inside the cubicle starting from the cubicle
terminal strips. These diagrams shall be used by owner for troubleshooting and shall
show every device, terminal and wire number.
Manufacturer shall submit the required number of prints and reproducible of schematic,
GA and wiring diagrams and catalogues, routine/ type test certificates as detailed in our
drawing data schedule given in the specific requirement of the tender document.
The manufacturers drawings shall replace HPCL‟s preliminary drawings sent with the
enquiry.
TESTS AND INSPECTION :
Inspection may be carried out at various stages of manufacture and also after the
completion of manufacture. The final despatch clearance shall be given by Third Party
Inspection agency appointed by vendor from the list of approved TPI agency. All
expenses towards TPI shall be to vendor‟s account.
The vendor shall submit QAP after placement of PO. During fabrication, switchgear
may be subjected to tests by vendor as per HPCL directive and same shall be witnessed
by the inspector. Manufacturer shall furnish all necessary information concerning the
supply to such inspectors. Stage inspection after the pre-treatment and preparation of
under surface and before final painting shall be carried out by HPCL, if specifically
mentioned in tender document.
During final inspection, all routine and acceptance tests shall be carried out at
manufacturer‟s works under his care and expense. Inspection shall not relieve vendor
of his responsibility of guarantee and other contractual responsibilities. The vendor
shall intimate the readiness of panels for inspection to owner also and owner at their
discretion may depute personnel to carryout inspection. Equipment shall be dispatched
only after the issuing of release note by TPI agency.
All routine and acceptance tests as specified by the applicable standard code shall be
conducted on the switchboard as a whole. Routine and acceptance test may also be
conducted on major components like relays, CT‟s, PT‟s etc, at respective
manufacturers works. In lieu, test certificates from respective manufacturers shall be
submitted during inspection and may also be acceptable. HPCL‟s decision will be final
on the matter.
In addition, acceptance test as detailed below shall be conducted to check mechanical
and electrical operation and switchboard wiring to the specification and approved
schematic drawings. These tests shall be provisionally conducted at manufacture‟s
works by providing temporary connection to switchgear units in order to simulate the
actual conditions. Tests shall be finally performed at site, in presence of the
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manufacturer‟s specialist, once the external cable connections have been completed.
Acceptance tests but not limited to the following shall be conducted by TPI, final QAP
shall be approved by owner and the testing & witness by TPI will be guided as per the
approved QAP ;
a) A general visual check, dimension measurement and bill of material check.
b) Manual and electrical operation of CB, relays, circuit functioning shall be
checked under the worst conditions of auxiliary supply voltage.
c) Dry insulation test with power frequency voltage for the main and auxiliary
circuits.
d) Insulation resistance of the main and auxiliary circuits shall be checked before
and after High Voltage withstand test.
e) Operation check shall be carried out for every control function as per the
approved schematic diagrams by manually simulating fault conditions and
operation of control switches/relays etc.
f) For equipment bought from other sub-suppliers certified test reports of test
carried out at the manufacturers works shall be submitted. Normally, all routine
tests as specified in the relevant standards shall be conducted by the sub-supplier
at his works.
g) Interchangeability of similar modules on a random basis and may be done on
one module of each size.
The TPI agency shall be one of the following:BV
EIL
DNV
IRS
LLOYDS
SGS
STATUTORY AUTHORITY APPROVAL:
The switchgear supplied shall be meet the Central Electrical Inspectorate requirement
and guidelines and changes required, if any, shall be carried out by the vendor without
any extra cost. Minor changes in wiring scheme, if required, to ensure working of the
electrical system in a logical and safe manner shall be carried out by the vendor at site
without any extra cost.
PACKING, TRANSPORT & UNLOADING :
The switchboard shall be shipped to site packed in wooden casings in order to facilitate
storage in open yards. No part of the switchboard shall be visible after packing. They
shall be wrapped with polythene sheets before being placed in wooden cases to prevent
damage to the finish and to avoid any ingress of water. Casings shall have skid bottoms
for handling. No other mode of packing shall be acceptable. Each panel after packing
shall be identified with details of panel by indelible ink. The unloading shall be carried
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out by the vendor at site through mechanical means and stored on a level ground. The
vendor‟s representative shall check the panels against any damage during the transit.
The vendor shall replace damaged parts without waiting for the insurance claims and
the responsibility of taking up the claims with Insurance agency shall be on the account
of vendor.
GUARANTEE :
The switchboard along with all equipment shall be guaranteed for trouble-freeoperation for a period of 12 months from the date of commissioning or 18 months from
the date of arrival at site, whichever is earlier. Any defects discovered during this
period shall be rectified free of cost. Any cost towards transportation, taxes and duties
for replacement shall also have to be borne by the vendor. The vendor shall furnish a
guarantee certificate to this effect.
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DOC NO.:
TECHNICAL PROCUREMENT
SPECIFICATION
TYPICAL SCOPE OF INSPECTION
AND TESTS
PAGE 1 OF 2
R0
TPS No.:
ITEM
: PANELS AT BATHINDA IRD - PUNJAB.
EQPT. NOS.:
The following inspection and test shall be conducted and records submitted. Please read the
same in conjunction with the “specific requirement document”. ( Any extra test required to be
done as per Specific requirement shall have to be carried out by the bidder. The QAP shall be
submitted by bidder after placement of PO.
Sl. No.
Description
Ins./test
Reqd.
Witness by
TPI Reqd.
1.0
Physical verification for compliance
with P.O. spec., scope, approved
drawings & BOM


2.0
Routine tests
2.1
Power frequency Voltage dry tests
on main circuits.
NA

2.2
Voltage tests on control and
auxiliary circuits


2.3
Measurement of resistance of main
circuit


2.4
Mechanical operation test


2.5
Tests of the auxiliary electrical and
pneumatic devices
NA

2.6
Verification of wiring


Remarks
Page 92 of 153
2.7
Electrical operation test


2.8
Megger test


2.9
Safety interlocks and protection
against electric shock and short
circuits


2.10
Verification of CT ratio and polarity
of CTs


2.11
Verification of nameplate
information & marking


2.12
Relay operation tests


Shall be conducted
by relay
manufacturer
2.13
Separate testing of breaker
operating mechanism and other
accessories
NA
NA
NA - Not Applicable


0
21.10.2009 ORIGINAL ISSUE
SDB
KSC
REV.NO.
DATE
PREPARED
CHECKED
DESCRIPTION
APPROVED
HINDUSTAN PETROLEUM CORP. LTD
Page 93 of 153
DOC NO.:
TECHNICAL
PROCUREMENT
SPECIFICATION
ITEM
SCOPE OF INSPECTION AND TESTS
PAGE 2 OF 2
R0
: PANELS AT BATHINDA IRD - PUNJAB.
The following inspection and test shall be conducted and records submitted
Sl.
No.
Description
3.0
Type tests
3.1
Impulse voltage dry test
3.2
Power frequency voltage dry test
Ins./test
Reqd.
Witness
Reqd.
Remarks
a) Temperature rise tests of Switchboard
3.3
b) Temperature rise tests of Circuit breaker
Copies of Certificates of
type tests conducted on
similar equipments shall
be furnished.
3.4
Verification of dielectric properties
3.5
Verification of making and breaking capacity of breaker
3.6
Verification of temp. limits and characteristics of relays
3.7
Short time current tests on main circuits
---
---
3.8
Short time current test on earthing circuits
---
---
3.9
Mechanical operation test
---
---
3.10
Verification of degree of protection
---
---
HINDUSTAN PETROLEUM CORP. LTD
Page 94 of 153
I.EARTH WORK AND BACKFILLING
1.0
SCOPE
1.1
This section of the specification covers the technical requirements for excavation and
filling & around structures, buildings, pipes, foundations, trenches, pits, drains, culverts,
channels, cable ducts, underground facilities & similar works. It also covers filling areas
and plinths with selected materials, conveyance and disposal of surplus spoils and/or
stacking them properly as directed by the Consultant.
1.2
The contractor shall be fully responsible for proper setting out works, profiling in
excavation, stacking, etc. taking adequate safety measures etc. The Contractor shall carry
out all works meant within the intent of this specification even if not explicitly mentioned
herein. All works shall be executed to the satisfaction of the Consultant.
1.3
Existing trees, shrubs, any other plants, pole lines, fences, signs, monuments, buildings,
pipelines, drains, sewers or other surface or subsurface systems/ drainage facilities within
or adjacent to the works being carried out which are not to be disturbed, shall be
protected from damage by the Contractor. The Contractor shall provide and install
suitable safeguards approved by the Consultant for this purpose.
1.4
During excavation, the Contractor shall take all necessary precautions against soil
erosion, water & environmental pollution, and where required undertake additional works
to achieve this objective. Before start of operations, the Contractor shall submit to the
Consultant for approval, his work plan and the procedure he intends to follow for
disposal of waste materials etc. and the schedule for carrying out temporary and
permanent control works. However, the approval of the Consultant to such plans and
procedures shall not absolve the Contractor of his responsibility for safe and sound work.
2.0
GENERAL
2.1
The Contractor shall make his own surveying arrangements for locating the coordinates
and positions of all work and establishing the reduced levels (RL‟s) at these locations
based on two reference grid lines and one bench mark which will be furnished by the
Owner. The Contractor has to provide at site all the required survey instruments, along
with qualified surveyors, to the satisfaction of the Consultant so that the work can be
carried out accurately and according to the specification and drawings.
2.2
The Contractor shall furnish all skilled and unskilled labour, plant, tools, tackle,
equipment, men and materials required for complete execution of the work in accordance
with the drawings and as described herein and/or as directed by the Consultant.
2.3
The Contractor shall control the grade in the vicinity of all excavations so that the surface
of the ground will be properly sloped or dyked to prevent surface water from running into
the excavated areas during construction.
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2.4
All materials obtained from excavation shall remain the Owner‟s property. All salvaged
materials of archeological importance or of value (in the opinion of the Consultant) shall
be segregated from the other materials and both stacked separately and in a regular
manner at location indicated by the Consultant.
2.5
Excavation shall include removal of trees including roots & organic remains, vegetation,
grass, bushes, shrubs, plants, poles, fences etc. that are in the area to be excavated as well
as beyond the excavation line so as to ensure safety of the excavated side slopes and of
men and equipment operating in the area. Before start of excavation work, joint
measurements of ground level shall be taken after clearing all grass, vegetation etc.
2.6
Excavation shall include the removal of all materials required to execute the work
properly and shall be made with sufficient clearance as decided by the Consultant to
permit the placing and setting of forms, inspection and completion of all works to the
satisfaction of the Consultant for which the excavation was done.
2.7
Classification of Earth Work: The earth work shall be classified under the following main
categories.
a)
b)
c)
All types of soils, murrum, boulders.
Soft rock.
Hard rock.
2.7.1
Ordinary soils: This includes earth, murrum, top deposits of agricultural soil, reclaimed
soil, clay, sand or any combination thereof and soft and hard murrum, shingle etc., which
is loose enough to be removed with spades shovel and pick axes. Boulders not more than
0.03 cum. in volume found during the course of excavation shall also fall under this
classification.
2.7.2
Soft Rock: This shall include all materials which are rock or hard conglomerate, all
decomposed weathered rock, highly fissured rock, old masonry, boulders bigger than
0.03 cum in volume but not bigger than 0.5 cum and other varieties of soft rock which
can be removed only with pick axes, crow bars, wedges and hammers with some
difficulty. The mere fact that the contractor resorts to blasting and / or wedging and
chiseling for reasons of his own, shall not mean the rock is classifiable as hard rock.
2.7.3
Hard Rock: This includes all rock other than soft rock mentioned in para 2.07.02 viz. Soft
rock, occurring in masses, boulders having approximate volume more than 0.5 cum plain
or reinforced cement concrete, which can best be removed by blasting or chiseling and
wedging where blasting cannot be permitted owing to any restriction at site.
3.0
CODES AND STANDARDS
Page 96 of 153
3.1
All standards, specifications, acts and code of practice referred to herein shall be the
latest editions including all applicable official amendments and revisions.
3.2.
In case of conflict between this specification and those (IS standards, codes etc.) referred
to here in, the former shall prevail.
3.3
Some of the relevant Indian standards, Acts and Codes are referred to here below:
IS: 383
1970
Specification for coarse and fine aggregates from natural
sources for concrete.
IS 2720 (Part- 2)
1973
Methods of test for soils-Determination of water content
IS 2720 (Part4-4 )
1985
Methods of test for soils-Grain size analysis
IS 2720 (Part-5 )
1985
Methods of test for soils-Determination of liquid limit &
plastic limit
IS 2720 (Part-6 )
1972
Methods of test for soils-Determination of shrinkage
factors
IS 2720 (Part-7 )
1980
Methods of test for soils-Determination of water
content-Dry density relation using light compaction
IS 2720 (Part-8 )
1983
Methods of test for soils- Determination of water
content-Dry density relation using heavy compaction
IS 2720 (Part-14 )
1983
Methods of test for soils-Determination of dry
index(relative density)
IS 2720 (Part-21 )
1977
Methods of test for soils-Determination of total soluble
solids
IS 2720 (Part-23 )
1976
Methods of test for soils-Determination of calcium
carbonate
IS 2720 (Part-24 )
1976
Methods of test for soils-Determination of cation
exchange capacity
IS 2720 (Part-27 )
1977
Methods of test for soils-Determination of total soluble
sulphates
IS 2720 (Part-29 )
1975
Methods of test for soils-Determination of dry density of
soil in-place by core cutter method
IS: 3764
1992
Safety code for excavation work
IS: 4081
1986
Safety code for blasting and related drilling operations
IS: 4701
1982
Code of practice for earth work on canals
Page 97 of 153
IS: 9759
1981
Guide lines of dewatering during construction
IS: 10379
1982
Code of practice for field control of moisture and
compaction of soils for embankment and sub grade
Indian Explosives Act 1940 as updated.
4.0
EXCAVATION IN SOIL
4.1
Side and bottom of excavation shall be cut sharp and true to line and level. Undercutting
shall not be permitted. When machines are used for excavation, the last 300 mm before
reaching the required level shall be excavated manually or by such equipment that soil at
the required final level will be left in its natural condition. Suitability of strata (at the
bottom of excavations) for laying the foundation thereon shall be determined by the
Consultant.
4.2.
Excavation for foundation shall be to the bottom of lean concrete and as shown on
drawing or as directed by the Consultant. The bottom of all excavations shall be trimmed
to required levels and when excavation is carried below such levels by error, it shall be
brought back to the specified level by filling with concrete of nominal mix 1:3:6 (cement:
coarse sand: 40 mm down aggregates) as directed by the Consultant.
4.3
The Contractor shall ascertain for himself the nature of materials to be excavated and the
difficulties, if any, likely to be encountered in executing this work., sheeting, shoring,
bracing, maintaining suitable slopes, draining etc. shall be provided and installed by the
Contractor, to the satisfaction of the Consultant.
4.4.
All excavation for installation of underground facilities, such as pipe lines, sewer line,
drain lines etc. shall be open cuts. For deep and huge excavations and in other
excavations, if required by the Consultant, the Contractor shall submit for Consultant‟s
approval an “Excavation Scheme” showing the methodology to be adopted for
excavation in order to maintain the stability of side slopes, means for ensuring safety of
existing facilities nearby, dewatering. However, the Contractor shall be fully responsible
for the scheme irrespective of any approvals granted. Benching shall be provided for
deeper excavation wherever required.
4.5
When excavation requires bracing, sheeting or shoring etc. the Contractor shall submit
drawings to the Consultant, showing arrangements and details of proposed installation.
The Contractor shall also furnish all supporting calculations as called for and shall not
proceed until he has received written approval from the Consultant. However, the
responsibility for adequacy of such bracing, sheeting, shorting etc. will rest with the
Contractor, irrespective of any approval of the Consultant.
4.6
The Contractor shall have to constantly pump out any water collected in excavated pits
and other areas due to rain water, springs etc. and maintain dry working conditions at all
times until the excavation, placement of reinforcement, shuttering, concreting, backfilling
Page 98 of 153
is completed. The Contractor shall remove all slush/muck from the excavated areas to
keep the work area dry. Sludge pumps, if required, shall be employed by the Contractor
for this purpose.
4.7
The Contractor shall remove all materials arising from excavations from the vicinity of
the work either for direct filling, stacking the subsequent filling or for ultimate disposal
as directed by the Consultant. In no case shall the excavated soil be stacked within a
distance of 1.5 m from the edge of excavation or one third the depth of excavation
whichever is more. Material to be used for filling shall be kept separately.
5.0
EXCAVATION IN ROCK
5.1
General
5.1.1
All clauses from 4.1 to 4.7 shall be applicable to excavation in rock also. In case of any
discrepancy between the above mentioned clause and those specified in this clause then
this clause shall govern.
5.1.2
For the work of excavation in rock, Contractor shall engage specialised agency having
experience of excavation in rock involving wedging and blasting. The agency shall be
subject to approval of Consultant and the Contractor shall furnish details of relevant
experience in support while seeking approval for the agency.
5.1.3
In case of overbreaks in rock excavation, the excavated level shall be brought to the level
shown on drawings with plain cement concrete of nominal mix 1:3:6 as described in para
4.02.00.
5.2
Excavation by Blasting
5.2.1
Blasting shall be resorted to only with the written permission of the Consultant. All the
statutory laws, (Explosives Act etc.) rules, regulations, Indian Standards etc. pertaining to
the acquisition, transport, storage, handling and use of explosives etc. shall be strictly
followed.
5.2.2
The contractor shall obtain Licenses from Competent Authorities for undertaking blasting
work as well as for procuring, transporting to site and storing the explosives as per
Explosives Act. The Contractor shall be responsible for the safe transport, use, custody
and proper accounting of the explosive materials.
5.2.3
The Contractor may adopt any method of blasting as permitted according to explosives
act/rule consistent with the safety and job requirements (after approval from the
Consultant) and so as not to injure men or damage materials/structures during blasting
operations.
5.2.4
The magazine for the storage of explosives shall be built by the Contractor to the designs
and specifications of the Explosives Department concerned and located at the approved
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site. No unauthorised person shall be admitted into the magazine which, when not in use,
shall be kept securely locked. No matches or inflammable material shall be allowed in the
magazine. The magazine shall have an effective lightning conductor and the following
shall be hung in the lobby of the magazine.
a) A copy of the relevant rules regarding safe storage, both in English and in the
language(s) with which the workers concerned are familiar.
b) A statement of up to date stock in the magazine.
c) A certificate showing the last date of testing of the lightning conductor.
d) A notice stating that smoking is strictly prohibited.
5.2.5
The Contractor shall also observe any specific instructions given by the Consultant. The
Contractor shall be responsible and liable for damage to property and any accident which
may occur to workmen or to the public or to materials on account of any operation
connected with the storage, transportation, handling or use of explosives and the blasting
operations. The Consultant or his authorised representative shall frequently check the
Contractor‟s compliance with these precautions and the manner of storing and accounting
of explosives. The Contractor shall provide necessary facilities for this.
5.2.6
All materials, tools and equipments used for blasting operations shall be of approved
make and type. In special cases, the Consultant may specify the type of explosives to be
allowed. The fuse to be used in wet locations shall be sufficiently water resistant so as to
be unaffected when immersed in water for 30 minutes. The rate of burning of the fuse
shall be uniform and precisely known to permit evaluation of the distance to which the
firer should move before explosion takes place. Detonators shall be capable of effective
blasting of the explosives.
5.2.7
The blasting powder, explosives, detonators, fuses etc. shall be fresh and not damaged
due to dampness or any other Cause. Explosives shall be kept dry and shall not be
exposed to direct rays of the sun or be stored in the vicinity of fire, stoves, steam pipes, or
heated metal etc. They shall be inspected before use and damaged articles shall be
discharged totally and removed from site immediately.
5.3
Blasting Operations
5.3.1
The blasting operations shall remain in the charge of a responsible, competent, authorised
and experienced supervisor (called Man-in-Charge) and workmen who are thoroughly
acquainted with the details of handling explosives and blasting operation and with the
rules governing such work.
Page 100 of 153
5.3.2
All rules under the Explosives Act and other local rules in force shall be fully observed.
All blasting works shall be done in accordance with the stipulations contained in IS:
4081. Blasting shall only be carried out at certain specified times preferably during the
mid-day lunchtime or at the close of work as directed in writing by the Consultant. The
hours when blasting will be done, shall be made known to people in the vicinity. All the
charges shall be prepared by the Man-in-Charge (as defined in 5.03.01) above) only.
Proper precautions for safety of persons and property shall be taken.
5.3.3
Prior to blasting, red danger flags shall be displayed prominently around the area to be
blasted and shall be kept in position until blasting work is completed. All people, except
those who actually light the fuses, shall be prohibited from entering this area. The flags
shall be planted 200 metres from the blasting site and all persons including workmen
shall be evacuated from the flagged area atleast 10 minutes before firing. A warning
whistle shall be sounded for this purpose.
5.3.4
Controlled Blasting shall be carried out within 200 metres of an existing structure unless
otherwise permitted by the Consultant in writing. Where (generally with in plant area)
controlled blasting is to be carried out in the proximity of other structures, then sand bags
and/or earth bags etc. shall be used on top of the blast holes to prevent the rock fragments
from causing damage to adjacent structures and property. At all stages of blasting
operations, precautions shall be taken to preserve the rock in the soundest possible
condition below and beyond the lines specified for the excavation. The quantity and
strength of explosives used shall be such that it will neither damage nor crack the rock
outside the limits of excavation. Any method of blasting which leads to overshooting
shall be discontinued.
5.3.5
No explosive shall be brought near the work in excess of the quantity required for a
particular amount of firing to be done and surplus left after filling holes shall be removed
to the magazine. A careful and day to day account of the explosives shall be maintained
by the Contractor in an approved manner and in an identified register, which shall be
open to inspection by the Consultant at all time.
5.3.6
At a time not more than ten such charges shall be prepared and fired. The man-inCharges shall blow the whistle in a recognised manner for cautioning the people. The
number of blasts to be fired and actual number of shots heard shall be compared and the
person responsible shall satisfy himself by examination that all blasts have exploded
before any person working in the area is permitted to re-approach the work site.
Sufficient time shall be allowed to account for delayed blasts. The Man-in-Charge shall
inspect all the charge. The withdrawal of the unexploded charge shall not be permitted
under any circumstances. After tamping, the unexploded charge shall be flooded with
water and the hole marked in a distinguishable manner. Another hole shall be jumped at a
distance of 450 mm from the old hole and fired in the usual way. This process shall be
continued till the original blast is exploded. The Man-in-Charge shall at once report to the
Contractor‟s office and the Consultant, all cases of misfire, the cause for the same and
what steps where taken in connection therewith.
Page 101 of 153
5.3.7
If misfire is found to be due to defective materials, the whole quantity in the box form
which the defective materials was taken must be sent to the Authority directive by the
Consultant for inspection to ascertain whether any of the remaining materials in the box
are also defective.
5.4
Chiseling / Wedging
Where blasting is prohibited for any reasons or it is not practicable in the opinion of the
Consultant, then the excavation shall be carried out by chiseling, wedging or any other
approved method. The decision of the Consultant in this regard shall be final binding on
Contractor.
5.5
Line drilling and pre-shearing
The number, size and location of holes shall be carefully worked out by the Contractor
and shall be subject to the approval of the Consultant. Line drilled holes shall generally
be 48 mm dia. and, if so directed, interior blasting holes shall also be made. The
Contractor shall carry out test to determine the amount of explosives required to ensure
an even break at the line drilled holes after the interior holes are blasted and irregularities
in the vertical drilled line face shall be removed and trimmed by wedging, splitting,
chiseling and barring.
6.0
EXCAVATION BELOW GROUND WATER TABLE
6.1
Wherever ground water table is met with during excavation, the Contractor shall
immediately report this fact to the Consultant who shall arrange to record the exact level
of the water table before start of dewatering operation. The decision of the Consultant
regarding sub-soil water level shall be final and binding on the Contractor. Ground Water
Table for the purpose of this clause shall be taken as the level of standing water observed
during the process of excavation. Capillary action of water in the surrounding soil mass
shall not be considered for the above purpose.
6.2
The Contractor shall dewater and maintain dry working conditions by maintaining the
water table below the bottom of the excavation level by well-point dewatering or deep
well dewatering or any other method approved by the Consultant. He shall continue
doing so till excavation, concreting, curing, and all other operation included in the scope
of work, which require dry condition in the area are completed.
7.0
LIFT
The Contractor is required to excavate upto any depth as shown on the drawings or as
directed by the Consultant. Lifting of excavated materials shall be done either by manual
Page 102 of 153
or mechanical or both means if called for by the Consultant.
8.0
CARRIAGE OF MATERIALS
8.1
The EIC shall indicate the disposal/ stacking areas for excavated materials. The carriage
of excavated materials shall be done by the methods mentioned below:
a) The excavated materials shall be carried beyond the initial lead of 50 m but upto 500
m by manual /animal labour or by mechanical means. If directed by the Consultant
this material shall be used directly for filling purposes.
b) For leads exceeding 500 m the Contractor shall transport the excavated materials by
mechanical means only and as directed by the Consultant. The Contractor may be
allowed to carry materials through Kuccha roads. Providing and maintaining of the
Kuccha roads shall be the responsibility of the Contractor. The transported material
shall be neatly stacked as directed by the Consultant.
8.2
Some excavated materials required for filling purposes, may have to be carried upto a
lead of 500 m and stacked as per instructions of the Consultant. Excavated materials
carried beyond 500 m shall normally be for disposal purpose only. Double handling of
materials shall be avoided as far as possible. However, depending on site condition
excavated materials carried beyond a lead of 500 m may also be required to be brought
back for filling purpose.
9.0
FILLING
9.1
Materials
9.1.1
Materials to be used for filling purpose shall be stone, sand or other inorganic materials
and they shall be clean and free from shingle, salts, organic matter, large roots and
excessive amount of sod, lumps, concrete or any other foreign substances which could
harm or impair the strength of the substances in any manner. All clods shall be suitably
broken to small pieces. When the materials are mostly rock boulders, these shall be
broken into pieces not larger then 150 mm size. Sand used for filling shall be clean,
medium grained and free from impurities. Fines less than 75 microns shall not be more
than 20%. In any case, the materials to be used for filling purposes shall have the prior
written approval of the Consultant.
9.1.2
If excavated materials are to be used for filling, then the Contractor shall select the
materials from the stockpile, land and transport this material and execute the filling. This
shall include excavation of earth, which may become hard due to lying in stockyard for a
long period of time.
Page 103 of 153
9.1.3
In case the materials have to be brought from pits/quarries, it shall be the Contractor‟s
responsibility for identification of such quarry areas, obtaining approval from their use
from concerned authorities, excavation/quarrying loading and carriage of such material,
unloading and filling at specified locations. The Contractor shall pay any fees, royalties
etc. that may have to be pain for utilisation of borrow areas.
9.2
Filling Procedure
9.2.1
After completion of foundation, footings, walls and other construction below the
elevation of the final grades, and prior to filling, all temporary shoring, timber etc. shall
be sequentially removed and the excavation cleaned of all trash, debris, and. perishable
materials. Filling shall begin only with the written approval of the Consultant. Also, areas
identified for filling shall be cleared of all soft pockets, vegetation, bushes, slash etc. In
case of plinth and similar filling the ground shall be dressed and consolidated by
ramming and light rolling.
9.2.2
Fill materials shall not be dropped directly upon or against any structure or facility where
there is danger of displacement or damage. Filling shall be started after the
concrete/masonry has fully set and shall be carried out in such a manner so as not to
cause any undue lateral thrust on any part of the structure.
9.2.3
All space between foundation (concrete or masonry) and the sides excavation shall be
filled to the original surface after making allowance for settlement, Fill shall be placed in
horizontal layers not exceeding 200 mm loose thickness. Each layer shall be watered and
compacted with proper moisture content and with such equipment as may be required to
obtain a compaction/density as specified. Trucks or heavy equipment for depositing or
compacting fill shall not be used within 1.5 meters of building walls, piers for operation.
The methods of compaction shall be subjected to approval of Consultant under any
circumstances.
9.2.4
Fill adjacent to pipes shall be free of stones, concrete etc. and shall be hand placed and
compacted uniformly on both sides of the pipe and where practicable up to a minimum
depth of 300 mm over the top of pipes. While tamping around the pipes, care should be
taken to avoid unequal pressure.
9.2.5
Filling shall be accurately finished to line, slope, cross section and grade as shown on the
drawings. Finished surface shall be free of irregularities and depressions and shall be
within 20 mm of the specified level.
9.2.6
Where filling with stone from excavated materials is specified, it shall be from broken
pieces of boulders. At first a 75 mm thick cushion of selected earth shall be laid over
which the 200 mm thick graded stones shall be laid in loose layers of 200 mm then the
interstices filled with properly graded fine materials consisting of selected earth brought
from borrow areas. Each layer shall be watered and compared to the specified density
before the next layer is laid. However, no cushion shall be required where filling is over
non-rocky surface.
Page 104 of 153
9.2.7
Where filling with 65 mm down graded stone obtained from excavated, it shall be
selected stone laid over and initial 50 mm thick cushion layer of selected earth and then
stone laid in 200 m loose thick layers, interstices filled with the specified density before
the next layer in laid. However, no cushion shall, be required where filling is over nonrocky surface.
9.2.8
Where clean stone fill is specified, it shall consist of clean selected stone metal of 40-mm
nominal size. It shall be laid in layers not exceeding 150 mm (loose) and lightly tamped
before the next layer is laid. No compaction shall be required for this type stone filling.
9.3
Compaction
9.3.1
Where compaction to 95% Standard Proctor Density or more is called for, it shall be by
mechanical means only. Where access is possible, compaction shall be by 12 tonne
rollers smooth wheeled, sheep foot or wobbly wheeled as directed by the Consultant. A
smaller weight roller may be permitted by the Consultant in special cases, but in any case
not less than 10 passes of the roller will be accepted for each layer. Each layer shall be
wetted or the material dried by aeration to moisture content of 3-5% above the Optimum
Moisture Content to be determined by the Contractor. Each layer shall be watered,
rammed and compacted to the density as specified Consultant.
9.3.2
For compacting sand layer, water shall be sprayed over it to flood it and it shall be kept
flooded for 24 hours to ensure maximum compaction. Vibro-compactors shall also be
used if necessary to obtain the required degree of compaction. Any temporary works
required to contain sand under flooded condition shall also be undertaken. The surface of
the consolidated sand shall be dressed to required levels or slope.
9.3.3
After the compacted fill has reached the desired level, the surface shall be flooded with
water for 24 hours, allowed to dry and then rammed and consolidated to avoid any
settlement, at a later date. The compacted surface shall be properly shaped, trimmed and
consolidated to an even gradient or level. All soft spots shall be excavated, filled and
consolidated.
9.3.4
The degree of compaction of compacted fill in place will be subject to tests by the
Consultant as the work progresses, and the contractor shall provide the necessary
facilities to make such tests. If any test indicates that the compaction achieved is less than
the specified degree of compaction, the Consultant may require fill placed subsequent to
the last successful test to be removed and re-compacted by the Contractor. Compaction
procedure shall be amended as necessary to obtain satisfactory results.
9.3.5
When semi-compacted fill is specified by the Consultant, the contractor shall fill up such
areas with available earth from stock piles of borrow pits or directly from excavation
without special compaction except that obtained by moving trucks etc.
Page 105 of 153
II. PLAIN AND REINFORCED CONCRETE & ALLIED WORKS
1.0
SCOPE
1.1
This specifications covers the general requirements for concreting to be used on jobs
using on-site production facilities including requirements in regard to handling, storage of
ingredients, proportioning, batching, mixing and testing and quality assurance. This also
covers the transportation of concrete from the mixer to the place of final deposit and the
placing consolidation, curing, protecting, repairing and finishing of concrete.
1.2
The work shall include providing of materials, all necessary plant and equipment,
providing adequate Consultating supervision and technical personnel, skilled and
unskilled labour, etc. as required to carry out the entire work as indicated on the drawings
and/or described herein subsequently and/or as directed by the Consultant.
1.3
The Contractor shall carry out all works meant within the intent of this specification even
if not explicitly mentioned herein. All works shall be executed to the satisfaction of the
Consultant.
2.0
GENERAL
2.1
The Contractor shall make his own surveying arrangements for locating the coordinates
and positions of all work and establishing the reduced levels (RLs) at these locations,
based on two reference grid lines and one bench mark, which will be furnished by
Owner. The Contractor has to provide at site, all the required survey instruments, along
with qualified surveyors, to the satisfaction of the Consultant so that the work can be
carried out accurately and according to the specifications and drawings.
2.2
The contractor shall establish a site laboratory for testing of material and quality
assurance as per the requirements of this specification. The laboratory shall be manned by
qualified Consultant.
2.3
Any approval, instructions, permission, checking, review, etc. whatsoever by the
Consultant, shall not relieve the Contractor of his responsibility and obligation regarding
adequacy, correctness, completeness, safety, strength, quality, workmanship, etc.
3.0
CODES AND STANDARDS
3.1
All work shall be carried out as per the stipulations contained in various sections of these
specifications and the latest Indian Standards, Acts, Codes and best practices.
3.2
All applicable standards, specifications, etc. and codes of practice shall generally be the
latest editions, including all applicable official amendments and revisions. A complete set
of all these documents shall generally be available at site, with the Contractor.
Page 106 of 153
3.3
3.4
In case of conflict between the stipulations contained in various sections of these
specifications and stipulations of Indian Standards, Codes, etc. the requirements of
stipulations contained in various sections of these specifications, shall prevail over that of
Indian Standards, Codes, etc.
The following are the various relevant Indian Standards:
IS: 73
1992
Specification for paving bitumen
IS : 216
1961
Specification for coal tar pitch
IS: 269
1989
Specification for 33 grade Ordinary Portland cement
IS: 280
1978
Specification for mild steel wire for general Consultanting
purposes
IS: 383
1970
Specification for coarse and fine aggregates from natural sources
for concrete
IS:432 (Parts I)
1982
Specification for mild steel medium tensile steel bars and hard
drawn steel wire for concrete reinforcement – Mild steel &
medium tensile bars
IS: 432(Parts II)
1982
Specification for mild steel medium tensile steel bars and hard
drawn steel wire for concrete reinforcement - Hard drawn steel
wire
IS: 455
1989
Specification for Portland slag cement
IS: 456
2000
Code of practice for plain and reinforced concrete
IS: 457
1957
Code of practice for general construction of plain & reinforced
concrete for dams & other massive structures
IS: 516
1959
Method of test for strength of concrete
IS : 650
1991
Specification for standard sand for testing of cement
IS: 702
1988
Specification for industrial bitumen
IS : 737
1986
Wrought aluminium and aluminium alloy plate for general
Consultanting purposes
IS: 800
1984
Code of practice for general construction in steel
Page 107 of 153
IS: 816
1969
Code of practice for use of metal are welding for general
construction in mild steel
IS: 1161
1998
Specification for steel tubes for structural purpose
IS: 1199
1959
Methods of sampling and analysis of concrete
IS: 1200 (Part-II)
1974
Method of measurement of building and civil Consultanting works
- Concrete works
IS: 1200
V)
(Part- 1982
Method of measurement of building and civil Consultanting works
- Form work
IS: 1200
VIII)
(Part- 1993
Method of measurement of building and civil Consultanting works
- Steel work & iron work
IS: 1200
XVIII)
(Part- 1974
Method of measurement of building and civil Consultanting works
- Demolition & dismantling
1993
Specification for bitumen felts for waterproofing and damp
proofing
IS: 1322
IS: 1363 (Part 1) 2002
Hexagon head bolts, screws and nuts of product grade „C‟ –
Hexagon head bolts (size range M 5 to M 64)
IS: 1363 (Part 2) 2002
Hexagon head bolts, screws and nuts of product grade „C‟ –
Hexagon head screws (size range M 5 to M 64)
IS: 1363 (Part 3) 2002
Hexagon head bolts, screws and nuts of product grade „C‟ –
Hexagon nuts ( size range M5 to M 64)
IS: 1489 (Part-I)
1991
Specification for Portland-pozzolana cement: Fly ash based
IS:1489 (Part-II)
1991
Specification for Portland Pozzolana Cement: Calcined clay based.
IS : 1566
1982
Specification for Hard-drawn steel wire fabric for concrete
reinforcement.
IS : 1609
1991
Code of practice for laying damp proofing
bitumen felts.
IS : 1786
1985
Specification for high strength deformed steel bars and wires for
concrete reinforcement.
IS : 1791
1985
General requirements for batch type concrete mixer.
treatment using
Page 108 of 153
IS: 1834
1984
Specification for hot applied sealing compound for joints in
concrete
IS : 1838 (Part-I)
1983
Specification for preformed fillers for expansion joints in concrete
pavements and structures (non extruding and resilient type).Bitumen impregnated fibe
IS: 2016
1967
Plain washers
IS: 2074
1992
Specification for ready mix paint, air drying, red oxide zinc
chrome
IS : 2386 (Part 1)
1963
Methods of test of aggregates for concrete – Particle size & shape
IS : 2386 (Part 2)
1963
Methods of test of aggregates for concrete – Estimation of
deleterious material and organis impurities
IS : 2386 (Part 3)
1963
Methods of test of aggregates for concrete – Specific gravity,
Density, voids, absorption and bulking
IS : 2386 (Part 4)
1963
Methods of test of aggregates for concrete – Mechanical properties
IS : 2386 (Part 5)
1963
Methods of test of aggregates for concrete – Soundness
IS : 2386 (Part 6)
1963
Methods of test of aggregates for concrete – Measuring mortar
making properties of fine aggregates
IS : 2386 (Part 7)
1963
Methods of test of aggregates for concrete – Alkali aggregate
reactivity
IS : 2386 (Part 8)
1963
Methods of test of aggregates for concrete – Petrographic
examination
IS : 2438
1963
Specification for roller pan mixer.
IS : 2502
1963
Code of practice for bending and fixing of bars for concrete
reinforcement.
IS : 2505
1992
General requirements for concrete vibrators, immersion type.
IS : 2506
1985
General requirements for concrete vibrators, screen board type.
IS : 2514
1963
Specification for concrete vibrating table.
IS : 2571
1970
Code of practice for laying in-situ cement-concrete flooring.
IS : 2645
2003
Specification for Integral cement water proofing compounds for
cement mortar and concrete
Page 109 of 153
IS : 2722
1964
Specification for portable swing weigh batchers for concrete.
(single and double type)
IS : 2750
1964
Specification for steel scaffoldings.
IS : 2751
1979
Code of practice for welding of mild steel plain and deformed bars
for reinforced concrete construction.
IS: 2812
1993
Recommendation for manual tungsten inert gas arc welding of
aluminium and aluminium alloys
IS : 3025 (Part 1986
22)
Methods of sampling and test (physical & chemical) for water &
waste water – Acidity
IS : 3025 (Part 1986
23)
Methods of sampling and test (physical & chemical) for water &
waste water – Alkalinity
IS : 3037
1986
Specification for bitumen mastic for use in water proofing of roofs
IS : 3150
1982
Specification for hexagonal wire netting for general purposes.
IS : 3370 (Part I)
1965
Code of practice for concrete structures for the storage of liquids –
General requirements
IS : 3370 (Part II)
1965
Code of practice for concrete structures for the storage of liquidsReinforced concrete structures
IS : 3384
1986
Specification for bitumen primer for use in waterproofing & damp
proofing.
IS : 3414
1968
Code of practice for design and installation of joints in buildings.
IS : 3550
1965
Methods of test for routine control for water used in Industry.
IS : 3558
1983
Code of practice for use of immersion vibrators for consolidating
concrete.
IS : 3696 (Part I)
1987
Safety code for scaffolds and ladders – Scaffolding
IS : 3696 (Part II)
1991
Safety code for scaffolds and ladders – Ladders
IS : 4014 (Part I)
Code of practice for steel tubular scaffolding – Definition &
amterials
IS : 4014 (Part II)
Code of practice for steel tubular scaffolding - Safety Regulation
for scaffolding
IS : 4031 (Part 1)
1996
Methods for physical tests for hydraulic cement – Determination
Page 110 of 153
of finess by dry sieving
IS : 4031 (Part 2)
1999
Methods for physical tests for hydraulic cement – Determination
of fineness by specific surface by Blaine air permeability method
IS : 4031 (Part 3)
1988
Methods for physical tests for hydraulic cement – Determination
of soundness
IS : 4031 (Part 4)
1988
Methods for physical tests for hydraulic cement – Determination
of consistency of standard cement paste
IS : 4031 (Part 5)
1988
Methods for physical tests for hydraulic cement – Determination
of initial and final setting times
IS : 4031 (Part 6)
1988
Methods for physical tests for hydraulic cement – Determination
of compressive strength of hydraulic cement (other than masonry
cement)
IS : 4031 (Part 7)
1988
Methods for physical tests for hydraulic cement – Determination
of compressive strength of masonry cement
IS : 4031 (Part 8)
1988
Methods for physical tests for hydraulic cement – Determination
of transverse and compressive strength of plastic mortar using
prism
IS : 4031 (Part 9)
1988
Methods for physical tests for hydraulic cement – Determination
of heat of hydration
IS : 4031 (Part 1988
10)
Methods for physical tests for hydraulic cement – Determination
of drying shrinkage
IS : 4031 (Part 1988
11)
Methods for physical tests for hydraulic cement – Determination
of density
IS : 4031 (Part 1988
12)
Methods for physical tests for hydraulic cement – Determination
of air content of hydraulic cement mortar
IS : 4031 (Part 1988
13)
Methods for physical tests for hydraulic cement – measurement of
water retentivity of masonry cement
IS : 4031 (Part 1989
14)
Methods for physical tests for hydraulic cement – Determination
of false set
IS : 4031 (Part 1991
15)
Methods for physical tests for hydraulic cement – Determination
of fineness by wet sieving
IS : 4130
Safety Code for demolition of buildings.
1991
Page 111 of 153
IS : 4218 (Part 3)
1999
ISO general purpose metric screws threads – Basic dimensions
IS : 4326
1993
Code of practice for earthquake resistant design and construction
of buildings.
IS : 4461
1998
Code of practice for joints in surface hydro-electric power stations.
IS : 4656
1968
Specification for form vibrators for concrete.
IS : 4671
1984
Expanded polystyrene for thermal insulation purposes
IS : 4925
1968
Specification for batching and mixing plant.
IS : 4990
1993
Specification for plywood for concrete shuttering work.
IS : 4995 (Part I)
1974
Criteria for design of reinforced concrete bins for the storage of
granular and powdery materials – General requirement &
assessment of bin loads
IS : 5256
1992
Code or practice for sealing joints in concrete lining on canals.
IS : 5525
1969
Recommendations for detailing of reinforcement in reinforced
concrete work.
IS : 5624
1993
Specification for foundation bolts.
IS : 5871
1987
Specification for bitumen mastic for tanking and damp proofing
IS : 6461 (Part 1)
1972
Glossary of terms relating to cement concrete – Concrete
aggregates
IS : 6461 (Part 2)
1972
Glossary of terms relating to cement concrete – Materials (other
that cement and aggregates)
IS : 6461 (Part 3)
1972
Glossary of terms relating to cement concrete – Concrete
reinforcement
IS : 6461 (Part 4)
1972
Glossary of terms relating to cement concrete – types of concrete
IS : 6461 (Part 5)
1972
Glossary of terms relating to cement concrete – Formwork for
concrete
IS : 6461 (Part 6)
1972
Glossary of terms relating to cement concrete – Equipment, tools
& plant
IS : 6461 (Part 7)
1973
Glossary of terms relating to cement concrete – Mixing, Laying,
Compaction, Curing and other construction aspects
IS : 6461 (Part 8)
1973
Glossary of terms relating to cement concrete – Properties of
Page 112 of 153
concrete
IS : 6461 (Part 9)
1973
Glossary of terms relating to cement concrete – Structural aspects
IS : 6461 (Part 1973
10)
Glossary of terms relating to cement concrete – Tests & testing
apparatus
IS : 6461 (Part 1973
11)
Glossary of terms relating to cement concrete – Prestressed
concrete
IS : 6461 (Part 1973
12)
Glossary of terms relating to cement concrete - Miscellenaneous
IS : 6494
1988
Code of practice for water proofing of underground water
reservoirs and swimming pools.
IS : 6509
1985
Code of practice for installation of joints in concrete pavements.
IS : 7193
1994
Specification for glass fiber base coal-tar pitch and bitumen felts.
IS : 7293
1974
Safety code for working with construction machinery.
IS : 7634 (Part 3)
2003
Code of practice for Plastic pipe selection, handling, storage and
installation for potable water supplies – Laying and jointing of
PVC pipes
IS : 7861 (Parts I)
1975
Code of practice for extreme weather concreting – Recommended
practice for hot weather concreting
IS : 7861 (Parts 1981
II)
Code of practice for extreme weather concreting – Recommended
practice for cold weather concreting
IS: 8042
1989
Specification for White Portland cement
IS: 8043
1991
Specification for hydrophobic Portland cement
IS: 8112
1989
Specification for 43 Grade Ordinary Portland Cement
IS : 9103
1999
Specification for concrete admixtures
IS : 9417
1989
Recommendations for welding cold-worked steel bars for
reinforced concrete construction.
IS : 9595
1996
Recommendations for metal-arc welding of carbon and carbon
manganese steels.
IS : 10262
1982
Recommended guidelines for concrete mix design.
IS : 11384
1985
Code of practice for composite construction in structural steel and
Page 113 of 153
concrete.
IS : 12118
1987
Specification for two-part poly-sulphide based sealants – General
requirements
IS : 12118
1987
Specification for two-part poly-sulphide based sealants – Methods
of test
IS : 12200
2001
Code of practice for provision of water stops at transverse
construction joints in masonry and concrete dams
IS : 12269
1987
Specification for 53 Grade ordinary Portland cement.
IS: 12330
1988
Sulphate resisting Portland Cement
IS : 12600
1989
Specification for low heat Portland cement
SP : 23
1982
Handbook of concrete mixes.
SP : 24
1983
Explanatory Handbook on IS: 456
SP : 34
1987
Handbook on concrete reinforcement and detailing.
4.0
MATERIALS
4.1
General:
4.1.1
All the materials used in the manufacture of concrete shall be in accordance with the
Technical Specification for Properties, Storage and Handling of Common Building
Materials, which shall be deemed to form a part of this specification.
4.1.2
The Consultant shall have the right to inspect the sources of materials, the layout and
operation of procurement and storage of materials, the concrete batching and mixing
equipments and the quality control system. Such an inspection shall be arranged by the
contractor and the Consultant s approval shall be obtained prior to starting the work.
4.2
Aggregates
4.2.1
Aggregate in general designates both fine and coarse inert materials used in the
manufacture of concrete. Coarse Aggregate is faction retained on 4.75 mm IS sieve. Fine
Aggregate is faction which passes through 4.75 mm IS sieve.
4.2.2
Aggregate shall consist of natural sand, crushed stone and gravel from a source known to
produce satisfactory aggregate for concrete and shall be chemically inert, strong, hard,
Page 114 of 153
durable against weathering, of limited porosity and free from deleterious materials that
may cause corrosion to the reinforcement or may impair the strength and / or durability of
concrete. Aggregates shall conform to I.S. 383
4.2.3
Properties: Aggregates with a specific gravity below 2.6 shall not be used without special
permission of the Consultant. Machine-made sand will be acceptable provided the
constituent (rock/gravel) is sound, hard, dense and is acceptable to the Consultant. Sand,
natural gravel and crushed rock shall be prepared for use by such screening or washing,
or both, as necessary to remove all objectionable foreign matter.
4.2.4
The coarse aggregate and fine aggregate shall be tested from time to time as required by
the Consultant to ascertain its suitability for use in construction and the charges for
testing aggregate shall be born by the contractor as specified herein after. Sampling of the
aggregates for mix design and determination of suitability shall be taken under the
supervision of the Consultant and delivered to the laboratory, well in advance of the
schedule placing of concrete. Records of tests which have been made on proposed
aggregates and on concrete made from this source of aggregates shall be furnished to the
Consultant in advance of the work for use, in determining suitability of the proposed
aggregate.
4.2.5
The grading of aggregates shall be such as to produce a dense concrete of specified
strength and consistency that will work readily into position without segregation and shall
be based on the “mix design” and preliminary test on concrete specified herein-after.
4.2.6
Grading of Coarse Aggregate : Coarse aggregates shall be either in single or graded, in
both the cases. The grading shall be within the following limits.
IS Sieve
Designa
tion
Percentage passing for single sized aggregates of
nominal size
63
40
20
16
12.5
mm
mm
mm
mm
mm
Percentage passing for graded
aggregates of nominal size
10 mm
40
20 mm
16
12.5
mm
mm
mm
75mm
100
-
-
-
-
-
-
-
-
-
63mm
85-
100
-
-
-
-
100
-
-
-
85-
100
-
-
-
95-
100
-
-
100
37.5mm
0-30
Page 115 of 153
100
19mm
0-5
0-20
100
85-
100
-
-
30-70
95-100
100
100
85-
100
-
-
-
90-100
-
100
16mm
-
-
-
100
11.2mm
-
-
-
-
85-100
100
-
-
-
90-100
9.5mm
-
0-5
0-20
0-30
0-45
85-100
10-35
25-55
30-70
40-85
4.75mm
-
0-5
0-5
0-10
0-20
0-20
0-5
0-10
0-10
0-10
2.36mm
-
-
-
-
0-5
0-5
-
-
-
-
4.2.7
Foreign Material Limitations: The percentages of deleterious substances in the coarse
aggregate delivered to the mixer shall not exceed the following :
Percentage by weight
of aggregates
Substances
4.2.8
Uncrushed
Crushed
i)
Material finer than 75 micron IS Sieve.
3.00
3.00
ii)
Coal and lignite
1.00
1.00
iii)
Clay lumps
1.00
1.00
iv)
Soft fragments
3.00
--
v)
Total of all the above substances
5.00
5.00
Grading of fine aggregate shall be within the limits indicated hereunder :
Page 116 of 153
4.2.9
4.2.10
IS Sieve Designation
Percentage Passing for
Grading
Grading
Grading
Zone-I
Zone-II
Zone-IIII
Grading
Zone-IV
10 mm
100
100
100
100
4.75 mm
90-100
90-100
90-100
95-100
2.36 mm
60-95
75-100
85-100
95-100
1.18 mm
30-70
55-90
75-100
90-100
600 micron
15-34
35-59
60-79
80-100
300 micron
5-20
8-30
8-30
20-65
150 micron
0-10
0-10
0-10
0-15
Foreign Material Limitations : The percentages of deleterious substances in fine aggregate,
delivered to the mixer shall not exceed the following :
Substances
Percent by weight
Uncrushed
Crushed
i)
Material finer than 75 micro IS
sieve
3.00
15.00
ii)
Shale
1.00
--
iii)
Coal and lignite
1.00
1.00
iv)
Clay lumps
1.00
1.00
v)
Total of all above substances 5.00
including items (I) to (iv) for
uncrushed sand and items (iii) and
(iv) for crushed sand
2.00
Fineness Modulus : The fine aggregate shall have a fineness modulus of not less than 2.2 or
more than 3.2. The fineness modulus is determined by adding the cumulative percentages
Page 117 of 153
retained on the following I.S. sieve sizes (4.75 mm, 2.36 mm, 1.18 mm, 600 micron, 300
micron and 150 micron) and dividing the sum by 100.
4.2.11
Storage of aggregates: All coarse and fine aggregates shall be stacked separately in stock
piles in the material yard near the work site in bins properly constructed to avoid inter mixing
of different aggregates. Contamination with foreign materials and earth during storage and
while heaping the materials shall be avoided. The aggregate must be of specified quality not
only at the time of receiving at site but also at the time of loading into mixer. Rakers shall be
used for lifting the coarse aggregate from bins or stock piles. Coarse aggregate shall be piled
in layers not exceeding 1.00 metres in height to prevent conning or segregation. Each layer
shall cover the entire area of the stock pile before succeeding layers are started. Aggregates
that have become segregated shall be rejected. Rejected material after re-mixing may be
accepted, if subsequent tests demonstrate conformity with required gradation.
4.3
Cement
4.3.1
The cement generally used shall be the Ordinary Portland cement 43 / 53 grade or PPC. However,
any special type of cement such as High strength cement or sulphate resisting cement may be
used under specific circumstances.
4.3.2
Cement unless otherwise specified or called for by the Consultant shall be measured in 50 kg
bags. Use of bulk cement will be permitted only with the approval of the Consultant. Changing
of brands of type of cement within the same structure will not be permitted. Joint account of
cement consumed at site for every day for items of work carried shall be maintained by the
Contractor for verification to ensure effective control on quality of work.
4.3.3
A certified report attesting to the conforming of the cement to IS specifications by the cement
manufacturer‟s chemist shall be furnished to the Consultant, if demanded. Should at any time the
Consultant have reasons to consider that any cement is defective, then irrespective of its origin
and / or manufacturers test certificate, such cement shall be tested immediately at a National Test
Laboratory / Departmental Laboratory or such approved laboratory, and until the results of such
tests are found satisfactory, it shall not be used in any work. Cement held in store for a period of
ninety (90) days or longer shall be retested before use in work.
4.3.4
The contractor shall make his own arrangements for the storage of adequate quantity of cement.
If supplies are arranged by the Department, cement will be issued in quantities to cover work
requirements of one month or more, as deemed fit by the Consultant and it will be the
responsibility of the contractor to ensure adequate and proper storage, which will provide
complete protection from dampness, contamination and minimize caking and false set. Cement
bags shall be stored in a dry enclosed shed (storage under tarpaulins will not be permitted), well
away from the outer walls and insulated from the floor to avoid contact with moisture from
ground and so arranged as to provide ready access. Damaged or reclaimed or partly set cement
will not be permitted to be used and shall be removed from the site. The storage arrangements
shall be such that there is no dead storage. No more than 12 bags shall be stacked in any tier.
The storage arrangement shall be got approved by the Consultant. Consignments in cement shall
be stored as received and shall be consumed in the order of their delivery.
Page 118 of 153
4.4
Reinforcement
4.4.1
Steel reinforcement bars for concrete shall be either cold twisted high yield strength deformed
bars conforming to IS 1786 or TMT bars with strength requirements conforming to IS 1786
manufactured by SAIL, TATA or RINL. The grade of steel shall be as shown in the drawings, or
as mentioned in the schedule of items or as directed by Consultant.
4.4.2
Storage: Steel reinforcement shall be stored in such a manner that they are not in direct contact
with ground but stacked on top of an arrangement of timbers sleepers or the like. Bars of
different classifications and sizes shall be stored separately. In cases of long storage or in coastal
areas, reinforcement shall be stacked above ground level by at least 15 cm, and a coat of cement
wash shall be given to prevent scaling and rusting at no extra cost to the owner. Fabricated
reinforcement shall be carefully stored to prevent, distortion, corrosion and deteriorations.
4.4.3
Contractor shall submit the manufacturers test certificate for steel. Random tests on steel
supplied by contractor may be performed if the Consultant so desires as per relevant Indian
Standards. All costs incidental to such tests shall be at contractors expense. Steel not conforming
to specifications shall be rejected.
4.5
4.5.1
Water
Water used for mixing and curing shall be clean and free from injurious amounts of oils, acids,
alkalis, sugar, organic materials or other substances that may be deleterious to concrete or steel.
Potable water is generally considered satisfactory for mixing concrete. The maximum permissible
values of impurities shall be as given in clause no. 5.4 of lS:456.
4.5.2
In case of doubt regarding development of strength, the suitability of water for making concrete
shall be ascertained by the compressive strength and initial setting time tests specified in lS:456.
4.5.3
Average 28 days compressive strength of atleast three 150 mm concrete cubes prepared with
water proposed to be used shall not be less than 90% of the average strength of three similar
concrete cubes -prepared with distilled water. The cubes shall be prepared, cured and tested in
accordance with IS:456.
4.5.4
The initial setting time of a concrete test block made with the appropriate cement and the water
proposed to be used shall not be less than 30 minutes and shall not differ by + 30 minutes from
the initial setting time of control test block prepared with the same cement and distilled water.
The test shall be carried out as per IS:4031.
4.5.5
Where concrete, made from water, proposed to be used does not satisfy the above requirements
and/or contains an excess of acid, alkali, sugar, salt or other deleterious, substances, then the
Consultant may refuse to permit its use. Sea water shall not be used for curing and mixing in
concrete.
Page 119 of 153
4.5.6
Testing of water shall be done at intervals indicated by Consultant. The sample of water taken for
testing shall be typical of the water proposed to be used for concreting, due account being paid to
seasonal variation. The samples shall not receive any treatment before testing other than that
envisaged in the regular supply of water proposed for use in concrete. The sample shall be stored
in a clean container previously rinsed out with similar water. The following concentrations
represent the maximum permissible values.
a)
Limits of acidity : To neutralize 200 ml sample of water, using phenolphthalein as an
indicator, it should not require more than 2 ml of 0.1 normal NaOH. The details of test
shall be as given in IS: 3025 (Part 22).
b)
Limits of alkalinity : To neutralize 200 ml sample of water, using methyl orange as an
indicator, it should not require more than 10ml of 0.1 normal HCL. The details of test
shall be as given in IS : 3025 (Part 23).
c)
Percentage of solids shall not exceed the following :
Organic
0.02% (200 mg/litre)
Inorganic
0.30% (3000 mg/litre)
Sulphates (as SO4)
0.05% (500 mg/litre)
Alkali chlorides (as cl)
0.20% (2000 mg/litre) for plain concrete work
&
0.10% (1000 mg/litre) for reinforced concrete
work
Suspended matter
0.20% (2000 mg/litre)
4.6
Admixtures
4.6.1
Admixtures in concrete for promoting workability, entraining air for similar purposes may be
used only after the written permission from the Consultant is obtained. These shall be free
from injurious amount of chloride, etc. Addition of admixtures should not reduce the specified
strength or durability of concrete and should not have detrimental effect on reinforcement. The
admixtures shall conform to lS:9103 and shall be of proven make and from a reputed
manufacturer. Calcium chloride as accelerating admixture is not permitted to be used other
than in mass concrete works. The Contractor shall produce latest test results carried out at
approved Government Test Houses for the approval of the Consultant, before use.
4.7
Embedded parts
4.7.1
Steel for light structural work and for preparation of inserts and embedments shall conform to
IS:2062.
Page 120 of 153
4.7.2
Bolts to be embedded in concrete shall, unless otherwise detailed in drawings, conform to
IS:5624. Material for bolts, shall, unless otherwise mentioned in drawings or the schedule of
items, be corrosive resistant/coated steel conforming to IS:2062.
4.7.3
Nuts and locknuts shall conform to IS:1363 (Part 1 to 3) for diameters 6 to 39 and IS 3138 for
Hexagon Bolts and Nuts (M-42 to M-150)”.
4.7.4
Plain washers shall conform to IS:2016 and spring washers shall conform to IS:3063.
4.7.5
Steel pipe sleeves shall conform to Medium class of IS: 1161.
4.8
Filling material
4.8.1
General: Filling material shall conform to what is shown in drawing, described in the
Schedule of Items or otherwise directed by the Consultant. Earth or sand for filling under
floors shall correspond to those described elsewhere in these specification.
4.8.2
Mastic Bitumen: Mastic Bitumen shall conform to IS: 3037 or IS: 5871 as appropriate.
4.8.3
Flexible Boards: Flexible boards for use in expansion joints shall correspond to the description
given in drawing or the Schedule of Items or the instruction of Consultant.
5.0
GRADES OF CONCRETE
5.0.1
Concrete shall be in grades as tabulated below:
Grade Designation
Specified Characteristic compressive
strength at 28 days (N/mm2)
M10
10
M15
15
M20
20
M25
25
M30
30
M35
35
M40
40
Page 121 of 153
5.0.2
The characteristic strength is defined as the strength of material below which not more than
5% of the test results are expected to fall.
5.0.3
In the designation of a concrete mix, latter M refers to the mix and the number to the specified
characteristic compressive strength of 15 cm cubes at 28 days.
5.0.4
Minimum grades of concrete to be followed shall be as per guidelines of Table 5 of IS: 456
unless otherwise mentioned in the drawings/ schedule of items. Concrete leaner than those
given above may be used for lean concerte, mudmat, or for foundations of masonry walls.
5.1
Concrete mix proportioning
5.1.1
Concrete mix proportions shall be selected based on the requirements of workability, strength,
and durability. The proportions of cement, aggregates and water shall be determined either by
designing the mix only. Adopting nominal mix is limited to leveling courses only. Design mix
concrete is designated as M20, M25, etc. and Nominal mix Concrete is designated as 1:2:4,
1:3:6, 1:4:8 or 1:5:10. The proportions referred to is by weight (mass) and not by volume. Use
of volumetric mix concrete shall not be permitted.
5.1.2
Workability of concrete
a)
Workability of fresh concrete is mainly governed by placing conditions and compaction. The
degree of workability necessary to allow the concrete to be well compacted and to be worked
into the corners of formwork and around the reinforcement shall be as stipulated under clause
no. 7.0 of IS:456.
b)
The workability of concrete shall be checked at frequent intervals. The workability of concrete
measured in accordance with IS:1199 for every sample taken for testing shall be recorded with
the corresponding cube test result.
c)
Not withstanding the above, the slump to be maintained for work in progress shall be as per
directions of the Consultant.
d)
Consultant may permit use of plastisizers for improving workability. Use of certain other
admixtures such has water proofing compounds also have an effect on workability and shall be
considered during mix design.
5.1.3
Durability of concrete:
Page 122 of 153
a)
The durability of concrete is mainly governed by the permeability of concrete. Dense concrete
is least permeable. In addition, cement content and water-cement ration and compaction of
concrete play a major role in producing impermeable concrete.
b)
Durability requirements is decided depending on the exposure conditions as stipulated in
clause 8.2 of IS 456. is to be taken into account while designing the mix. For given
aggregates, the cement content should be sufficient to make sufficiently low water cement
ratio and table 5 of IS: 456-2000 shall be taken as guideline for durability considerations.
c)
Stipulations of minimum cement content and limiting water cement ratio should be considered
during design of mix.
5.1.4
Design Mix Concrete
a)
Design Mix Concrete shall be used for all reinforced concrete works. The mix proportions
shall be as per mix design, designed for each grade of concrete, workability and durability
requirements. The characteristic strength shall not be less than the appropriate values given in
Table-2 of IS:456:2000.
b)
In proportioning concrete, the quantity of both cement and aggregates shall be determined by
mass. Water shall be either measured by volume in calibrated tanks or weighed. All measuring
equipment at site shall be maintained in a clean and serviceable condition, and their accuracy
shall be periodically checked.
c)
To keep the water-cement ratio to the designed value, allowance shall be made for the
moisture contents in both fine and coarse aggregates and determination of the same in
accordance with lS:2386 Part (III) shall be made as frequently as directed by the Consultant..
d)
With the permission of the Consultant, for any of the above mentioned grades of concrete, if
the water quantity has to be increased, proportionately cement quantity shall also be increased,
to keep the ratio of water to Cement same as adopted in mix design for the corresponding
grade of concrete. The extra cement required on account of this shall be at no extra cost to
Owner.
e)
At the beginning of the project, if so desired by the contractor, he/they may be allowed by the
Consultant , till the designed mix is obtained, to carry out the reinforced concrete work in
foundation and plinth as per equivalent nominal mix against the specified design mix concrete
as per IS codes. However, all other specification for design mix shall govern for nominal mix
also and nothing extra shall be paid for use of extra cement or else on this account whether the
cement is supplied by the Owner or procured by the contractor.
5.1.5
Mix design: Mix design shall generally be done at any of the approved laboratory. The
following is the guideline to be followed:
Page 123 of 153
a)
IS:10262 shall be followed as general guidance for mix design. The minimum value of target
strength of design mix of various grades of concrete shall be as per clause no. 9.2 of IS:456.
However, the Consultant may allow change in target strength values based on adequate
numbers of works test results.
b)
Minimum cement content from durability consideration for different exposures and sulphate
attack shall be as given in Table-4 and 5 of IS:456. In case higher value is obtained from
strength consideration, same shall be provided.
c)
Preliminary tests/trial mix, as specified or as required by the Consultant, shall be carried out
sufficiently ahead of the actual commencement of the work with different grades of concrete
made from representative samples of aggregates and cement expected to be used on the works.
These tests are to be conducted to arrive at the grading of aggregates, water-cement ratio,
workability and the quantity of cement required to give Preliminary (target) compressive
strengths as specified in clause 9.2 of IS 456.
d)
At least four trial mixes are to be made and minimum six test cubes taken for each trial mix
noting the slump for each type of mix. The cubes shall then be properly cured and three cubes
for each mix shall be tested in a laboratory (approved by the Consultant) at 7 days and others
at 28 days for obtaining the compressive strength. The test reports shall be submitted to the
Consultant. The design mix particulars shall indicate, with the help of graphs and curves etc.
the extent of variation in the grading of aggregates which can be allowed. While designing
mixes, over wet mixes shall be avoided. For the structures, where assessment of early strength
is required the concrete cubes shall also be tested for early age strength at 1 day and 3 days for
establishing the values.
d)
The Contractor shall submit the test reports of mix design to the Consultant for his review,
indicating design criteria, analysis and proportioning of materials, etc. On the basis of the
above test reports, a mix proportion by mass and the water-cement ratio, shall be determined
by the Contractor such that concrete prepared with this mix will yield the desired characteristic
strength and shall have suitable workability. The mix design to be adopted on the works shall
be subject to the approval of the Consultant. The proportions, once decided for different grades
of concrete, shall be adhered to, during all concreting operations as long as the quality of the
materials does not change. If, however, at any time, the quality of materials being used has
changed from those for Preliminary mix design, or there is a change either in the required
strength of concrete, or water-cement ratio or workability, the Contractor shall have to make
similar trial mixes and Preliminary tests to ascertain the revised mix proportions and watercement ratio to be used for obtaining the desired strength and consistency.
e)
The entire cost of all the trial mixes including all the preparatory works for trial mixes,
preparation of test cubes and their testing shall be borne by the Contractor.
5.1.6
Nominal mix Concrete
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a)
Nominal mix concrete shall be used only for plain cement concrete works and where shown on
drawings or specifically allowed by the Consultant. Such concrete shall not require preparation
of trial mixes and all such concrete shall be mixed in a mechanical mixer. Proportions for
nominal mix concrete shall be according to Table-9 of IS:456.
b)
The proportion of mix may be slightly adjusted within limits, keeping the total value of
aggregates to a given quantity of cement constant to suit the sieve analysis of both the
aggregates. Cement shall on no account be measured by volume, but it shall always be used
directly from the bags (i.e. 50 kg/bag). The proportion of cement, sand, aggregate and water
for concrete of proportion 1:5:10, 1:4:8, 1:3:6 & 1:2:4 by volume shall generally consist of
quantities as given below :
Quantity of materials used per bag of cement
Proportion of
Ingre
c)
Cement
Fine
aggregate
(sand)
Coarse
aggregate
Total of fine
and coarse
aggregates
Water
1:5:10
1
170 kg.
340 kg.
800 kg.
60 ltrs.
1:4:8
1
130 kg.
272 kg.
625 kg.
45 ltrs.
1:3:6
1
102 kg.
204 kg.
480 kg.
34 ltrs.
1:2:4
1
68 kg
136 ltrs.
350 kg.
32 ltrs.
The quantity of water used shall be such as to produce concrete of consistency required by the
particular class of work and shall be decided by the use of slump cone. Sufficient care should
be taken to see that no excess quantity of water is used. The final proportion of the aggregate
and quantity of water shall be decided by the Consultant on the basis of test in each case. The
for each class of work shall in general be as follows:
Type of concrete
Max slump (in mm)
Mass concrete
50
Concrete below water proofing treatment
50
Coping
25
Floor paving
50
Page 125 of 153
d)
As a general guidance the Nominal mix concrete of mix proportion 1:5:10 shall approximately
correspond to grade M5, 1:4:8 shall correspond to grade M7.5, 1:3:6 to grade M10 and 1:2:4
to grade M15 of IS:456.
e)
If fine aggregates are moist, the amount of surface water shall be determined. Also an
allowance shall be made for bulking in case of volume batching, in accordance with IS:2386
(Part-Ill). Allowance shall also be made for surface water present in the aggregates, when
computing the water requirement. In the absence of exact data the amount of surface water
may be estimated as follows:
Aggregate
Very wet sand
Moderately wet sand
Moist sand
Moist gravel or crushed rock
Approximate quantity of surface water
Percentage by mass
l/ cum
7.5
120
5.0
80
2.5
40
1.25-2.5
20-40
f)
If nominal mix Concrete made in accordance with specified proportions does not yield the
specified strength of the corresponding grade and fails to satisfy the requirements of
“acceptance criteria for concrete” as specified in IS:456, such concrete shall be treated in the
following manner:
i)
In case the Consultant is satisfied that lower strength of concrete is attributed to material and
workmanship of the Contractor, then such concrete shall be replaced by concrete of specified
strength. The Consultant may, however, also accept such lower strength concrete but such
lower strength concrete shall be classified as belonging to the appropriate lower grade
proportion.
ii)
In case the Consultant is satisfied that lower strength of concrete is not attributable to the
Contractor, he may direct in writing to increase the cement content to obtain specified strength
at no extra cost to Owner. The use of richer mix shall be continued until the Consultant
instructs otherwise.
g)
Nominal mix proportion shall not be classified as higher grade proportion either on the ground
that the test strengths are higher than the minimum specified or in the case where the
Consultant directs use of additional cement over the quantity specified for the particular mix
proportion to achieve the minimum specified strength.
h)
However, only in some exceptional cases including concreting in some isolated areas, the
Consultant may allow the quantity of aggregates to be determined by an equivalent volume
basis after the relationship between weight and volume is well established by trials and the
same shall be verified frequently.
Page 126 of 153
SPECIAL CONDITIONS
OF
CONTRACT
Page 127 of 153
1.0
GENERAL
1.1
Special Conditions of Contract (SCC) shall be read in conjunction with the General
Conditions of Contract (GCC) also referred to as General Terms & Conditions of
Works Contract, Schedule of Quantities, specifications of work, drawings and any
other document forming part of this Contract wherever the context so requires.
1.2
Notwithstanding the sub-division of the document into these separate sections and
volumes, every part of each shall be deemed to be supplementary of every other
part and shall be read with and into the Contract so far as it may be practicable
to do so.
1.3
Where any portion of the GCC is repugnant to or at variance with any provisions
of the Special Conditions of Contract, then unless a different intention appears,
the provision(s) of the Special Conditions of Contract shall be deemed to override
the provision(s) of GCC only to the extent that such repugnancy or variations in
the Special Conditions of Contract are not possible of being reconciled with the
provisions of GCC.
1.4
Wherever it is stated in this Bidding Document that such and such a supply is to
be affected or such and such a work is to be carried out, it shall be understood
that the same shall be affected and /or carried out by the Contractor at his own
cost, unless a different intention is specifically and expressly stated herein or
otherwise explicit from the context. Contract Price shall be deemed to have included
such cost.
1.5
The materials, design & workmanship shall satisfy the applicable relevant Indian
Standards, the job specifications contained herein & codes referred to. Where the
job specifications stipulate requirements in addition to those contained in the
standard codes and specifications, these additional requirements shall also be
satisfied. In the absence of any Standard / Specifications / Codes of practice for
detailed specifications covering any part of the work covered in this bidding
document, the instructions / directions of Engineer-in-Charge will be binding upon
the Contractor.
1.6
In case of contradiction between relevant Indian standards, GCC, Special Conditions of
Contract, Specifications, Drawings and Schedule of Rates, the following shall
prevail in order of precedence.
i)
ii)
Detailed Purchase Order along with Statement of Agreed Variations, if any, and its
enclosures .
Fax of Intent (FOI)/Letter of Intent(LOI)
Page 128 of 153
iii)
iv)
v)
vi)
vii)
viii)
Schedule of Quantities AND Technical specifications
Special Conditions of Contract
Drawings/data sheets/job procedures
Instructions to Bidders
General Conditions of Contract
Relevant Indian Standards.
1.7
SAFETY, FIRE FIGHTING AND SPECIFIC REQUIREMENTS OF HPCL
1.7.1
Contractor shall provide adequate number of standard lengths of IS Stamped Fire hoses,
IS Stamped DCP Fire extinguishers, fire buckets with sand and nozzles. These items can
be taken back by the Contractor after completion of work. Sand shall also be maintained
dry by the Contractor with fresh supply, whenever required. Work permit may not be
issued by HPCL in the absence of above items.
1.7.2
Safety Helmets shall be provided to all the employees of Contractor including that of his
labour contractors.
1.7.3
Safety Belts and Harnesses shall be provided by the Contractor in adequate number for
the workers working at heights.
1.7.4
Proper earthing shall be provided for all equipments and generators.
2.0
THE WORK
2.1
Scope of Work & Scope of Supply
2.1.1
2.2
The scope of work and Scope of Supply covered in this Contract will
be as described in Scope of work provided in the Instructions to bidders,
Schedule of Quantities, Technical Specifications, Drawings, etc.
Time Schedule
The Completion period for this job shall be 4 (FOUR) Months from the date of LOI.
2.2.1
Time is the essence of this Contract. The period of completion given includes the
time required for mobilization as well as testing, rectifications, if any, retesting,
demobilization and completion in all respects to the satisfaction of the Engineerin-Charge.
2.2.2
A joint program of execution of work will be prepared by the Engineer-in-Charge
and Contractor. This program will take into account the time of completion period of the
Contract.
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2.2.3
Monthly execution program will be drawn up by the Engineer-in-Charge jointly
with the Contractor based on availability of materials, work fronts and the joint
program of execution as referred to above. The Contractor shall scrupulously
adhere to the Targets / Program by deploying adequate personnel, Construction
Equipment, Tools and Tackles and also by Timely Supply of required materials
coming within his scope of supply as per Contract. In all matters concerning the
extent of target set out in the monthly program and the degree of achievement,
the decision of the Engineer-in-Charge will be final and binding upon the
Contractor.
2.2.4
Contractor shall give every day category-wise labour and equipment deployment
report along with the progress of work done on previous day in the proforma
prescribed by the Engineer-in-Charge.
2.3
Measurement of Works
2.3.1
Mode of measurement will be as specified in Specifications or SOR.
2.4
Payment Terms
2.4.1
Payment will be released within 15 days of submission of duly certified Running
Account Bills at Disbursement section at Mumbai after deduction of WCST(Works
Contract Sales Tax) or VAT whichever is applicable, IT(Income Tax) and any other
statutory deduction as applicable from time to time, Any MRR(Materials Received
Report- An internal document forwarded by HPCL Site –in-Charge/ Engineer to
Disbursement Section along with Contractor‟s Bill and duly certified measurement sheets
for release of payment) Deductions, LD, etc. In case of Final Bill, Payment will be
released within 45 days of submission of duly certified Final Bill along with all requisite
documents, drawings, etc. Payment break up for various items covered in SOR/PRICED
BID is as indicated as Appendix 1 to SCC. No further alteration is permitted in approved
payment break up.
2.5
Temporary Works
2.5.1
All temporary works, enabling works, including dewatering of surface and subsoil
water, preparation and maintenance of temporary drains at the work site,
preparation and maintenance of approaches to working areas, adequate lighting,
wherever required, for execution of the work, shall be the responsibility of the
Contractor and all costs towards the same shall be deemed to have been included
in the quoted prices.
2.6
Quality Assurance
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2.6.1
Detailed quality assurance programme to be followed for the execution of Contract
under various divisions of works will be mutually discussed and agreed to.
2.6.2
The Contractor shall establish, document and maintain an effective quality
assurance system as outlined in the specifications and various codes and standards.
2.6.4
2.6.4
The Owner/Consultant or their representative shall reserve the right to
inspect/witness, review any or all stages of work at shop/site as deemed necessary
for quality assurance and / or timely completion of the work.
In case Contractor fails to follow the instructions of Engineer-in-Charge with
respect to above clauses, next payment due to him shall not be released unless
and until he complies with the instructions to the full satisfaction of Engineer-inCharge
2.7
Leads
2.7.1
For the various works, in case of contradiction, leads mentioned in the Schedule
of Quantities shall prevail over those indicated in the Technical specifications.
3.0
ROYALTY, INCOME TAX, SERVICE TAX AND PRICES
3.1
Royalty
3.1.1
All royalties etc., as may be required for any Borrow Areas, including right of way
etc., to be arranged by Contractor shall be deemed to have been included in the
quoted prices.
3.1.2
Contractor‟s quoted rates should include the royalty on different applicable items
as per the prevailing State Government rates. In case, Owner is able to obtain the
exemption of royalty from the State Government the Contractor shall pass on the
same to Owner for all the items involving royalty. Any increase in prevailing rate of
royalty shall be borne by the Contractor at no extra cost to the Owner.
3.2
Income Tax
3.2.1
Income Tax at the prevailing rate as applicable from time to time shall be deducted from
Contractor‟s Bills as per Income Tax Act and quoted rates shall be inclusive of this.
Owner will issue the TDS (Tax Deduction at Source) Certificate.
Firm Prices
3.3
3.3.1
The contract price shall remain firm and fixed till the completion of work in all
respects and no escalation in prices on any account shall be admissible to the
Contractor except for statutory variations as per General Terms and Conditions (GTC).
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4
4.1
PROVIDENT FUND,LABOUR, LABOUR LAWS AND SITE REQUIREMENTS
Provident Fund
4.1.1
The Contractor shall strictly comply with the provisions of Employees Provident
Fund Act and register himself with Regional Provident Fund Commissioner
(RPFC) before commencing work. The Contractor shall deposit Employees and
Employers contributions to the RPFC every month. The Contractor shall furnish
along with each Running bill, the challan / receipt for the payment made to the
RPFC for the preceding month. The Contractor shall furnish the code number
allotted by the RPFC Authority to the Engineer-in-Charge before commencing the
work.
4.1.2
In case the RPFC challan / receipt, as above, is not furnished, Owner shall deduct
16% (sixteen percent) of the payable amount from Contractor‟s running bill and
retain the same as a deposit. Such retained amounts shall be refunded to
Contractor on production of RPFC Challan / receipt for the period covered by the
related running bill.
4.2
Labour License
4.2.1
Before starting of work, Contractor shall obtain a license from concerned
authorities under the Contract Labour (Abolition and Regulation) Act 1970, and
furnish copy of the same to Owner.
4.3
Labour Relations
4.3.1
In case of labour unrest/labour dispute arising out of non-implementation of any
law, the responsibility shall solely lie with the Contractor and they shall
remove/resolve the same satisfactorily at his cost and risk.
4.3.2
The Contractor shall at all times take all reasonable precautions to prevent any
unlawful, riotous or disorderly conduct by or amongst his staff and labour and to
preserve peace and protection of persons and property in the neighbourhoods of
the Works against such conduct.
4.4
4.4.1
Employment of Local Labour
The Contractor shall ensure that local labour skilled and / or unskilled, to the
extent available shall be employed in this work. In case of non – availability of
suitable labour in any category out of the above persons, labour from outside
may be employed.
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4.4.2
The Contractor shall not recruit personnel of any category from among those who
are already employed by other agencies working at site but shall make maximum
use of local labour available.
4.5
Site Cleaning
4.5.1
The Contractor shall clean and keep clean the work site from time to time to the
satisfaction of the Engineer-in-Charge for easy access to work site and to ensure
safe passage, movement and working.
4.5.2
The Contractor shall dispose off the unserviceable materials, debris etc., to the
earmarked area within the premises or any other location outside the premises as
decided by the Engineer-in-Charge. No extra payment shall be paid on this account.
4.5.3
Review/Approval of Drawings, Design and other documents submitted by
Contractor
4.5.3.1
HPCL/consultant will normally require and utilize a maximum time frame of seven (07)
working days from the date of Receipt for Review/Approval of Drawings, Design and
other documents submitted by Contractor. Upon Review of the submitted documents,
HPCL may give their comments and ask for redesign/ resubmission after necessary
rectifications/ modifications and the time frame of 7 working days will be applicable for
same.
4.6
Protection of Existing Facilities
4.6.1
Contractor shall obtain all clearance (work permit) from the Owner, as may be
required from time to time, prior to start of work. Work without permit shall
not be carried out within the existing premises.
4.6.2
Contractor
shall obtain plans and full details of all existing and planned
facilities/services/utilities from the Owner and shall follow these plans closely at
all times during the performance of work. Contractor shall be responsible for
location and protection of all facilities/utilities and structures at his own cost.
4.6.3
Despite all precautions, should any damage to any structure / utility etc. occur, the
Contractor shall contact the Owner / authority concerned and Contractor shall
forthwith carry out repair at his expenses under the direction and to the
satisfaction of Engineer-in-Charge and the Owner/concerned authority.
4.6.4
Contractor shall take all precautions to ensure that no damage is caused to the
existing facilities etc., during construction. Existing structures/facilities/utilities
damaged / disturbed during construction shall be repaired and restored to their
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original condition by Contractor after completion of construction to the complete
satisfaction of Owner.
4.7
Work Front
4.7.1
The work involved under this Contract may include such works as have to
be taken up and completed after other agencies have completed their jobs. The
Contractor will be required and bound to take up as and when the fronts are
available for the same and no claim of any sort whatsoever shall be admissible to
the Contractor on this account. Only extension of time limit shall be admissible,
if the availabilities of work fronts to the Contractor are delayed due to any
reason not attributable to the Contractor and the same is clearly recorded.
4.8
Site Facilities
4.8.1
The Contractor shall arrange for the following facilities at site, for workmen
deployed/engaged by him / his sub-contractor, at his own cost:
i)
ii)
iii)
iv)
4.9
Arrangement for First Aid.
Arrangement for clean & potable drinking water.
A crèche where 10 or more women workers are having children below the age
of 6 years.
Any other facility/utility as may be required under the Contract as per the
existing legislation/regulations.
Contractor’s Site Office and Stores
4.9.1
Owner shall provide land only for contractor‟s site office and stores and fabrication
yard, if any at site. However, same shall be dismantled prior to submission of Final Bill.
4.9.2
The Contractor shall remove all temporary buildings / facilities etc., before leaving
the site after completion of works in all respect.
4.10
4.10.1
Construction Power and Water
Owner shall not provide power and the Contractor shall be exclusively responsible
to make his own arrangements for supply of power, without any extra cost to the
Owner.
4.10.2
Water required for the works shall be arranged by the Contractor. The contractor has to
make all necessary arrangement for drawing water including making temporary
storage, pumping etc.
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4.10.3
CEMENT :
Cement required for execution of the job under the entire scope of work ( other
than for Ready Mix Concrete where the cement is from the RMC manufacturer
scope ) contained in this tender shall be supplied at provided at site by the
contractor at his own cost. Contractor to include the cost of cement required for
execution of various items included in this tender in their quoted rates. Cement shall be
of 43 / 53 Grade PPC as specified in the technical specifications of Ultra Tech Cement/
Gujarat Ambuja / ACC / Birla/Lafarge Makes only and shall conform to IS relevent
standards of latest edition.. Contractor to produce Invoice Copy of every batch of cement
procured at site to EIC. However, HPCL‟s decision with regard to the specific brand of
cement to be procured for the execution of the work shall be final and binding on the
contractor.
Cement shall be procured and brought to site atleast 15 days in advance. Sample from
every batch of cement brought to site shall be tested for standard test as per the
specification of relevant IS standards in approved Laboratory and Test Certificate shall be
submitted to EIC for verification. Only after obtaining approval of EIC, cement shall be
put into use. Manufacturer‟s Batch Test Certificates backed by Factory‟s Invoice for the
batch will also be acceptable for approval of cement. Contractor shall bring cement well
in advance before full consumption of previous lot. No claims for extension of
completion period for stoppage of work on account of non-availability of cement / delays
is testing procedures will be entertained/accepted by HPCL.
For all computation purposes, the theoretical cement consumption shall be considered as
per CPWD standards. Cement cost shall be recovered for under-consumption at the penal
rate of Rs.7000/- per MT. Empty cement bag shall be the property of the contractor.
Theoretical weight of cement in a bag will be considered as 50 Kgs. Bags weighing upto
4% less shall be accepted by HPCL. Any shortage in weight of any cement bag by more
than 4% will be to contractor‟s account. Contractor shall maintain necessary weighing
scale at site for the purpose of random checking of the weight of cement bags by
representative of HPCL.
The contractor will be required to maintain a stock register for receipt, issuance and daily
consumption of cement at site. Cement shall be regulated on the basis of 1st receipt to go
as 1st issue. Cement not consumed within 3 months after bringing to site shall not be
used and shall be removed from site with prior written permission of EIC.
All RA bills including the final bills will be accompanied by Cement Consumption
Statements giving the detailed working of cement used.
Contractor shall construct suitable temporary godown at site for storage of cement under
his lock and key. The contractor will be fully responsible for safe custody of cement.
HPCL will not entertain any claims by the Contractor for theft, loss or damages to
cement. Contractor shall not remove from the site any cement bags at any time.
Permissible wastage shall be total 3% of the theoretical consumption. However, these
wastage shall be considered in excess of the theoretical quantity required for the various
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items of work. No extra payment will be made towards this wastage and the same will be
in the contractor‟s account. The contractor shall be penalised for any under-consumption
of cement at the rate of Rs7000/- per MT.
4.10.4
STEEL :
Entire quantity of reinforcement / structural steel required for the project shall be
supplied and provided at site by the contractor at his own cost. Contractor to include
the cost of steel reinforcement / structural steel required to be used against various items
of this scope of work in their quoted rates. HPCL shall not supply any reinforcement /
structural steel. The contractor shall make necessary arrangement at his own cost for
unloading, storage of steel in the open duly fenced under locking arrangement. The
reinforcement steel shall be procured from Tata/SAIL/Vizag Steel only as per SOR &
technical specifications and will produce invoice for the same to EIC for every batch of
procurement along with Manufacturer‟s Test Certificate.
In the case of steel reinforcement or structural steel the theoretical quantity of steel shall
be taken as the quantity required as per design or as authorised by Architect/Consultant
/HPCL‟s Engineer including authorised lap lengths/chairs etc. No further claim towards
additional wastage due to lap length / full length bars or other consideration including
rolling margin will be entertained. No payment will be made or measurement recorded
for binding wires which shall be of 18 SWG gauge and shall be provided by the
contractor.
For the purpose of dealing and accounting, only linear measurements will be taken and
any difference in weight based on linear measurement and actual weight shall be to
contractor‟s account. Quoted rate shall be deemed to include the above and the wastage
mentioned below. No claim whatsoever shall be entertained on account of wastage and
difference in weight as referred to above.
All binding wires required for tying the reinforcement in position etc. will be supplied by
the contractor. Cost of this binding wire and labour will be included in the item for
binding and placing reinforcement in position.
It will be necessary that the contractor get the steel tested at his own cost at a Govt.
approved laboratory as per the testing schedule or as per the EIC‟s advise, for strength
and other properties specified in IS – 1786 latest editioin before using it in the work.
The contractor will be required to maintain a register for recording details of steel receipt,
steel utilised and balance at site.
Final bill will be accompanied by steel consumption statement.
In every case, it shall be the contractor‟s responsibility to ensure the standard of quality
and the correctness of quantity of steel procured at site by him.
The permissible wastage (wastage defined as bars having less than 3 mt. Length) shall be
of 3% of theoretical consumption. Recovery for less consumption as per theoretical
consumption will be recovered at Rs.50,000/- per MT. All scrap (scrap defined as pieces
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of steel bars measuring less than 3 mt. in length) shall be the property of the contractor.
The wastage quantity shall not be considered to be included within the theoretical
quantity and no extra shall be payable on account of wastage.
4.11
Construction
4.11.1
Rules and Regulations
4.11.2
Contractor shall observe in addition to Codes specified in respective specification,
all national and local laws, ordinances, rules and regulations and requirements
pertaining to the work and shall be responsible for extra costs arising from
violations of the same.
5.0
Procedures
5.1
Various procedures and method statements to be adopted by Contractor during the
construction as required as per the respective specifications shall be submitted to
Engineer-in-Charge in due time for approval.
5.2
Security
5.2.1
As the premises will be protected area, entry into the area shall be restricted and
may be governed by issue of photo gate passes. The Contractor shall arrange to
obtain through the Engineer-in-Charge, well in advance, all necessary entry
permits/gate passes for his staffs and labourers and entry and exit of his men and
materials shall be subject to vigorous checking by the security staff. The
Contractor shall not be eligible for any claim or extension of time whatsoever on
this account.
5.2.2
It shall be the responsibility of the contractor to safeguard all his materials/owned from
theft, damage etc. For this purpose the contractor shall be allowed to keep his own
security inside HPCL premises
5.3
Drawings and Documents
5.3.1
Drawings accompanying the Bidding Document are indicative of scope of work and
issued for bidding purpose only. Purpose of these drawings is to enable the
bidder to make an offer in line with the requirements of the owner.
5.3.2
The contractor as per „scope of work‟ shall carry out preparation of detailed and
working drawings. Detailed construction layout drawings as needed shall be
prepared by contractor and got reviewed/approved by Engineer-in-Charge/Architect
before taking up the work.
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5.4
Rounding off
5.4.1
All payments to and recoveries from the Contractor shall be rounded off to the
nearest rupee. Wherever the amount to be paid / recovered consists of a fraction
of a rupee (paise), the amount shall be rounded off to the next higher rupee if
the fraction consists of 50 (fifty) paise or more and if the faction of a rupee is
less than 50 (fifty) paise, the same shall be ignored.
5.5
Contractor’s Billing System
5.5.1
HPCL will provide an approved format for Measurement sheets, Bill Summary and Bill
Abstract. Contractor has to ensure that these data are updated for each subsequent RA
and Final Bill.
5.5.1
HPCL will utilize these data for processing and verification
Contractor‟s bill.
5.6
Site Organization
5.6.1
The Contractor shall without prejudice to his overall responsibility to execute and
complete the works as per specifications and time schedule progressively deploy
adequate qualified and experienced personnel together with skilled / unskilled
manpower and augment the same as decided by Engineer-in-Charge depending on
the exigencies of work to suit the construction schedule without any additional
cost to Owner.
5.6.2
The Contractor shall provide all necessary superintendence during the execution of
the Works and as long thereafter as the Engineer-in-Charge may consider
necessary for the proper fulfilling of the Contractor‟s obligations under the
Contract Such superintendence shall be given by sufficient persons having
adequate knowledge of the operations to be carried out (including the methods
and techniques required, the hazards likely to be encountered and methods of
preventing accidents) for the satisfactory and safe execution of the Work. The
workmen deployed by the Contractor should also possess the necessary license
etc., if required under the existing laws, rules and regulations.
5.7
of
the
Additional / Extra Works
Owner reserves the right to execute any additional works / extra works, during the
execution of work, either by themselves or by appointing any other agency, even
though such works are incidental to and necessary for the completion of works
awarded to the Contractor.
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5.8
Responsibility of Contractor
5.8.1
It shall be the responsibility of the contractor to obtain the approval for any
revision and/or modifications decided by the contractor from the Owner / Engineerin-Charge before implementation. Also such revisions and / or modifications if
accepted / approved by the Owner / Engineer-in-Charge shall be carried out at no
extra cost to the owner. Any change required during functional requirements or
for efficient running of system, keeping the basic parameters unchanged and which
has not been indicated by the contractor in the data / drawings furnished along
with the offer shall be carried out by the contractor at no extra cost to the
owner.
5.8.2
All expenses towards mobilization at site and demobilization including bringing in
equipment, work force, materials, dismantling the equipment, clearing the site etc.
shall be deemed to be included in the prices quoted and no separate payments on
account of such expenses shall be entertained.
5.8.3
It shall be entirely the contractor‟s responsibility to provide, operate and maintain
all necessary construction equipment, steel scaffoldings and safety gadgets, cranes
and other lifting tackles, tools and appliances to perform the work in a workman
like and efficient manner and complete all the jobs as per time schedule.
5.8.4
Preparing approaches and working area for the movement of his men and machinery.
5.8.5
The procurement and supply in sequences and at the appropriate time of all
materials, and consumables shall be entirely the contractor‟s responsibility and his
rates for execution of work will be inclusive of supply of all these items.
5.9
Coordination with other agencies
5.9.1
Contractor shall be responsible for proper coordination with other agencies
operating at the site of work so that work may be carried out concurrently,
without any hindrance to others. The Engineer – in – Charge
shall resolve
disputes, if any, in this regard, and his decision shall be final and binding on the
Contractor.
5.10
Underground and overhead structures
5.10.1
The Contractor will familiarize himself with and obtain information and details
from the Owner in respect of all existing structures, and utilities existing at the
job site before commencing work. The Contractor shall execute the work in such
a manner that the said structures, utilities, etc. are not disturbed or damaged, and
shall indemnify and keep indemnified the Owner from and against any destruction
thereof or damages thereto.
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5.11
Documents required with final bill
5.11.1
Statement of final bills – issue of No Claim/ No Due Certificate
5.11.2
The Contractor shall furnish a No-Claim/No-Due declaration indicating that there are no
balance dues to his sub-vendor/sub-contractors/labour contractors along with the Final
Bill.
5.12
Working hours
5.12.1
Depending upon the requirement, time schedule / drawing/ programme and the
target set to complete the job in time, the works may also have to continue
beyond normal working hours/night hours / holidays or during such periods with out
causing any inconvenience to the neighbours/others with due permission from EIC, for
which no extra claim shall be entertained. However for all such working contractor‟s
responsible representative shall be available at site to receive the work permit to be issued
by HPCL. With out responsible representative of the contractor, no work shall be allowed
inside the premises.
6.0
TESTS, INSPECTION AND COMPLETION
6.1
Tests and Inspection
6.1.1
The Contractor shall carry out the various tests as enumerated in the technical
specifications of this Bidding Document and technical documents that will be
furnished to him during the performance of the work at no extra cost to the
Owner.
6.1.2
All the tests either on the field or at outside laboratories concerning the execution
of the work and supply of materials by the Contractor shall be carried out by
Contractor at his cost.
6.1.3
The work is subject to inspection at all times by the Engineer-in-Charge. The
Contractor shall carry out all instructions given during inspection and shall ensure
that the work is being carried out according to the technical specifications of this
bidding document, the technical documents that will be furnished to him during
performance of work and the relevant codes of practice.
6.1.4
Compressed air for carrying out works ,if required shall be arranged by the
Contractor at his own cost.
6.1.5
For material supplied by Owner, Contractor shall carry out the tests, if required
by the Engineer-in-Charge, and the cost of such tests shall be reimbursed by the
Owner at actual to the Contractor on production of documentary evidence.
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6.1.6
6.2
All results of inspection and tests will be recorded in the inspection reports,
proforma of which will be approved by the Engineer-in-Charge. These reports shall
form part of the completion documents. Any work not conforming to execution
drawings, specifications or codes shall be rejected and the Contractor shall carry
out the rectifications at his own cost.
Final Inspection
After completion of all tests as per specification the whole work w ill be subject to a
final inspection to ensure that job has been completed as per requirement. If any
defect is noticed, the Contractor will be notified by the Engineer-in-Charge and he
shall make good the defects with utmost speed. If however, the Contractor fails to
attend to these defects within a reasonable time (time period shall be fixed by the
Engineer-in-Charge) then Engineer-in-Charge may have defects rectified at
Contractor‟s cost.
6.3
Inspection of Supply Items
6.3.1
All inspection and tests on bought out items shall be made as required by
specifications forming part of this contract. Various stages of inspection and
testing shall be identified after receipt of Quality Assurance Programme from the
contractor / manufacturer.
6.3.2
Inspection calls shall be given for association of Owner , as per mutually agreed
programme in prescribed proforma , giving details of equipment and attaching
relevant test certificates and internal inspection report of the contractor. All
drawings, general arrangement and other contract drawings, specifications,
catalogues etc. pertaining to equipment offered for inspection shall be got
approved by Owner and copies shall be made available to Owner before hand for
undertaking inspection.
6.3.3
The contractor shall ensure full and free access to the inspection engineer of Owner
at the contractor‟s or their sub-contractor‟s premises at any time during contract
period to facilitate him to carry out inspection and testing assignments.
6.3.4
The contractor / sub – contractor shall provide all instruments, tools, necessary
testing and other inspection facilities to inspection engineer of Owner free of cost
for carrying out inspection.
6.3.5
Where facilities for testing do not exist in the contractor‟s / sub-contractor‟s
laboratories, samples and test pieces shall be drawn by the contractor / subcontractor in presence of Inspection Engineer of Owner and duly sealed by the later
and sent for tests in Government approved test house or any other testing
laboratories approved by the Inspection Engineer at the contractor‟s cost.
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6.3.6
The contractor shall comply with the instructions of the Inspection Engineer fully
and with promptitude.
6.3.7
The contractor shall ensure that the equipment / assemblies / component of the plant
and equipment required to be inspected are not assembled or dispatched before
inspection.
6.3.8
The contractor shall not offer equipment for inspection in painted conditions
unless otherwise agreed in writing with the Owner .
6.3.9
The contractor shall ensure that the parts once rejected by the inspection engineer
are not used in the manufacture of the plant and equipment. Where parts rejected
by the inspection engineer have been rectified or altered, such parts shall be
segregated for separate inspection and approval, before being used in the work.
6.3.10
On satisfactory completion of final inspection and testing, all accepted part of the
work and equipment shall be stamped suitably and inspection certificate shall be
stamped suitably and inspection certificate shall be issued in requisite copies for
all accepted items. For stage inspection and for rejected items, only inspection
memo shall be issued indicating therein the details of observations and remarks.
6.3.11
All inspections and tests shall be made as required by the specifications forming
part of this contract. Contractor shall advise HPCL in writing at least fifteen days
in advance of the date of final inspection / tests. Manufacturers inspection or
testing certificate for equipment and materials supplied may be considered for
acceptance, at the discretion of Engineer-in-Charge. All costs towards testing etc.
shall be borne by the contractor within their quoted rates.
6.4
6.4.1
Documentation
Completion Documents
The following documents shall also be submitted by the Contractor in triplicate
as part of completion documents :
a)
b)
c)
d)
e)
Test certificate for materials supplied by the Contractor.
Certified records of field tests on materials / equipment, as applicable.
Material appropriation statement as required.
Six sets of drawings showing therein the as built conditions of the work
duly approved by the Engineer-in-Charge along with one set of
reproducible on polyester film (drawings prepared by Contractor) along with
soft form of the same.
Other documents as mentioned in Technical Specification.
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6.4.2
“AS BUILT” Drawings
Upon completion of work, the Contractor shall complete all drawings to “As
built” status (including all vendor / Sub – vendor‟s drawings for bought
out items) and provide the Owner, the following :
a.
b.
7.0
7.1
7.1.1
7.2
One complete set of all original tracings / reproducible along with the soft form
of the same.
Six complete sets of prints.
OTHERS
Dispute Settlement between Govt. Dept. / PSU & PSE
In the event of any disputes or differences between the Contractor and the Owner,
if the Contractor is a Government department, a Government company or an
undertaking in the public sector, then such disputes or differences shall be
resolved amicably by mutual consultation or through the good offices or
empowered agencies of the Government. If such resolution is not possible, then
the unresolved disputes or differences shall be referred to arbitration of an
arbitrator to be nominated by the Secretary. Department of legal affairs (Law
Secretary) in terms of the Office Memorandum No. 55 / 1 / 75 – CF dated 19th
December 1975 issued by the Cabinet Secretariat (Dept. of Cabinet Affairs) as
modified from time to time. The Arbitration Conciliation Act 1996 shall not be
applicable to the arbitrator under this clause. The award of the arbitrator shall be
binding upon parties to the dispute, provided, however any party aggrieved by
such award may make a further reference for setting aside or revision of the
award to Law Secretary whose decision shall bind the parties finally and
conclusively.
Project Scheduling and Monitoring
7.2.1
The following schedules / documents / reports shall be prepared and submitted
by the CONTRACTOR for review / approval at various stages of the contract.
7.2.3
After placement of Purchase Order
Upon placement of Purchase Order, Contractor has to furnish a detailed bar chart within
15 days of issue of FOI/LOI.
7.2.4
7.2.4.1
Project Review Meetings
The CONTRACTOR shall present the programme and status at various review
meetings as required.
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Monthly Review Meeting
Level of Participation: Senior Officers of Owner & Contractor.
Agenda
a)Progress Status/ statistics.
b) Completion Outlook
c) Major hold ups / slippages.
.
d) Assistance required.
e) Critical issues.
f) Client query / approval.
Venue
7.2.5
: Site
Progress Reports
I)
a)
b)
c)
d)
e)
f)
Monthly Progress Report
This report shall be submitted in three copies on a monthly basis within
Ten calendar days from cut-off date as agreed upon, covering overall
scenario of the work. The report shall include but not be limited to the
following :
Brief introduction of the work.
Activities executed / achievements during the month.
Scheduled vs actual percentage progress and progress curves for subordering, manufacturing / delivery, sub-contracting, construction activities and
overall quantum wise status of purchase orders against scheduled.
Areas of concern / problems / hold ups, impact and action plans.
Resource deployment status.
Annexure giving status summary for Material Requisitions and deliveries,
sub-contracting and construction
Distribution: OWNER
II)
Two copies & One at Site.
Daily Report:
Daily report in duplicate as out lined in 2.2.4 of SCC and any other
additional
information/data/guideline/job procedure sought by Engineer-in-Charge shall be
submitted without fail to HPCL at site by contractor.
7.3
General Environment Requirement
The contractor has to ensure efficient use of natural resources like water, fuel oil
and lubricants. The contractor should ensure proper awareness to workers to
maintain a green and clean environment inside / outside the building premises. The
contractor must collect and dispose of all the waste and scrap materials at the
designated place only as directed by Engineer – in – Charge.
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7.4
DEFECT LIABILITY PERIOD/Warranty Period
As per clause No. 5n of GTC.
7.5
Form C/D etc will not be issued by M/s HPCL
APPENDIX -1 TO SCC
TERMS OF PAYMENTS
1.1
The basis and terms of payment without prejudice to any other mode of recovery
available to Owner, shall be as given below :
1.2
The Contractor shall be paid monthly running account bills at stages of
completion of individual item / work, based on the joint measurement, in the
following manner after deductions of necessary dues payable by Contractor to the
Owner such as Retention money, Taxes, Duties etc. in accordance with various
provisions made elsewhere in this document.
1.3
SPECIAL PAYMENT TERMS
Following payment shall be made to the contractor against the running bills subject to the
rate awarded to him and the clause regarding retention money as per general terms and
conditions.
FOR ITEM NOS. 5, 6, 8, 12 TO 16, 18 TO 34, 70 TO 111, 117 TO 142, 147 TO 159,
168 & 169



70% against Supply
25% against installation & commissioning
5% after completion and acceptance by HPCL as per SOQ
ALL OTHER ITEMS


95% progressively till completion of the concerned job
5% after completion and acceptance by HPCL as per SOQ
NOTES :
1. For Each stage, necessary testing shall be completed prior to claiming the
break-up as given above
percentage
2. Partial bill will be processed only after submission of duly certified copy of proof of
payment towards royalty.
3. Final bill will be processed only after submission of “No objection certificate” from
relevant statutory authorities towards payment of royalty.
Page 145 of 153
SAFETY, HEALTH
AND
ENVIRONMENT
REQUIREMENTS
Page 146 of 153
SAFETY , HEALTH & ENVIRONMENT POLICY
SPECIFICATION FOR SAFETY HEALTH AND ENVIRONMENT (SHE) MANAGEMENT
CONTENTS
________________________________________________________________________
CLAUSE NO.
TITLE
________________________________________________________________________
1.0
SCOPE
2.0
REFERENCES
3.0
REQUIREMENT OF SAFETY, HEALTH AND
ENVIRONMENT (SHE)
4.0
3.1
MANAGEMENT RESPONSIBILITY
3.2
HOUSE KEEPING
3.3
SAFETY, HEALTH & ENVIRONMENT
DETAILS OF SHE MANAGEMENT SYSTEM
BY CONTRACTOR
4.1
ON AWARD OF CONTRACT
4.2
DURING JOB EXECUTION
Page 147 of 153
1.0
SCOPE
This specification establishes the Safety Health and Environment (SHE) management
requirement to be complied with by the Contractors during construction.
Requirements stipulated in this specification shall supplement the requirements of SHE
Management given in relevant Act (s) / legislations. General Conditions of Contract (GCC),
Special Conditions of Contract (SCC) and Job Specifications. Where different documents
stipulate different requirements, the most stringent shall be adopted.
2.0
REFERENCES
This document should be read in conjunction with following:
-
3.0
General Conditions of Contract (GCC)
Special Conditions of Contract (SCC)
Job Specifications
REQUIREMENTS
OF
SAFETY HEALTH &
ENVIRONMENT (SHE)
MANAGEMENT SYSTEM TO BE COMPLIED BY BIDDERS
3.1
MANAGEMENT RESPONSIBILITY
3.1.1
The Contractor should have a documented SHE policy to cover commitment of their
organization to ensure health, safety and environment aspects in their line of operations.
3.1.2
The SHE management system of the Contractor shall cover the SHE requirements
including but not limited to what is specified under Para 1.0 and para 2.0 above.
3.1.3
Contractor shall be fully responsible for planning and implementing SHE requirements.
Contractor as a minimum requirement shall designate / deploy the following to co-ordinate
the above :
No. of workers deployed
Up to 250
- Designate one safety supervisor
Above 250 & up to 500
- Deploy one qualified and experienced safety
Engineer / officer
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Above 500
engineer/officer as above.
- One additional safety (for every 500 or less)
Contractor shall indemnify & hold harmless Owner / HPCL & either representatives free
from any and all liabilities arising out of non – fulfillments of SHE requirements.
3.1.4
The Contractor shall ensure that the Safety, Health and Environment (SHE) requirements
are clearly understood & faithfully implemented at all levels at site.
3.1.5
The Contractor shall promote and develop consciousness for Safety , Health and
Environment among all personnel working for the Contractor. Regular awareness, program
site meetings shall be arranged on SHE activities to cover hazards involved in various
operations during construction.
3.1.6
Arrange suitable first aid measures such as First Aid Box, trained personnel to give First
Aid, Stand by Ambulance or Vehicle and install fire protection measures such as :
adequate number of steel buckets with sand and adequate fire extinguishers to the
satisfaction of HPCL/Owner.
3.1.7
The Contractor shall evolve a comprehensive planned and documented system for
implementation and monitoring of the SHE requirements. This shall be submitted to
HPCL/Owner for approval. The monitoring for implementation shall be done by regular
inspections and compliance to the observations thereof. The Contractor shall get similar
SHE requirements implemented at his sub-contractor(s) work site/office. However,
compliance of SHE requirements shall be the sole responsibility of the Contractor. Any
review / approval by HPCL/Owner shall not absolve contractor of his responsibility /
liability in relation to all HSE requirements.
3.1.8
Non-Conformance on SHE by Contractor (including his Sub-contractors) as brought out during
review/audit by HPCL/Owner representatives shall be resolved forthwith by Contractor.
Compliance report shall be provided to HPCL/Owner.
3.1.9
The Contractor shall ensure participation of his Resident Engineer / Site-in-Charge in the
Safety Committee / SHE Committees meetings arranged by HPCL/Owner. The compliance of
any observations shall be arranged urgently. He shall assist HPCL/Owner to achieve the targets
set by them on SHE during the project implementation.
3.1.10 The Contractor shall adhere consistently to all provisions of SHE requirements. In case of
non-compliance or continuous failure in implementation of any of SHE provisions;
HPCL/Owner may impose stoppage of work without any Cost & Time implication to Owner
and/or impose a suitable penalty for non-compliance with a notice of suitable period, up to a
cumulative limit of 1.0% (one percent) of Contract Value with a maximum limit of Rs. 10
Page 149 of 153
lakhs. This penalty shall be in addition to all other penalties specified else where in the
contract. The decision of imposing stoppage work, its extent & monitory penalty shall rest
with HPCL/Owner & binding on the Contractor.
3.1.11 All fatal accidents and other personnel accidents shall be investigated by a team of
Contractor‟s senior personnel for root cause & recommend corrective and preventive actions.
Findings shall be documented and suitable actions taken to avoid recurrences shall be
communicated to HPCL/Owner. Owner / HPCL shall have the liberty to independently
investigate such occurrences and Contractor shall extend all necessary help and co-operation
in this regard.
3.2
HOUSE KEEPING
3.2.1 Contractor shall ensure that a high degree of house keeping is maintained and shall
ensure inter alia the followings wherever applicable:
a.
All surplus earth and debris are removed/disposed off from the working
areas to identified location(s).
b.
Unused/Surplus Cables, Steel items and steel scrap lying scattered at
different places within the working areas are removed to identified
location(s).
c.
All wooden scrap, empty wooden cable drums and other combustible
packing materials, shall be removed from work place to identified
location(s).
d.
Roads shall be kept clear and materials like: pipes, steel, sand boulders,
concrete, chips and bricks etc. shall not be allowed on the roads to
obstruct free movement of men & machineries.
e.
Fabricated steel structural, pipes & piping materials shall be stacked
properly for erection.
f.
Water logging on roads shall not be allowed.
g.
No parking of trucks / trolleys, cranes and trailers etc. shall be allowed on
roads which may obstruct the traffic movement.
h.
Utmost care shall be taken to ensure over all cleanliness and proper
upkeep of the working areas.
Page 150 of 153
i.
j
3.3
Trucks carrying sand, earth and pulverised materials etc. shall be covered while
moving within the premises.
Only properly designed steel scaffolding materials to be used for working at
heights more than 3.0M . Double scaffolding using wooden ballis may be
allowed for working at height less than 3.0M
SAFETY, HEALTH AND ENVIRONMENT
3.3.1
The Contractor shall provide safe means of access to any working place including
provisions of suitable and sufficient scaffolding at various stages during all
operations of the work for the safety of his workmen, and, HPCL/Owner.
Contractor shall ensure deployment of appropriate equipment and appliances for
adequate safety and health of the workmen and protection of surrounding areas.
3.3.2
The Contractor shall ensure that all their staff and workers including their subcontractor(s) shall wear Safety Helmet and Safety shoes. Contractor shall also
ensure use of safety belt, protective goggles, gloves etc. by the personnel as per
job requirements. All these gadgets shall conform to relevant IS specifications or
equivalent.
3.3.3
Contractor shall ensure that a proper Safety Net System shall be used at
appropriate locations. The safety net shall be located not more than 30 feet (9.0
metres) below the working surface at site to arrest or to reduce the consequences
of a possible fall of persons working at different heights.
3.3.4
Contractor shall ensure that flash back arrester shall be used while using Gas
Cylinders at site. Cylinders shall be mounted on trolleys.
3.3.5
The Contractor shall assign to his workmen, tasks commensurate with their
qualification, experience and state of health for driving of vehicles, handling and
erection of materials and equipments. All lifting equipments shall be tested
certified for its capacity before use. Adequate and suitable lighting at every work
place and approach there to, shall be provided by the Contractor before starting
the actual operations at night.
3.3.6
Hazardous and/or toxic materials such as solvent coating, or thinners shall be
stored in appropriate containers.
3.3.7
All hazardous materials shall be labelled with the name of the materials, the
hazards associated with its use and necessary precautions to be taken.
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3.3.8
Contractor shall ensure that during the performance of the work, all hazards to be
health of personnel, have been identified, assessed and eliminated.
3.3.9
Chemical spills shall be contained & cleaned up immediately to prevent further
contamination.
3.3.10
All personnel exposed to physical agents such as ionizing radiation, ultraviolet
rays or similar other physical agents shall be provided with adequate shielding or
protection commensurate with the type of exposure involved.
3.3.11
Where contact or exposure of hazardous materials could exceed limits or could
otherwise have harmful affects, appropriate personal protective equipments such as
gloves, goggles, aprons, chemical resistant clothing and respirator shall be used.
-
A Crèche where 10 or more female workers are having children below the
age of 6 years.
-
Reasonable Canteen facilities are made available at appropriate location
depending upon site conditions.
3.3.13
Suitable facilities for toilet, drinking water, proper lighting shall be provided at
site and labour camps, commensurate with applicable Laws / Legislation.
3.3.14
Contractor shall ensure storage and utilization methodology of materials that are
not detrimental to the environment. Where required Contractor shall ensure that
only the environment friendly materials are selected.
3.3.15
All persons deployed at site shall be knowledgeable of and comply with the
environmental laws, rules & regulations relating to the hazardous materials
substances and wastes. Contractor shall not dump, release or otherwise discharge
or dispose off any such materials without the express authorization of
HPCL/Owner.
4.0
DETAILS OF SHE MANAGEMENT SYSTEM BY CONTRACTOR
4.1
On Award of Contract
The Contractor shall prior to start of work submit his Safety Health and Environment
Manual or procedure and SHE Plans for approval by HPCL/Owner. The Contractor shall
participate in the pre-start meeting with HPCL/Owner to finalise SHE Plans including the
following :
-
Job procedure to be followed by Contractor for activities covering. Handling of
equipment, Scaffolding, Electric Installation, describing the risks involved, actions
to be taken and methodology for monitoring each activity.
-
HPCL/Owner review / audit requirement.
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-
4.2
4.2.1
Organization structure along with responsibility and authority records / reports etc. on
SHE activities.
During job execution
Implement approved Safety Health, and Environment management procedure including but not
limited to as brought out under para 3.0. Contractor shall also ensure to:
- arrange workmen compensation insurance, registration under ESI Act, third
party liability insurance etc., as applicable.
- arrange all HSE permits before start of activities (as applicable) like hot
work, confined space, work at heights, storage of chemical / explosive materials
and its use and implement all precautions mentioned therein.
-
submit timely the completed checklist on SHE activities, Monthly SHE report,
accident reports, investigation reports etc. as per HPCL/Owner requirements.
Compliance of instructions on SHE shall be done by Contractor and informed
urgently to HPCL/Owner.
-
ensure that Resident Engineer / Site-in-Charge of the Contractor shall attend all the
Safety Committee / SHE meetings arranged by HPCL/Owner. Only in case of his
absence from site that a second senior most person shall be nominated by him in
advance and communicated to HPCL/Owner.
-
display at site office and work locations caution boards, list of hospitals,
emergency services available.
-
provide posters, banners for safe working to promote safety consciousness.
-
carryout audits / inspection at sub contractor works as per approved SHE
document and submit the reports for HPCL/Owner review.
-
assist in SHE audits by HPCL/Owner, and submit compliance report.
-
generate & submit HSE records / report as per SHE Plan.
-
appraise HPCL/Owner on SHE activities at site.
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